description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
BACKGROUND OF THE INVENTION
The present invention relates to a compressor. More particularly, the present invention relates to a piston type compressor that provides a piston ring fitted onto a piston.
A piston type compressor such as a swash plate type compressor generally includes a cylinder block and suction and discharge chambers so as to sandwich a valve plate assembly, and the cylinder block accommodates a piston. By reciprocation of the pistons, fluid in the suction chamber is sucked into the cylinder block, and the fluid sucked in the cylinder block is compressed and discharged to the discharge chamber. Also, to suck the fluid into the cylinder block and compress and discharge the fluid to the discharge chamber efficiently, sealing performance between the pistons and the cylinder block is important. Japanese Unexamined Patent Publication No. 11-294322 discloses a compressor that provides a coating made of fluoro resin on the outer circumferential surface of the pistons and a piston ring fitted onto the pistons. Thereby, sealing performance between the pistons and the cylinder block is ensured.
To achieve higher compression efficiency, sealing performance between the pistons and the piston rings in addition to sealing performance of the pistons and the cylinder block is also required to improve. Alternative refrigerant gas such as carbon dioxide is promoted to be a practical use to deal with environmental problems these days. However, carbon dioxide for using in a compressor as a compressing target requires quite a high compression ratio. Therefore, the above-mentioned requirements for sealing performance have been further increasing these days.
SUMMARY OF THE INVENTION
The present invention addresses the above-mentioned problems traceable to a relatively high compression ratio by improving sealing performance between pistons and piston rings.
According to the present invention, a piston type compressor has a housing, a cylinder block and a piston. The cylinder block is fixed to the housing. The piston is accommodated in the cylinder block. A piston ring is provided between the cylinder block and the piston. A sealing coat is made of soft metal, and is provided between the piston ring and the piston.
In the piston type compressor mentioned above, sealing performance between the piston ring and the piston is improved by the sealing coat made of soft metal.
The present invention also provides a method of forming a sealing coat on a surface of a groove on a piston. The method includes forming a coat made of fluoro resin on the outer circumferential surface of the piston, recessing a groove for accommodating a piston ring on the outer circumferential surface of the piston by machining, and immersing the piston in soft metal.
Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a longitudinal cross-sectional view of a piston type compressor according to an embodiment of the present invention;
FIG. 2 is a side view of a piston in FIG. 1;
FIG. 3 is an enlarged cross-sectional partial view showing a piston ring fitted onto a piston in FIG. 1;
FIG. 4 is a side view of a piston with a plurality of grooves according to another embodiment of the present invention; and
FIG. 5 is an enlarged cross-sectional partial view showing a piston ring fitted onto a piston in FIG. 1 according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention, which is applied to a swash plate type variable displacement piston type compressor for compressing refrigerant gas, will now be described with reference to FIGS. 1 through 4. The left side and the right side in FIG. 1 correspond to the front end and the rear end, respectively.
As shown in FIG. 1, a bolt 4 screws a front housing 1 to a rear housing 2 via a gasket 3 , thus constructing a housing 5 of a compressor. The rear housing 2 provides a step 6 inside. A retainer plate 7 , a discharge valve plate 8 , a valve plate 9 and a suction valve plate 10 are fitted onto the step 6 . The retainer plate 7 and a rear end wall 11 of the rear housing 2 define a suction chamber 12 and a discharge chamber 13 such that a partition wall 14 separates the suction chamber 12 and the discharge chamber 13 from each other.
A cylinder block 15 is fitted onto the suction valve plate 10 in the rear housing 2 . The cylinder block 15 and the front housing 1 rotatably support a drive shaft 16 . The drive shaft 16 protrudes its front end outside the front housing 1 , and connects with a driving source such as an engine and a motor of a vehicle, which is not shown. In the front housing 1 , a lug plate 17 is secured to the drive shaft 16 , and a swash plate 18 engages with the lug plate 17 . The drive shaft 16 extends a through hole, which is formed through the center of the swash plate 18 . A pair of guide pins 19 extending from the swash plate 18 is slidably fitted into a pair of guide holes 20 formed with the lug plate 17 . The swash plate 18 integrally rotates with the drive shaft 16 so that the guide pins 19 engages with the guide holes 20 , and is tiltably supported by the drive shaft 16 so as to slide along the axis of the drive shaft 16 .
A plurality of cylinder bores 21 is defined in the cylinder block 15 so as to surround the drive shaft 16 , the cylinder bores 21 each slidably accommodate respective pistons 22 . The pistons 22 each engage with the periphery of the swash plate 18 through a pair of shoes 23 . As the swash plate 18 rotates with the drive shaft 16 , the pistons 22 each reciprocate relative to the axis of the drive shaft 16 in the associated cylinder bores 21 through shoes 23 . Besides, the single cylinder bore 21 and the single piston 22 are shown in FIG. 1 . However, the compressor provides seven cylinder bores 21 and the seven pistons 22 in this embodiment.
The discharge chamber 13 communicates with a crank chamber 29 , or a control chamber 29 , which is defined in the front housing 1 via a supply passage 27 and a control valve 28 , and the crank chamber 29 communicates with the suction chamber 12 via a bleed passage 30 . As the control valve 28 opens, refrigerant gas in the discharge chamber 13 flows into the crank chamber 29 via the supply passage 27 and the control valve 28 , thus increasing pressure in the crank chamber 29 . The inclination of the swash plate 18 varies in accordance with the pressure in the crank chamber 29 . As the pressure in the crank chamber 29 increases, the inclination angle relative to the plane perpendicular to the axis of the drive shaft 16 decreases. As the pressure in the crank chamber 29 decreases, the inclination angle increases. Namely, the inclination of the swash plate 18 is varied by adjusting the control valve 28 due to an external control or an internal control.
As shown in FIGS. 1 through 3, the outer circumferential surface of the pistons 22 adjacent to a piston head each provide annular grooves 31 . A groove surface 22 a , the cross section of which is rectangular defines the groove 31 on the piston 22 . An annular piston ring 32 occupies the groove 31 . The piston ring 32 is made by shaping a cast iron member, the cross section of which is rectangular, into a ring. Also, the groove surface 22 a provides soft metal, or a sealing coat 33 made of tin in the present embodiment by nonelectrolytically coating. The thickness of the tin sealing coat 33 is from 2 μm to 3 μm. A process of forming the sealing coat 33 will now be described. In the present embodiment, a coat made of fluoro resin is formed on the outer circumferential surface of the piston 22 , which is made of aluminum. After that, the groove 31 is recessed by machining. The tin sealing coat 33 coats the groove surface 22 a by immersing the piston 22 with the groove 31 in tin. No tin coats the circumferential surface of the piston 22 , which is coated with fluoro resin. Since the groove 31 is formed by machining, the tin sealing coat 33 coats the groove surface 22 a , which is not coated with fluoro resin. For example, when not the tin sealing coat but a resin sealing coat is formed, the following processes are required: 1) recessing a groove on a piston; 2) coating with resin; and 3) treating the surface of a resin coat. However, when the tin sealing coat is formed, the above-described process 1) recessing a groove on a piston and process 2) coating with tin are required only. Thereby, manufacturing cost is reduced. Also, wettability of the tin sealing coat is higher than that of the resin sealing coat. Therefore, the tin sealing coat is available in performing such higher sealing performance relative to the resin sealing coat without treating the surface of the tin sealing coat.
The operation of the piston type compressor constructed above will now be described. Due to motion that the piston 22 moves from a top dead center toward a bottom dead center, refrigerant gas in the suction chamber 12 flows into a suction port 34 of the valve plate 9 , and pushes a suction reed valve of the suction valve plate 10 aside, then flows into the cylinder bore 21 . Due to motion that the piston 22 moves from the bottom dead center toward the top dead center, the refrigerant gas flows into a discharge port 35 of the valve plate 9 , and pushes a discharge reed valve of the discharge valve plate 8 aside, then flows into the discharge chamber 13 . Also, the tin sealing coat 33 performs high wettability with lubricant contained in the refrigerant gas. Thereby, when pressure of refrigerant gas such as carbon dioxide is high, the tin sealing coat 33 raises sealing performance between the piston ring 32 and the piston 22 during reciprocation of the piston 22 , and inhibits the refrigerant gas from leaking therebetween. Therefore, compression efficiency improves, and lubrication is ensured. Also, when roughness of the groove surface 22 a does not satisfies requirement, high sealing performance is ensured by coating the groove surface 22 a with the tin sealing coat 33 .
The present invention is not limited to the embodiment described above, but may be modified into the following examples.
The sealing coat is not limited to the tin sealing coat. For example, other soft metals, which performs high wettability with lubricant such as lead and zinc may be applied. Also, a position coated with the sealing coat, which is made of soft metal, is not limited to the groove surface 22 a . The sealing coat may coat the piston ring 32 .
The groove 31 on the piston is not limited to a single groove. As shown in FIG. 4, a plurality of the grooves 31 may be recessed on the piston 22 .
The sealing coat may coat parts of the groove surface 22 a , as shown in FIG. 5 . Particularly, the sealing coat resides only on the facing end surfaces of the groove surface 22 a other than the bottom of the groove surface 22 a.
According to the present invention described above, the piston type compressor provides the sealing coat, which is made of soft metal, between the piston ring and the piston. Thereby, sealing performance therebetween improves, and compression efficiency improves.
Also, when a sealing coat, which is made of soft metal, is a film coating the surface of a groove on a piston, and even when roughness of the surface of the groove does not satisfies requirement, high sealing performance is ensured.
Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein but may be modified within the scope of the appended claims.
|
A piston type compressor has a housing, a cylinder block and a piston. The cylinder block is fixed to the housing. The piston is accommodated in the cylinder block. A piston ring is provided between the cylinder block and the piston. A sealing coat is made of soft metal, and is provided between the piston ring and the piston.
| 5
|
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to an apparatus and method for supplying thread in a chain stitch sewing machine that produces over-edging stitches, double chain stitches and other stitches composed of needle and looper threads, in which at least a needle thread is forcibly supplied.
(2) Description of the Related Art
In a chain stitch sewing machine, a needle thread supplied to a needle with too high tension may cause puckering of the sewn fabric, especially a thin fabric. In contrast, a needle thread supplied without tension may cause skip stitches by the loose loops the thread forms.
To avoid such problems, the tension of the needle thread is controlled by a thread tension regulator.
However, the above tension applied to the needle thread greatly varies according to the movement of the needle because the tension is produced by the needle thread, which extends to the needle drop point, being pulled out against the friction with the thread tension regulator. Therefore, the thread tension regulator is not easily adjusted so that good sewing results can be obtained.
On the other hand, proposed in U.S. Pat. No. 5056446 is an automatic thread supply device by which a thread is forcibly supplied, and the supply length of the thread is controlled by electrifying/de-electrifying a solenoid. According to this approach, the thread tension is substantially made zero by the thread being supplied forcibly, and consequently, loosening of the needle thread is avoided by supplying the predetermined length of thread needed to form a stitch. Thus, puckering, skip stitches, and other problems can be decreased.
However, the inventors of this invention have found out it is difficult to obtain stable, good sewing results under different sewing conditions, such as differing thickness of fabrics, by the above approach. After various experiments, the timing of applying the thread tension has proved to greatly affect the sewing appearance.
SUMMARY OF THE INVENTION
The object of this invention is to provide an apparatus and method for supply thread in a chain stitch sewing machine which seldom causes puckering, skip stitches, and other problems.
The above object can be achieved by a method for supplying thread in of a chain stitch sewing machine having an apparatus for supplying thread which forcibly supplies a needle thread to a needle, the method being characterized in that each sewing cycle has at least two periods in which the thread is supplied, the periods being discontinuous.
The above object can be achieved by an apparatus for supplying thread in a chain stitch sewing machine, comprising a needle vertically reciprocating between a top end point and a bottom end point in one sewing cycle; a looper horizontally reciprocating in one sewing cycle; a thread supply device for forcibly supplying a needle thread to the needle; and a thread supply control device for controlling the thread supply device so that the needle thread is supplied in at least two periods in each sewing cycle, the periods being discontinuous.
According to the above construction, the tension of the needle thread can be kept low during the first and second periods in which the thread is supplied and until it the thread supplied during the periods has been used. The tension can be keep properly high during the remaining periods. Consequently, the proper amount of needle thread is smoothly supplied to form good stitches, and the formed stitches are appropriately tightened, which results in good sewing appearance even under different sewing conditions.
The first period in each sewing cycle can be from the time the needle begins to enter a triangle formed by a looper, a looper thread and the needle thread, to the time the tip of the looper begins to leave the needle. The second period in each sewing cycle can be from the time the looper begins to enter the loop formed by the needle thread while the needle is rising from a bottom end point, to the time the rising needle reaches as a predetermined height. According to the above conditions, the needle moves without the supply of the needle thread after the needle thread is supplied while the needle is in the middle of its patch to the bottom end point or to the top end point. The tension caused by the balance between the needle thread and the looper thread maintains the regular triangle formed in every sewing cycle. Consequently, the wrinkling of fabrics to be sewn can be minimized and good sewing results can be obtained even for easily wrinkled fabrics such as georgette or broad cloth without puckering, skip stitches, or other problems.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, advantages and features of the invention will become apparent from the following description thereof taken in conjunction with the accompanying drawings which illustrate a specific embodiment of the invention. In the drawings:
FIG. 1 shows a front view of a chain stitch sewing machine of the present invention.
FIGS. 2a-c show needle thread tension in accordance with the vertical movement of the needle.
FIGS. 3a-f show illustrations of sewing process in accordance with the movement of the needle and the a looper.
FIG. 4 shows a hard ware construction as its control device to control their thread supplying apparatus.
FIG. 5 shows a flow chart explaining operations of the construction shown in FIG. 4.
FIG. 6 shows a flow chart explaining operations of the construction shown in FIG. 4.
FIG. 7 shows a flow chart explaining operations of the construction shown in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the sewing machine of the present invention comprises a machine bed 1 and an arm 2 mounted thereon.
Installed in the machine bed 1 are a main shaft 3 supported horizontally, a looper 4 moved elliptically thereby, and a cam unit 5 to control feeding length of a looper thread S4 according to the movement of the looper 4. A pulley 6 attached to one end of the main shaft 3 is coupled with the main motor (not shown) to drive the machine by a belt 7.
The arm 2 is equipped with an arm shaft 8 parallel to the main shaft 3 and a needle clamp 10 reciprocating vertically above a sewing area 9 by the rotation of the arm shaft 8. The arm shaft 8 is linked with the main shaft 3 by a belt 11 so that they can rotate synchronously. The needle clamp 10 is provided with, for example, three needles 12a, 12b, and 12c. The top end point is indicated by continuous lines, and the bottom end point by double dashed lines.
The looper 4 is positioned at its left end point as shown in FIG. 1 when the needles 12a-12c are at their top end point, and at a right end point when the needles are at their bottom end point.
Attached to the front surface of the arm 2 are a thread supply device 13 for forcibly supplying three needle threads S1-S3 to the needles 12a-12c, a thread tension regulator 14 for supplying the looper 4 with the looper thread S4 applied a specified tension, and thread guide paths 15 for guiding each of the threads S1-S4 along specified paths. As shown in FIG. 1, thread guide 15a for the needle threads S1-S3 is provided above the needle clamp 10 and moves up and down with the needles 12a-12c.
The thread supply device 13 includes a pair of thread supply rollers 16 and 17, and thread clampers 18-20 provided upstream of the rollers. The thread supply rollers 16 and 17 face each other to hold the three needle threads S1-S3 therebetween, and are rotated in opposite directions as the arrows show in FIG. 1 by a roller drive motor 36 which rotates at a certain speed independently of the rotation of the shafts 3 and 8. The thread supply rollers 16 and 17 rotate at a speed corresponding the maximum sewing speed of the sewing machine.
In this embodiment, each of the thread clampers 18-20 respectively has a pair of strip members 18a/18b-20a/20b which are bimorph-type piezoelectric elements. They can lock a thread with a force greater than the transporting force of the thread supply rollers 16 and 17 to stop the thread supply, and release the thread so that it can be fed at a high speed by the rotation of the rollers 16 and 17. These operations of clampers are realized by electrifying the bimorph-type piezoelectric elements at opposite phases to each other. Employing the above piezoelectric elements ensures that the thread clamping/releasing operation is performed within a short period.
The detailed construction of the above thread clampers 18-20 is described in Japanese Laid-open Patent Application 4-2394 (Refer to U.S. Ser. No. 07/686518). Although the piezoelectric elements are suitable, various known high-speed actuators may be used instead.
The machine shown in FIG. 1 forms a stitch of a Federal Standard No. Stitch Type 407 by the three needles 12a, 12b, and 12c and a looper 4. However, to simplify the description, the forming operation of a stitch type 401 is described which needs only the needle 12a and the looper 4 and is controlled by the thread supply rollers 16 and 17, and the thread clamper 18 of the thread supply device 13.
The clamping timing of the thread clamper 18 according to the present invention is described with reference to FIG. 2.
The axis of abscissa A indicates the rotating angle of the main shaft 3. Rotation through 360° corresponds to one sewing cycle.
FIG. 2(a) shows a graph of thread tension of the needle thread S1 controlled by the thread clamper 18 of this invention indicated by continuous lines, and thread tension of the needle thread K controlled by a conventional thread tension regulator indicated by short dashed lines.
FIG. 2(b) is a motion diagram showing vertical movement of the needle 12a of the sewing machine shown in FIG. 1 (B: the top end point, C: the bottom end point), and horizontal movement of the looper 4 (B: the left end point, C: the right end point).
FIG. 2(c) is a graph showing, the total amount of needle thread supplied in one stitch (the axis supplied to the sewing area 9, with ordinate D) the needle thread S1 of the present invention being indicated by continuous lines and the needle thread K of a conventional example being indicated by short dashed lines.
As shown in FIG. 2(a)(b), the thread tension of the needle thread K controlled by the conventional thread tension regulator begins to rise when the rotating angle of the main shaft is 90°, reaches a peak at around 130°, falls gradually after that, rises again around 250°, and reaches another peak at around 360° (0°). Responding to the two peaks of the tension, the needle thread K is pulled out of the thread supply source twice, one around 130° and the other around 320° to 340° as shown in FIG. 2(c). The amount of thread required for one sewing cycle was conventionally gained by the generation of this tension.
To the contrary, according to this invention, the needle thread S1 is forcibly supplied toward the sewing area 9 within each period at the maximum speed of the sewing machine by making the angle between 70° and 110° a first period, and the one between 220° and 300° a second period. More precisely, the thread clamper 18 is released in the entire first period, and between 220° and 250° in the second period to forcibly supply the required amount of thread for a determined sewing cycle by the thread supply rollers 16 and 17.
Thus, the thread tension of the needle thread S1 shown in FIG. 2(a) is generated by supplying an amount of the needle thread required for one sewing stitch in the new period by intentionally dividing the period to supply the thread. In other words, the two peaks around 130° and 360° can be maintained at a higher level than the peak of the conventional needle thread K, and another peak having the same tension as the one around 130° can be generated around 170° .
It is desirable that the peaks around 130° and 170° be maintained as high as, or a little lower than the one around 360°.
The following describes the effectiveness of the high tension of the needle thread S1, which is generated by supplying it forcibly in new periods, in a forming process of a stitch by the needle thread S1 and the looper thread S4, with reference to FIG. 3.
When the rotating angle of the main shaft is 0°, the needle 12a is at the top end point and the looper 4 is at the left end point as shown in FIG. 3 (a). At this time, since the needle thread has rather high tension, the needle thread S1, the looper thread S4, and the looper 4 form a regular triangle T as shown. The tension of the needle thread S1 continues until immediately before the needle 12a enters the triangle T, at which point the rotating angle of the main shaft is around 70°. Consequently, the needle 12a can enter the triangle T without fail, causing no skip stitches.
Since the needle 12a falls during the angle between 70° and 180° as shown in FIG. 3(b)-(e), the needle thread S1 is needed to form a stitch. The needle thread S1 is supplied only during the period between 70° and 110°, avoiding an oversupply, to form a seam. As a result, since the needle thread S1 falls during the angle between 110° and 180° without a thread supply, its tension heightens. The tension generated during the period is considered to properly tighten a just formed stitch. The supply of the needle thread S1 is suspended until the angle reaches 220°, thereby continuing to tighten the seam.
When the angle has reached 220°, the looper 4 enters a loop of the needle thread S1 generated by the needle 12a rising from the bottom end point as shown in FIG. 3(f). During the angle between 220° and 360° (=0°), the looper 4 moves to the left with the needle thread S1 hooked, and the needle 12a rises to the top end point. Since the needle thread S1 is needed to form stitches, it is supplied between 220° and a predetermined angle (250° in this embodiment). During the angle between 250° and 70°, the tension of the needle thread S1 is increased by suspending the supply of the needle thread S1, forming the above mentioned regular triangle T.
The following is a description of a control system to supply the needle thread S1 only during the first and second periods as above to obtain good sewing results, with reference to FIGS. 4-7.
In FIG. 4, there are a CPU 30, a ROM 31, a RAM 32, an I/O device 33, and a main shaft pulse encoder 34 provided to the main shaft 3.
The main shaft pulse encoder 34 generates one pulse every time the main shaft 3 rotates a determined angle (hereinafter referred to as a rotation pulse), and another pulse, every time the angle becomes 0° (hereinafter referred to as original pulse).
A thread supply pulse encoder 35 built in the thread supply roller 16 generates further another pulse every time the roller 16 rotates a determined angle (hereinafter referred to as a thread supply pulse).
An operational key unit 37 is used to set the pulse number N1 of the thread supply pulse encoder 35 corresponding to the amount of thread supplied in the first period, the pulse number N2 of the encoder 35 corresponding to that in the second period, the main shaft rotating angle (70° and 220°) to start the opening operation of the thread clamper 18, and the angle (110° and 250°) to quit the opening operation of the clamper 18.
A machine driving pedal 38 is used to control the rotating speed of the main motor by changing its stepping force.
As shown in FIGS. 5-7, at first, the CPU is initialized (#1) followed by necessary operations including closing the thread clamper 18, admitting pulses from the main shaft pulse encoder 34, clearing the thread supply pulse counter n which counts the number of thread supply pulses outputted from the L thread supply pulse encoder 35 and a register θ which holds the rotating angle of the main shaft, and setting a state counter K to 1. The register θ, thread supply pulse counter n, and the state counter K are built in the CPU 30.
The state counter K to operate depending on each control state can take any value of from 1 to 6. When the value is 1, the operations in #3-#6 are performed. When it is 2, #7-#9. When it is 3, #10-#16. When it is 4, #17-#24. When it is 5, #25-#32. When it is 6, #33 and #34. A value of the state counter K is shifted to another value to perform a next operation at #6, #9, #11, #13, #15, #16, #20, #28, and #34. The value of the state counter is checked at #2. Since the state counter K has its value set to 1 immediately after the CPU is initialized, the operation proceeds to #3 to judge if the main shaft 3 is rotating or not. This judgement is done either by using a rotating sensor to detect the rotation of the main motor or by detecting the operation of the machine driving pedal 38.
When the main shaft 3 is judged not to be rotating, the supplying operation of the needle thread S1 is terminated. When it is rotating, the original pulse from the main shaft pulse encoder 34 is checked if it has been raised (#4), and the register θ is cleared (#5). If it has not been raised, the value of the state counter K is set to 2 (#6), and then the operation is returned to #2. If it is judged that the value has been set to 2 at #2, the operation proceeds to #7 to check if the rotating pulse from the main shaft pulse encoder 34 has been raised or not, and the value of the register θ is updated to θ+Δθ (#8). If it has not been raised, the operation is returned to #2 after the value of the state counter K is set to 3 (#9). If it is judged that the value has been set to 3 at #2, the value of the register θ is judged at or after #10, and the corresponding value is set to the state counter K as follows.
When 70°≦θ<110° (#10), the value of the state counter K is set to 4 (#11).
When 220°≦θ<250° (#12), the value of the state counter K is set to 5 (#13).
When θ=110° or 250° (190 14), the value of the state counter K is set to 6 (#15).
When the value of the register θ is other than the above, the value of the state counter K is set to 1 to repeat the operations in #3-#16 (#16).
If the value of the state counter K is set at #11, #13, #15, or #16, the operation is returned to #2.
When the value of the state counter K is set to 4 at #11 (70°≦θ<110°), the operation proceeds to #17 via #2 to control a thread supply of the first period as follows.
At first, it is judged if the thread supplying operation is completed or the thread clamper 18 is opened (#17). When the thread clamper 18 is closed and not supplied yet, it is opened after the thread supply pulse counter n is set to 0 (#18), which starts supplying the needle thread S1 with the thread supply roller 16. After that, the state counter K is set to 1 (#20), and the operations in #3-#6, #7-#9, #10, and #11 are performed to resume the operation in #17.
Since the thread clamper 18 is opened at the second operation in #17, the operation proceeds to #21 to detect the thread supply pulse of the thread supply pulse encoder 35.
When it has been detected, the value of the thread supply pulse counter n is increased by 1 (#22). When the value has reached N1 (#23), the thread clamper 18 is closed (#24) to terminate the thread supply control in the first period, and then the state counter K is set to 1 (#20) to return to #2.
On the other hand, if the thread pulse is not detected at #21 or the value n of the thread supply pulse counter has not reached N1 at #23, the state counter K is set to 1 (#20) without closing the thread clamper 18 to return to #2. After this, the same operation is repeated until the counter reaches N1. If it is detected that the rotating pulse of the main shaft pulse encoder 34 has been raised at #7 during the time, the value of the register θ is updated to θ+Δθ as above (#8).
After the value of the state counter K is set to 5 at #12 (220°≦θ<250°), the operation proceeds to #25 via #2 to control thread supply at the second period.
The control is not described because it includes the same operations as those in #17-24 except that the judged value of the thread supply pulse counter is N2.
Usually, the period for the thread supply pulse counter n to count N1 or N2 pulses is shorter than the first period (70°≦θ<110°) or the second period (220°≦θ<250°) respectively. However, if the rotating angle of the main shaft reaches 110° or 250° for some reason, before counting these pulses, it is not desirable to continue supplying the thread. Therefore, the supply is forcibly stopped by the judgement in 190 14 and the operations in #15, #33, and #34 in this embodiment.
Although FIGS. 4-7 show the system to control the thread clamper 18 only, the other thread clamper 19 and 20 can be controlled in the same manner just by changing the timing of starting and ending of the first and second periods according to the paths of the needle threads S2 and S3, to obtain good sewing results.
This embodiment is applicable also to an over-edging stitching machine for a stitch type 505 in addition to the stitch type 407. Since the type 505 used for a blindstitch hemming needs more threads than the ordinary over-edging stitching, the seam, which can not be stable in conventional control, can be stable by this invention.
Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be construed as being included therein.
|
An apparatus and a method for supplying thread in a chain stitch sewing machine are disclosed, the apparatus comprising a needle vertically reciprocating between a top end point and a bottom end point in one sewing cycle; a looper horizontally reciprocating in one sewing cycle; a thread supply device for forcibly supplying a needle thread to the needle; and a thread supply control device for controlling the thread supply device so that the needle thread is supplied in at least two periods in each sewing cycle, the periods being discontinuous.
| 3
|
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a machine which determines ophthalmic frame groove dimensions in up to three axes of a metal or plastic optical frame so that a ophthalmic lens can be cut with a precise bevel allowing the lenses to individually fit inside the eye wire with their optical centers aligned to a user's pupil positions with minimal frame distortion.
BACKGROUND OF THE INVENTION
[0002] Existing techniques to measure eyeglass frame dimensions employ a mechanical stylus. See, for example, US20140020254, US20130067754, and U.S. Pat. No. 8,578,617, which all describe mechanical contact methods to measure the shape and dimensions of the frame needed to fit the glass. These patents describe measuring the groove of the frame to get information about the shape and dimensions of the frame which assists an eyeglass maker to decide on the dimensions to cut a lens and its bevel to fit a frame.
[0003] The problems with these methods include:
a. Measurements with a stylus in the tracer machine at a optician's office location result in errors in the lens cut at a lab which has the cut/edger machine due to calibration errors between the different instruments. The mechanical instrument needs to be calibrated often in the optician's office to ensure accurate measurements. b. The tracer stylus often falls out of the groove and fails to accurately measure the depth due to groove width or sharp curving turns around the frame corner. The resulting lens may end up with gaps between the frame and the lens in those corners. c. Frame shapes can be easily distorted, especially thin plastic frames, because the lenses (dummy or actually used) are removed for enabling stylus-based measurement. d. Frame bending can occur as a result of bevel incorrectly positioned on the lens edge. This results in the frame user feeling that the frame does not look like what he expected while trying on the frame with dummy lenses. e. Additional time and shipping charges result from the need to ship frames to the remote lab for tracing, cutting, edging and fitting of the lens to the selected frame. Any delay can impact frame scheduling, sometimes for multiple opticians, piling up in the labs for measurement and processing.
SUMMARY OF THE INVENTION
[0009] The present invention eliminates a physical stylus tracing the lens shape by using an imaging system to create a computer model, and then using that model to determine how a lens should be best cut to fit the frame.
[0010] A computer model of an eyeglass frame lens groove is created in a two-stage process, which is then used to manufacture the lenses. A microscopic camera is used to track a frame's lens groove and provide data for the computer frame model. A lighting system is designed specifically to assist the camera to create images which the programmed computer can use to find frame and groove contour lines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a better understanding of the disclosure, and to show by way of example how the same may be carried into effect, reference is now made to the detailed description along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts.
[0012] FIG. 1A shows the front view of a typical pair of eyeglass frames.
[0013] FIG. 1B shows an orthogonal side view of a typical pair of eyeglass frames shown in FIG. 1A .
[0014] FIG. 1C shows the top view of a typical pair of eyeglass frames shown in FIG. 1A , showing the significant degree of curvature (wrap) associated with the frames. It also shows the curve of the front face of the lens, also known as the “Base Curve”. The base curves are typically standard values.
[0015] FIG. 1D-1F show an example of a frame-groove imaging and curve-fitting process. FIG. 1D shows the captured imaging data of the frame's upper and lower surface, and contour lines of the lens grove. FIG. 1E shows the imaging data after a curve-fitting adds missing information. FIG. 1F shows the Groove Width 37 and Location 39 of the Groove 27 with respect to the frame edges. Tracking this distance allows a more precise determination of the bevel of the lens so it matches the Frame 11 better than in the prior art.
[0016] FIG. 2A is a block diagram of a first embodiment of the invention, referred to as the Imaging Method, consisting of a first Frame Measurement stage, and a second Grove Measurement stage.
[0017] FIG. 2B is a block diagram of a second embodiment of the invention referred to as the Mechanical Touch Probe Method.
[0018] FIG. 3A shows an orthogonal view of the Frames 11 and Camera 13 used in the Imaging Method acquiring a full field-of-view front Macro-Image 15 .
[0019] FIG. 3B shows the Imaging System 17 positioned to begin capturing Micro-Images 19 of the Frame 11 using a Camera Mirror 55 .
[0020] FIG. 3C shows the groove imaging system in relation to a Frame 11 (used to acquire z-axis or depth information for all methods described herein), including the Touch Probe 31 , Z-Axis Stage 35 and Touch Probe Retraction Spring 57 .
[0021] FIG. 4A shows the Imaging method, specifically using the Z-Axis Laser 25 and Laser Camera 26 , which determine height of Frame 11 at a number of points on the Frame 11 . FIG. 4B shows the Mechanical Touch Probe method, specifically using the Touch Probe 31 , Z-Axis Stage 35 and Touch Probe Retraction Spring 57 .
[0022] FIG. 5 shows the multi-color LED Frame Lighting 41 sheet used for background and foreground zone based illumination, and the Frame Mount 51 apparatus.
[0023] FIG. 6 is an orthogonal view of an optional advanced base using a six-axis Hexapod for the Frame Holder Assembly shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] While the making and using of various embodiments of the present disclosure are discussed in detail below, it should be appreciated that the present disclosure provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The disclosure is primarily described and illustrated hereinafter in conjunction with various embodiments of the presently—described systems and methods. The specific embodiments discussed herein are, however, merely illustrative of specific ways to make and use the disclosure and do not limit the scope of the disclosure.
[0025] Two measurement methods are disclosed in the present invention: (1) an Imaging Method; (2) a Mechanical Touch Probe Method. In both of these methods, a computer model of an eyeglass frame lens groove is created in a two-stage process, which is then used to manufacture the lenses. The two methods differ only in their first stage, in which the initial data to drive a microscopic camera is collected.
[0026] These methods capture multiple images from the interior of an eyeglass lens grove; the computer processes the images to identify, measure and store the features of the frame's lens groove. In the current embodiment, a user removes a lens from the left side of the frames to allow for the frame groove can be measured and modeled. This method can be used to generate a standalone three-dimensional model generation of the lens that is cut and beveled.
[0027] The Imaging Method uses a Z-Axis Laser 25 to determine the vertical dimension (z-axis) of the top of a Frame 11 as it is mounted in the invention, as it creates a computer model of the Frame 11 and designs the lens to properly fit the Frame 11 .
[0028] The Mechanical Touch Probe method uses a Touch Probe to find the vertical dimension, rather than a camera and laser, to correct the computer model for the frame's curvature,
[0029] The objective of the invention is to characterize the precise shape of a pair of eyeglass frames, including that of the internal groove (see FIG. 1A-1D ), to a spatial resolution of better than 50 microns in all three physical directions, referred to as “x”, “y”, and “z”.
[0030] The imaging system based method is performed in two stages. The first stage measures the dimensions of a pair of glasses. The second stage focuses on the frame's inside grooves in which a lens fits and is held in place. Together, these processes produce a data set sufficient to cut the real lens and form the proper bevel on its edge.
[0031] One embodiment of the first stage is the Imaging System, shown on FIG. 2A , in which a two-step imaging system is used to capture images of the frames and dummy lenses. The first step is to create an image of the entire Frame 11 , referenced as the Macro-Image 15 . Then the camera approaches the Frame 11 and creates images taken very close, known as Micro-Images 19 , generating highly detailed images from with a microscopic field of view. From these detailed Micro-Images 19 , the profiles of the Frame 11 and Dummy Lenses 21 are constructed in detail.
[0032] In the Frame Measurement stage of the Imaging Method, the eyeglass Frame 11 is positioned by small steps in the x-y plane with a computer-controlled linear X-Y Stage 33 , as shown in FIG. 3B . Commercially available stages may be positioned within 2 microns (millionths of a meter). A Camera 13 creates a full front Macro-Image 15 , as shown in FIG. 3A . This image is processed to determine Frame Points 23 , coordinates of locations around the Frame 11 and Lenses 21 where the Camera 13 should create microscopic images to add detail in the Frame Model 49 .
[0033] In the current embodiment, the algorithm overlays places two lines horizontally across the lens locations on the Macro-Image 19 , and two vertically over both lens areas. The algorithm determines the x- and y-coordinates of points close to the boundary of the Frame lens. In this embodiment, this process creates eight sets of coordinates, called Frame Points 23 .
[0034] The Camera 13 is then placed in a position close to the frame to capture Micro-Images 19 in front of each Frame Point, as shown in FIG. 3B . In this stage, the invention lowers a Camera 13 and Mirror 55 . The Camera 13 captures images of the reflection on the Mirror 55 , which is positioned toward the Frame Groove 27 . During this process, the Frame Lighting 41 is automatically adjusted to generate the most visible contour lines in the in the image.
[0035] These Micro-Images 19 are recorded, and any mismatch between expected coordinates is used to correct initially collected coordinate data. The Frame Groove 27 is thereby tracked in real time as the Camera sweeps in a full circle, tracking the Groove 27 during the sweep, and collecting its modeling data.
[0036] The Micro-Images 19 are taken at a constant distance from the Frame 12 and lens. This is necessary to keep the pixel scale the same in each Micro-Image 19 . The constant distance is maintained by Z-Axis Stage 35 . Its data may be supplied either by the Mechanical Touch Probe Method, shown in FIG. 4 , or the Groove Measurement (Image Method), shown in FIG. 3C .
[0037] By applying established and proprietary image processing algorithms, the exact coordinates of points on the boundary of the Frame 11 and Lens 21 may be determined to better than one-micron accuracy in any dimension.
[0038] For the Groove Measurement (stage 2 ), the Camera 13 must have miniature imaging capability system.
[0039] This imaging system is rotated with the frame in series of steps. A series of Micro-Images, close-up photos, is taken over a full 360 degrees. The steps can be as little as two microns, depending on the precision of the encoders used on each positioning stage
[0040] The Micro-Images are processed to determine the thickness of the groove and its path in the x-y plane. This process also gives the z-axis data with respect to the frame scan in stage one.
[0041] As shown in FIG. 4B , the Mechanical Touch-Probe Method is used to collect z-axis depth data over the Frames 11 . It uses a commercially-available linear positioning Z-Axis Stage 35 that can measure changes in height with micron accuracy.
[0042] To initiate the Mechanical Touch-Probe Method, the eyeglass frames are mounted on a high-accuracy X-Y Stage 33 . The probe is mounted on a Z-Axis Stage 35 .
[0043] The Frame Point 23 position data from the Imaging Method (described above) is used to position the probe. The probe samples the depth of the frame at each of the strategic Frame Points 23 . These measurements characterize the profile of the Frame 11 .
[0044] The method disclosed assumes that the invention's user has no access to factory construction data of the eyeglass Frames 11 . However, if this data is available, then it provides significant data to begin a successful model, including the ‘A’ and ‘B’ industry dimensions of lens height and depth.
[0045] The current embodiment of the method described is typically performed on the left lens, and a dummy lens is kept in the right lens Frame Groove 27 . This allows the user to detect if a dummy lens 27 is missized or misshapen by comparing the examination results of the method on the left side of the frame with the expected shape found on the right, during the first stage of the process, using the Macro-Image.
[0046] The current invention also uses a color and intensity controllable light array with multiple independent zones to improve contrast, front and back lighting in the area of interest, when different types of frame materials, like metal, plastic, transparent plastic, translucent plastic or rimless frames are measured in the same apparatus. This allows easy detection of edges and groves under a variety of material conditions.
LEGEND
[0047]
[0000]
Frame 11
Camera 13
Macro-Image 15
Imaging System 17
Micro-Image 19
Lens 21
Frame Point 23
Z-Axis Laser 25
Laser Camera 26
Frame Groove 27
Touch Probe 31
X-Y Stage 33
X-Stage 33X
Y-Stage 33Y
Z-Axis Stage 35
Groove Width 37
Groove Position 39
Frame Model 49
Frame Lighting 41
Frame Mount 51
Z-Stage Encoder 53
Mirror 55
Touch Probe Retraction Spring 57
Hexapod 59
|
Described herein is an apparatus and method for characterizing the precise dimensions of a pair of eyeglass frames, including that of the internal setting groove, through a non-mechanical measurement mechanism. The intended spatial resolution in all three orthogonal axes (x, y, & z) is better than 50 microns (millionths of a meter).
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a booster fan and air deflector adapted to rest on a conventional floor furnace vent. More specifically, the invention relates to a low profile plastic housing containing a thermostatically controlled electric fan and motor with a rotatable air deflector on the top of the housing which is intended to rest on a forced air heating/air conditioning floor vent to assist in moving greater volumes of air through the vent.
2. Description of the Prior Art
It is generally acknowledged in the heating and air conditioning industry that the concept of zone heating, wherein a single dwelling is equipped with multiple forced air heating/air conditioning units dedicated to separate portions or zones of the dwelling, represents a more economical and efficient operating method relative to a single centralized unit. However, the additional capital expenditure for a second or third furnace and air conditioner is not always economically justified. Therefore, it would be desirable if an inexpensive yet reliable method of selectively delivering more air to a desired zone of a dwelling equipped with a single centralized contemporary heating/air conditioning unit was available. However, to approach the operational characteristics of zone heating and air conditioning using a booster fan or the like in connection with a single centralized unit represents a pragmatic problem in that such a booster fan system would ideally have to be automatic and selective with respect to which air outlet vent is being assisted.
Prior to the present invention and to the best knowledge of the inventor, no highly portable, yet automatic booster fan specifically compatible with conventional floor furnace bents have been available. However, booster fans for use in conjunction with heating units have generally been employed in the prior art. For example, U.S. Pat. No. 2,135,461 discloses the use of a squirrel cage blower resting on top of a steam radiator and window sill above the radiator for circulating fresh air through the radiator. Also, U.S. Pat. No. 1,843,786 proposes the use of a booster fan in an air duct from a hot air register; however, no automatic sensing or control of the air movement is proposed. Other non-automated booster fans can be found in U.S. Pat. Nos. 1,743,994; 1,645,140 and 770,074.
SUMMARY OF THE INVENTION
In view of the prior art and the problems associated with selectively delivering more air to a given room to either cool or warm the room, I have discovered a booster fan and deflector for floor vents comprising:
(a) an essentially rectangular open grilled bottom member with a plurality of substantially vertical support legs with openings therebetween wherein the legs are attached to the underside of the outer perimeter of and extend downwardly from the rectangular bottom member and wherein the bottom member is adapted to rest on the legs suspended above and substantially covering a furnace floor vent;
(b) a first substantially vertical sidewall attached along and extending upwardly from one long side of the rectangular bottom member;
(c) a second substantially vertical sidewall attached along and extending upwardly from the other long side of the rectangular bottom member;
(d) a first inwardly and upwardly sloped sidewall attached along one of the short sides of the perimeter of the bottom member;
(e) a second inwardly and upwardly sloped sidewall attached along the other short side of the perimeter of the bottom member;
(f) an essentially square, horizontal top member attached along the upper edges of the sidewalls wherein the top member contains a circular opening;
(g) an essentially circular rotatable grill deflector means operatively attached to the opening in the top member wherein the parallel bars making up the grill deflector means are sloped such as to deflect air passing through the grill deflector means;
(h) an electric fan and motor means operatively positioned within the booster fan for moving air from the floor furnace vent through the circular rotatable grill deflector means; and
(i) a thermostatic switch means responsive to temperature wherein the switch means turn the electric fan and motor means on and off depending on the temperature of the air passing through the booster fan.
It is an object of the present invention to provide a portable booster fan/deflector that can be selectively placed on a conventional furnace/air conditioning floor vent. It is an associated object to provide such a booster fan/deflector that is thermostatically controlled and will automatically turn on and off according to a change in temperature of the air passing through the floor vent. Fulfillment of these objects and the presence and fulfillment of additional objects will become apparent upon complete reading of the specification and claims taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective view of the booster fan/deflector according to the present invention.
FIG. 2 is a partial cut-away view of the booster fan of FIG. 1 resting on a conventional furnace floor vent.
FIG. 3 is a top view of the booster fan of FIG. 1.
FIG. 4 is a bottom view of the booster fan of FIG. 1.
FIG. 5 is a partial cut-away side view of the booster fan of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The thermostatically controlled floor vent booster fan according to the present invention, how it functions, how it differs from prior art devices and the advantages associated with its use can perhaps be best explained and understood by reference to the drawings. FIG. 1 illustrates a booster fan according to the present invention, generally designated by the numeral 10. FIG. 2 illustrates the booster fan 10 resting directly on a conventional furnace floor vent 12. As illustrated in these figures, the booster fan 10 is made up of a low profile housing 14 supported on an open grid with legs 16 that allow for some room air circulation in addition to the air flow directed from beneath through the floor vent 12. On top of the housing 14 is a circular vent 18 that can be rotated such as to direct the air exiting the vent 18 as desired. An internal electrical motor 20 and fan 22 (see FIGS. 4 and 5) is powered by a conventional electrical connection 24 and a selection switch 26 on the top surface of the housing.
As further illustrated in the top view of FIG. 3, the low profile housing 14 is made up of a pair of substantially vertical sidewalls 28 and 30 extending upwardly from the leg supported grill 16 along the long side of the housing and a pair of inwardly and upwardly sloping sidewalls 32 and 34 along the short side of the housing terminating in a substantially square horizontal flat surface 36 on the top of the housing 14. Centrally located in the top surface 36 is the circular rotatable grill 18 which is equipped with a plurality of finger grips 40 around the outer perimeter to assist with the manual positioning of the grill 18. In this manner, the direction of the air flow exiting the booster vent 10 can be selected as desired. Also, the top surface 36 of the housing 14 is equipped (in this specific embodiment) with the three-way electrical switch 26 for turning the fan on and off or selecting the automatic thermostatically controlled mode of operation, as explained later.
As illustrated from the bottom view of FIG. 4, the support grill 16 is essentially an open grid structure allowing air exiting the floor vent to enter the underside of the booster fan 10. Since the support grill 16 is elevated on legs 38, the booster fan 10 does not form an air seal around the floor vent, thus allowing air circulating under the sidewalls of the booster fan as well as through the top vent 18.
As further illustrated in FIG. 3 and as can be seen in FIG. 5, the electric motor 20 is centrally positioned within the underside of the booster fan housing such as to drive the fan 22 positioned directly below the circular rotatable grill 18. As seen in FIG. 5, the electric power leads are directed to one side 40 of the electric motor and to the three-way switch 26. When switch 26 is in the automatic mode, the electric current is directed through thermostatic switch 42 before being directed to the other side 44 of the electric motor 20. In this manner, when switch 26 is in the central position, the fan and motor are off; when in the right position (relative to FIG. 5), the fan and motor are continuously on and when in the left position, the fan and motor are on only when a preselected temperature is achieved, thus closing the thermostatic switch 42. In this manner, the booster fan can be used manually or automatically. In the automatic mode, the selection of the thermostatic switch determines how the booster fan is to be used. For example, a switch that turns on at a temperature a few degrees in excess of room temperature will be useful as a booster fan during cold weather; that is, it will assist circulation of the hot air exiting the floor furnace vent once the temperature begins to rise. Similarly, a switch that turns on a few degrees below room temperature will be useful as a booster fan for an air conditioning system. The combination of both types of switches will allow for the booster fan to provide additional air movement during heating and air conditioning modes of operation.
Preferably, the major components of the booster fan according to the present invention are to be constructed out of molded thermoplastic. Generally, this can be achieved by fabricating the entire booster fan out of only three separate components (i.e., the support grill 16 with legs, the rotatable grill 18 and the rest of the sidewalls and top surfaces of the booster fan housing as a single unit). To assemble the unit, the rotatable plastic grill 18 is merely snapped into the opening in the top of the booster fan housing, the fan and motor, wiring and switch are attached to the inside of the booster fan housing and the bottom grill is then fastened to the lower lip of the sidewalls of the booster fan housing.
The selection of plastic to fabricate the components can generally be any polymeric material compatible with the temperature ranges experienced during operation of the booster fan. This would include by way of example, but not limited thereto, various polyolefins, impact polystyrene, ABS, polycarbonates, various high temperature vinyls and acrulics and the like. Preferably, the booster fan is fabricated out of ABS.
The advantages associated with the thermostatically controlled floor vent booster fan according to the present invention are considered numerous and significant. First and foremost, the booster fan represents a relatively inexpensive, convenient, reliable, yet safe device for assisting air movement exiting a floor vent. The relatively low profile of the booster fan housing is considered esthetically pleasing, functionally consistent with the intended use and relatively safe. The fact that the device is not intended to be attached permanently to a floor vent allows the user to reposition the device from vent to vent as well as from room to room, thus making the device a relatively versatile unit. This portability also allows the user to employ the device such as to simulate zone heating and air conditioning even when only one centralized unit is present in the dwelling.
Having thus described the invention with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. Therefore, it is to be understood that the invention is not limited to the embodiment set forth herein for the purposes of exemplification, but is to be limited only by the scope of the attached claim, including a full range of equivalents to which each element thereof is entitled.
|
A booster fan and deflector for placing over a forced air heating/air conditioning floor vent to deliver more cool air in warm weather and more warm air in cold weather. The booster fan and deflector comprises a low profile plastic housing adapted to sit on a rectangular floor vent and blow air from the furnace air duct through a circular rotatable deflector on the top. A thermostatic switch is employed to automatically turn the fan motor on and off.
| 5
|
FIELD OF THE INVENTION
[0001] The present invention relates to an improved system and method for magnetic position tracking, and more particularly to a system and a method that reduces the magnetic field induced noise signal in the sensor interconnect system by periodically switching the polarity of the noise signal.
BACKGROUND OF THE INVENTION
[0002] Magnetic position tracking systems are becoming more widely used in the medical field, particularly when paired with an ultrasound imaging system. Due to the problems introduced into magnetic systems by conductive metals, medical magnetic tracking systems may operate in a low frequency band, in the sub 2 KHz range down to near DC levels. Distortion of the transmitted fields due to nearby conductive metals is minimized when operating in this low frequency range. A problem which arises due to these low frequencies is that the magnetic signals tend to be less affected by signal shielding materials such as aluminum or copper which are effective at higher frequencies. The shields for low frequency must employ high permeability materials and the design must be optimized such that leakage fields are well controlled. This makes the design of low frequency shielding much more difficult than for higher frequencies where thin conductive foils and loosely fitting shells can be employed. Due to the sensitive nature of the signals from the magnetic sensors, the signal path interconnect must be carefully designed to minimize sensitivity to the transmitted field. Electromotive force (EMF) errors are induced into the interconnect system if there is an unbalanced loop area within the interconnect system that is exposed to the transmitted field. In the case of an ultrasound probe, the probe interconnect system is designed to accommodate hundreds of co-axial cable elements and their associated terminations. This type of interconnect presents a relatively large unbalanced loop area into the signal path of the magnetic sensor.
[0003] Prior art systems have avoided this problem by running the optimized magnetic interconnect cable assembly adjacent to the probe interconnect cable assembly. The external mounting of the magnetic sensor and the bulk of a second independent cable running alongside the probe cable is objectionable to many end users. In order to disconnect a probe from the ultrasound chassis, both the probe interconnect and magnetic sensor interconnect must be disconnected. The mass of the probe interconnect, which is attached to the magnetic sensor cable and connector, stresses the smaller interconnect causing reliability concerns. Another limitation of prior art systems is seen when the sensor signals must be passed through a connector which shares the same physical structure as a therapeutic device, such as is found on an endoscope. In this case, the magnetic signal must be contained within the instrument due to size constraints. Currently, prior art systems employ magnetic shielding around the magnetic portion of the instrument connector. This shielding can become bulky, complex, and expensive. Sterilization and reprocessing are needed in order to safely re-use such an instrument, and these costs are moving the industry towards inexpensive disposable devices. The ability to pass the magnetic sensor signals through a single, uncomplicated, low cost interconnect, without adding large cost elements to the magnetic sensor, is thus very desirable.
SUMMARY OF THE INVENTION
[0004] In general, in one aspect, the invention features a system for magnetic position tracking of a device including a magnetic transmitter, a magnetic sensor, a computing system and a polarity inverter. The magnetic transmitter includes at least one transmitter coil that outputs a transmitted magnetic field having a time derivative component. The magnetic sensor includes at least one sensor coil that has coil terminals having a polarity, and the sensor coil is responsive to the time derivative component of the transmitted magnetic field and outputs a sensor signal. The computing system computes position and angular orientation data of a device based on the sensor signal and the polarity inverter is configured to connect to the coil terminals and to cause the polarity of the coil terminals to be reversed according to a switching signal.
[0005] Implementations of this aspect of the invention may include one or more of the following features. The system may further include a sign inverter configured to invert a digitized output from an analog to digital (A/D) converter. The sign inverter is operated concurrently with the switching signal, so that the polarity of the coil terminals is maintained at the computing system's input. The system may further include a synchronizer configured to operate concurrently with the magnetic transmitter. The system may further include averaging means. The sign inverter is also configured to invert the sensor signal at the A/D converter's input. The transmitted magnetic field may be a sinusoid. The sinusoid may include a plurality of sine waves. The sinusoid may be continuous with respect to time. The sinusoid may be time division multiplexed. The transmitted magnetic field may have one of trapezoidal, triangular, half sinusoid, exponential, or square amplitude versus time characteristics shape. The polarity inverter is located adjacent to the magnetic sensor. The polarity inverter is connected to the magnetic sensor via a twisted pair cable. The polarity inverter may be an analog switch. The switching signal is transmitted wirelessly or via a wired connection. The averaging means is configured to sum signals received with opposite polarity from the sign inverter. The averaging means may be a lowpass filter.
[0006] In general, in another aspect, the invention features a method for magnetic position tracking of a device including the following steps. Providing a magnetic transmitter having at least one transmitter coil. The transmitter coil outputs a transmitted magnetic field having a time derivative component. Providing a magnetic sensor having at least one sensor coil. The sensor coil has coil terminals having a polarity, and the sensor coil is responsive to the time derivative component of the transmitted magnetic field and outputs a sensor signal. Providing a computing system for computing position and angular orientation data of a device based on the sensor signal and providing a polarity inverter configured to connect to the coil terminals and to cause the polarity of the coil terminals to be reversed according to a switching signal.
[0007] This invention is applicable to electromagnetic tracking of medical instruments. Applications include tracking of instruments such as ultrasound probes, biopsy needles, ablation instruments, and so on.
[0008] The details of one or more embodiments of the invention are set forth in the accompanying drawings and description below. Other features, objects, and advantages of the invention will be apparent from the following description of the preferred embodiments, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Referring to the figures, wherein like numerals represent like parts throughout the several views:
[0010] FIG. 1 illustrates a schematic of a magnetic transmitter and sensor integrated with an ultrasound imaging system;
[0011] FIG. 2 illustrates a schematic of prior art magnetic sensor cable and signal conditioning elements;
[0012] FIG. 3 illustrates a schematic of the magnetic sensor cable with improved signal conditioning elements;
[0013] FIG. 4 illustrates states and transitions of a single-channel DC pulsed magnetic sensor signal with and without the improved signal conditioning elements;
[0014] FIG. 5 illustrates extension of the single-channel DC pulsed magnetic sensor signal to a three channel magnetic sensor signal stream with polarity switch timing;
[0015] FIG. 6 illustrates application of the improved signal conditioning schema to a single-channel AC driven magnetic sensor signal with polarity switch timing.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The ideal magnetic tracking system receives 100% of its signal input exclusively from the sensor coil, where the sensor signal is a response to a transmitted time varying magnetic field. The sensor coil signal traverses the sensor assembly interconnect system travelling from the sensor coil through cable wires, to and through the connector, and through signal conditioning such as an amplifier and analog-to-digital converter mounted on a printed circuit board. The interconnect system components generate spurious signals in response to the transmitted time varying magnetic field. These spurious signals sum to corrupt the otherwise ideal sensor coil signal, and thus induce position and orientation error of the tracked instrument.
[0017] The invention described herein electronically periodically switches polarity of the summed spurious signal, enabling its self-cancellation. The invented polarity switch method and apparatus is applied to remove the spurious error-inducing signals generated within the interconnect, leaving the desired sensor coil signal uncorrupted.
[0018] Referring to FIG. 1 , a magnetic position tracking system 100 includes a magnetic sensor 1 , a magnetic transmitter 4 , a computer 7 and an instrument 2 whose position is being tracked. Magnetic sensor 1 is connected to the computer 7 via cable 5 and connector 6 . Magnetic transmitter 4 is connected to computer 7 via cable 50 . Magnetic sensor 1 outputs signals in response to the time derivative of magnetic fields,
[0000]
B
t
,
[0000] generated by the magnetic transmitter 4 . Computer 7 receives the output signals from the magnetic sensor 1 by way of cable 5 and connector 6 and computes the position of magnetic sensor 1 relative to the magnetic transmitter 4 .
[0019] Magnetic sensor 1 may contain one or more signal channels. In one example, a typical 6 degree of freedom magnetic position tracking system may be constructed using 3 signal channels within magnetic sensor 1 combined with 3 orthogonal magnetic transmitting coils housed within transmitter 4 . For better clarity in this description, a single signal channel is described, because the operation of any additional signal channel is identical.
[0020] Referring to FIG. 2 , a single signal channel magnetic position tracking system 110 , includes a magnetic sensor coil 13 , a connector 6 , an amplifier 8 , an analog to digital (A/D) converter 9 and a processor 10 . Coil 13 is connected to the amplifier 8 via a pair of twisted wires 5 and via connector 6 . The sensing signal passes through the amplifier 8 , then through the A/D converter 9 and then goes to processor 10 .
[0021] Coil 13 detects the time derivative of the magnetic field, dB/dt, generated by the transmitter 4 according to the formula
[0000]
EMF
coil
=
A
*
N
*
U
*
B
t
[0022] A=area of coil 13 in square meters
[0023] N=number of turns in coil 13
[0024] U=free space permeability
[0025] dB/dt=time rate of change of the magnetic flux density, B, from transmitter 4 , in Tesla per second.
[0026] It is important to ensure that coil 13 is the only element of magnetic sensor 1 that is responsive to the magnetic signal from transmitter 4 . Any additional signal sources between coil 13 and A/D converter 9 will result in an incorrect position computation for sensor 1 . Prior art systems depend upon a high quality twisted pair cable 5 to conduct the EMF from coil 13 to connector 6 . The twisted pair cable 5 provides cancellation of magnetic signals by way of forming small opposing loops along its length, causing the EMF of each successive loop to change polarity with respect to its neighbors and thereby to cancel the effects of any external magnetic fields. This cancellation works well in a uniform magnetic field. However, in a gradient magnetic field, the dB/dt magnitude is not uniform along cable 5 and therefore the EMF for successive loops is not uniform. In this case cable 5 introduces a cable error, EMF cable . EMF cable has the highest magnitude when cable 5 is placed on or near the transmitter 4 , due to the high gradient field near the transmitter 4 . An example of this occurrence is when instrument 2 is an ultrasound transducer and the operator inadvertently pulls cable 5 across the transmitter 4 .
[0027] An additional source of error occurs where the signals from coil 13 pass through connector 6 . In most high density pin type connectors, the pins form a parallel path over their mating length. This path has a net area described by the product of pin length and pin separation. This net area is shown as a connector pin loop 14 in FIG. 2 . The EMF from connector pin loop 14 is then described as:
[0000]
EMF
connector
=
L
pin
*
W
pin
*
U
*
B
t
[0028] L pin =length of a connector pin
[0029] W pin =pin separation distance
[0030] U=free space permeability
[0031] dB/dt=time rate of change of the magnetic flux density, B, from transmitter 4
[0032] An important factor with the EMF error from loop 14 is that loop 14 may be located near transmitter 4 while sensor 1 may be near the outside limits of its range. Thus dB/dt at loop 14 may be orders of magnitude larger than the dB/dt at coil 13 . This could occur, for example, if an ultrasound operator positions computer 7 and connector 6 near the transmitter 4 due to space constraints in a procedure room. Prior art systems commonly place a restriction on the position of the connector 6 relative to the transmitter 4 , a common restriction being 0.6 meters of minimum separation. Prior art systems also commonly employ a magnetic shield around connector 6 , to decrease the dB/dt magnitude at loop 14 . Such a shield adds cost and bulk to connector 6 , and can cause distortion of the magnetic field transmitted by transmitter 4 if placed too closely.
[0033] An additional source of EMF error is the net loop area of the printed circuit board traces, as the physical paths of the signal lines through amplifier 8 and into A/D 9 are separate. The loop formed by these printed circuit board traces is shown by trace area 15 in FIG. 2 . Trace area 15 error is important because circuitry used to energize transmitter 4 is contained within computer 7 and there is commonly some leakage dB/dt from this circuitry. Since it is desirable to fit computer 7 into a small form factor, the spacing between this energizing circuitry and trace area 15 may be only a few tens of millimeters. This can result in a significant leakage dB/dt component being present at trace area 15 , giving:
[0000]
EMF
trace
=
A
trace
*
U
*
B
t
[0034] A trace =trace loop area
[0035] U=free space permeability
[0036] dB/dt=time rate of change of the magnetic flux density, B, from transmitter 4
[0037] Prior art systems protect area 15 using magnetic shielding and also attempt to locate the transmitter drive circuitry as far from area 15 as is practical.
[0038] Once the signal from coil 13 is digitized by the A/D converter 9 it is no longer susceptible to dB/dt effects from transmitter 4 and is processed by processor 10 .
[0039] The total signal at the input of the A/D converter 9 is thus;
[0000] EMF total =EMF coil +EMF cable +EMF connector +EMF trace
[0040] The last three terms of this equation are significant errors that need to be minimized.
[0041] The above mentioned cable, connector and trace errors (EMF coil , EMF connector , EMF trace ) are minimized in the present invention by periodically switching the polarity of the noise signal. Referring to FIG. 3 , in one embodiment of the present invention, a single signal channel magnetic position tracking system 120 , includes a magnetic sensor coil 13 , a connector 6 , a dual single-pole-double-throw (SPDT) analog switch 18 , an amplifier 8 , an analog to digital (A/D) converter 9 , a polarity control 11 , a multiplier 12 and a processor 10 . Coil 13 is connected to the amplifier 8 via a pair of twisted wires 5 and via connector 6 . The sensing signal passes through the SPDT analog switch 18 , the amplifier 8 , then through the A/D converter 9 , then through the multiplier 12 and then goes to processor 10 . Multiplier 12 also receives information from the polarity control 11 . Polarity control 11 controls the polarity of the sensor signal at the end of the coil terminals. Polarity control 11 is set to output a logic 0 or a logic 1. Logic 0 is interpreted by multiplier 12 and switch 14 as normal or non-inverting polarity (value=1) and logic 1 is interpreted as inverted polarity (value=−1). The effect of switch 18 and multiplier 12 is to negate the polarity of coil 13 as seen by the A/D converter 9 , and to simultaneously negate the data from the A/D converter 9 as seen by processor 10 . The net effect is that the signal from coil 13 as seen by processor 10 does not change sign regardless of the state of polarity control 11 . The error inputs, EMF cable , EMF connector , and EMF trace , however, change polarity at processor 10 in accordance with the state of polarity control 11 .
[0042] Referring to FIG. 4 , the state of polarity control 11 is synchronized with the operation of transmitter 4 so that it is logic 0 (non-inverting) during the first pulse A 19 and logic 1 (inverting) during the second pulse B 20 . EMF total for the rising and falling edges of pulse 19 are integrated within processor 10 to produce an output proportional to
[0000] EMF coil +EMF cable +EMF connector +EMF trace
[0043] This equation is described in U.S. Pat. No. 6,172,499, the contents of which are expressly incorporated herein by reference. At the boundary between pulse 19 and pulse 20 , polarity control 11 is switched to logic 1 and multiplier 12 is set to negate data from A/D 9 . The EMF total for the rising and falling edges of pulse B is integrated within processor 10 to produce an output proportional to
[0000] EMF coil −EMF cable −EMF connector −EMF trace
[0044] If we add the integral results from first pulse 19 and second pulse 20 and divide by two, the resulting average is an integral proportional only to EMF coil . Since the positions of computer 7 , connector 6 , and portions of cable 5 are relatively stable with respect to transmitter 4 , the magnitudes of EMF cable , EMF connector , and EMF trace remain essentially constant during the pulse AB sequence. The present invention thus eliminates the need to shield loop 14 , area 15 , and eliminates gradient error from cable 5 .
[0045] Placing a lowpass filter at the output of multiplier 12 can also accomplish the averaging function of the first pulse 19 and second pulse 20 sequence. The lowpass filter should be chosen such that the ripple at the output of multiplier 12 as an amplitude function of
[0000] EMF cable +EMF connector +EMF trace
[0046] is within acceptable limits and the system response bandwidth is adequately fast. For example, in a system employing the present invention, a 4th order infinite impulse response (IIR) filter, implemented in a digital signal processor (DSP), with a cutoff frequency of 2 Hz is adequate for a system employing a three axis transmitter 4 and a three axis sensor 1 operating at 240 transmitter pulses per second.
[0047] In addition to magnetic EMF error cancellation, the present invention may also be employed to remove EMF errors from sources such as ground coupling. Current from computer 7 flowing into transmitter 4 may induce some resistive voltage drops within the conductors of computer 7 . One important conductor is the grounding system. Generally the circuitry will employ a ground plane on a printed circuit board. This ground plane generally has a small but measurable resistance, on the order of a milliohm for points a few centimeters apart. Imperfections in amplifier 8 , ground feedthrough from biasing circuitry, and numerous other parasitic sources can cause error signals to appear at the output of amplifier 8 . Collectively these EMF error sources are shown as circuit error source 17 . Source 17 will exhibit a reasonably constant response to each of pulse 19 and pulse 20 in FIG. 4 . Due to the constant nature of this response, the multiplier 12 and polarity control 11 will cause the error from source 17 to be periodically inverted. The error source 17 is thus removable by averaging or lowpass filtering as previously described.
[0048] Referring to FIG. 5 , in another embodiment of the present invention, pulse 19 and pulse 20 are each comprised of multiple pulses. In this example, transmitter 4 is comprised of 3 orthogonal coils, referred to as X,Y, and Z respectively, energized sequentially. X axis pulse 21 represents the X coil excitation, Y axis pulse 22 represents the Y coil excitation, and Z axis pulse 23 represents the Z coil excitation. The combination of pulses 21 , 22 , and 23 herein referred to first transmitter sequence 24 and second transmitter sequence 25 . Using the device described in U.S. Pat. No. 6,172,499, as an example, the response of sensor 1 to each of the pulses 21 , 22 , 23 in first sequence 24 is processed in the same manner as previously disclosed for first pulse 19 and stored. Next, polarity control 11 is switched and the response of sensor 1 to each of the pulses 21 , 22 , 23 in second sequence 25 is computed and averaged with the corresponding response values from first sequence 24 . The sequence of FIG. 5 is useful because analog switch 18 may have some undesirable parasitic error effects on the output of coil 13 . One such effect is commonly known as charge injection. The injection components change amplitude and polarity synchronously with polarity control 11 and thus appear as a transient offset at the output of multiplier 12 . Introducing a short amount of dead time 26 between the first sequence 24 and the second sequence 25 will allow this transient offset to decay to zero before being sampled by processor 10 .
[0049] The system of FIG. 3 , may also be use for error reduction in an AC magnetic tracking system. FIG. 6 shows a pictorial description of key waveforms present at the input of processor 10 when the system 120 of FIG. 3 is operated to cancel transmitter induced offset signals in an AC magnetic tracking system. Transmitter 4 emits an AC magnetic field 27 . Sensor coil 13 outputs an EMF proportional to the time derivative of magnetic field 27 according to the formula
[0000] EMF coil =A*N*U*B *sin Ω t
[0050] A=area of coil 13 in square meters
[0051] N=number of turns in coil 13
[0052] U=free space permeability
[0053] B=peak to peak magnitude of field, in Tesla
[0054] ω=angular frequency of magnetic field, in radians per second
[0055] t=time, in seconds
[0056] Parasitic, unbalanced loops exposed to the magnetic field from transmitter 4 are added to the signal from coil 13 and the digitized signal at processor 10 is described as
[0000] EMF total =(EMF coil +EMF cable +EMF connector +EMF trace )*sin ω t
[0057] EMF coil sin ωt=signal from coil 13 due to magnetic field from transmitter 4
[0058] EMF cable sin ωt=induced EMF due to gradient field of transmitter 4 acting on cable 5 .
[0059] EMF connector sin ωt=induced EMF in connector pin loop 14 due to magnetic field from transmitter 4 .
[0060] EMF trace sin ωt=induced EMF from printed circuit board trace loops
[0061] EMF trace sin ωt=induced EMF in trace area 15 due to magnetic field from transmitter 4
[0062] Ideally, EMF coil sin ωt would be the only signal digitized by the A/D converter 9 and processed by processor 10 and by a demodulator. EMF cable sin ωt, EMF connector sin ωt, and EMF trace sin ωt are undesireable signals.
[0063] The total signal at the A/D converter 9 due to transmitter 4 is described as
[0000] EMF total =(EMF coil +EMF cable +EMF connector +EMF trace )*sin ω t
[0064] After demodulation and detection in processor 10 , the value corresponding to EMF total is stored and the polarity control 11 is switched. The output of the A/D converter 9 is then equal
[0000] EMF total =(EMF coil −EMF cable −EMF connector −EMF trace )*sin ω t
[0065] Demodulating and detecting this second sequence and averaging with the stored result from the first results in an output value proportional only to EMF coil . It should be noted that it is not required that the AC magnetic field 27 be continuous, nor fixed in frequency. The technique shown will work with time division multiplexed AC magnetic fields, and with fixed, variable, or multiple frequencies.
[0066] In the embodiment of FIG. 6 , the gain of amplifier 8 was set to unity to simplify the expressions. The waveforms are shown in continuous time format for clarity purposes, although in actuality the waveforms shown in FIG. 6 are discrete digital values output by the A/D converter 9 . FIG. 6 , assumes that the sampling rate of the A/D converter 9 is high enough to accurately capture the details shown.
[0067] The embodiment of FIG. 3 may be employed on numerous other signal transmission methods used in magnetic tracker art by employing the following principals:
[0068] 1) Define a measurement sequence, including magnetic transmitter excitations and receipt of magnetic signals from sensor coils.
[0069] 2) Feeding coil signals into a switching array capable of reversing the coil polarity relative to subsequent interconnect and processing elements. The switching array should be located such that parasitic loops are located between the switching array and the A/D converter.
[0070] 3) Controlling the switching array such that the processor receiving A/D data inverts the data synchronously with coil polarity changes at the output of the switching array.
[0071] 4) Alternating the polarity of the switching array and A/D sign inversion such that these operations are synchronous with the defined magnetic transmitter excitation sequences.
[0072] 5) Averaging alternate sign inverted processed data sequences such that the offset components cancel, or alternatively low pass filtering the processed data sequence, or alternatively storing a sequence of a first polarity, subtracting a sequence of opposing polarity, and utilizing the remainder offset value to correct future readings.
[0073] Several embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
|
An improved system for magnetic position tracking of a device includes a magnetic transmitter, a magnetic sensor, a computing system and a polarity inverter. The magnetic transmitter includes at least one transmitter coil that outputs a transmitted magnetic field having a time derivative component. The magnetic sensor includes at least one sensor coil that has coil terminals having a polarity, and the sensor coil is responsive to the time derivative component of the transmitted magnetic field and outputs a sensor signal. The computing system computes position and angular orientation data of a device based on the sensor signal and the polarity inverter is configured to connect to the coil terminals and to cause the polarity of the coil terminals to be reversed according to a switching signal.
| 0
|
BACKGROUND OF THE INVENTION
The present invention relates generally to an anti-skid brake control system for an automative vehicle, which controls braking pressure in order to optimize braking characteristics. More particularly, the invention relates to a method and system for deriving a measure of the angular speed of a vehicle wheel.
As is well known, in anti-skid control, the braking force applied to wheel cylinders is so adjusted that the peripheral speed of the wheels during braking is held to a give ratio, e.g. 80%, of the vehicle speed. Such a practice has been believed to be effective, especially when road conditions and other factors are taken into consideration. Throughout the accompanying disclosure, the ratio of wheel peripheral speed to vehicle speed will be referred to as "slip rate" or "slip ratio".
U.S. Pat. No. 4,267,575, issued on May 12, 1981 to Peter BOUNDS, discloses a system, which serves to provide signals to a microcomputer-based control system from which instantaneous values of speed can be computed, includes a wheel-driven alternator which provides an alternating current output whose frequency varies with wheel speed. A signal processor converts this signal to a series of sensor pulses whose width varies inversely with frequency. A sample pulse supplied by a microprocessor sets the period or length of time during which the sensor pulses are examined for each speed calculation cycle of the microprocessor. The sample period pulses are AND-gated with a high-frequency clock signal and also with the sensor pulses to provide a series of maker pulses marking the up and down excursions of the sensor pulses. The marker pulses occurring in each sample period are counted directly in a first counter, and in addition are supplied to a latch circuit and from thence to an AND gate which responds to the first marker pulse in the sample period to count occurrences of the first counter exceeding its capacity. A third counter is also connected to receive the high-frequency clock pulses and counts only the clock pulses occurring after the last market pulse in the sample period. At the end of the sample period, the counts from all three counters are transferred to the microprocessor which uses this information to compute a value for wheel velocity over the sample period. The system continuously provides the input counts to enable the microprocessor to calculate wheel velocity over each sample period.
In addition, U.S. Pat. No. 4,315,213, issued on Feb. 9, 1982 to Manfred WOLFF, discloses a method for obtaining an acceleration or deceleration signal from a signal proportional to speed and apparatus therefore. The method for obtaining an acceleration or deceleration signal from a signal proportional to the speed consists of storing the n most recently ascertained changes in the speed signal in a memory, and upon ascertainment of a new change to be stored in memory, erasing the change which has been stored the longest, and forming a deceleration or acceleration signal by addition of the stored n changes periodically at intervals of dT. In this method, the occurrence of deceleration or acceleration exceeding the threshold is recognized quickly.
In another approach, U.S. Pat. No. 4,384,330 to Toshiro MATSUDA, issued on May 17, 1983 discloses a brake control system for controlling application and release of brake pressure in order to prevent the vehicle from skidding. The system includes a sensing circuit for determining wheel rotation speed, a deceleration detecting circuit for determining the deceleration rate of the wheel and generating a signal when the determined deceleration rate becomes equal to or greater than a predetermined value, a target wheel speed circuit for determining a target wheel speed based on the wheel rotation speed and operative in response to detection of a peak in the coefficient of friction between the vehicle wheel and the road surface, and a control circuit for controlling application and release of brake fluid pressure to wheel cylinders for controlling the wheel deceleration rate. The wheel rotation speed sensing circuit detects the angular velocity of the wheel to produce alternating current sensor signal having a frequency corresponding to the wheel rotation speed. The wheel rotation speed sensor signal value is differentiated to derive the deceleration rate.
Another approach for deriving acceleration has been disclosed in U.S. Pat. No. 3,943,345 issued on Mar. 9, 1976 to Noriyoski ANDO et al. The system disclosed includes a first counter for counting the number of pulse signals corresponding to the rotational speed of a rotating body, a second counter for counting the number of pulses after the first counter stops counting, and a control circuit for generating an output signal corresponding to the difference between the counts of the first and second counters.
In the present invention, another approach has been taken to derive the wheel rotation speed which will be hereafter referred to as "wheel speed" based on input time data representative of the times at which wheel speed sensor signal pulses are produced. For instance, by latching a timer signal value in response to the leading edge of each sensor signal pulse, the intervals between occurrences of the sensor signal pulses can be measured. The intervals between occurrences of the sensor signal pulses are inversely proportional to the rotation speed of the wheel. Therefore, wheel speed can be derived by finding the reciprocal of the measured intervals. In addition, wheel acceleration and deceleration can be obtained by comparing successive intervals and dividing the obtained difference between intervals by the period of time over which the sensor signals were sampled.
To perform this procedure, it is essential to record the input timing in response to every sensor signal pulse. A difficulty is encountered due to significant variations in the sensor signal intervals according to significant variations in the vehicle speed. In recent years, modern vehicles can be driven at speeds in the range of about 0 km to 300 km. Sensor signal intervals vary in accordance with this wide speed range. In particular, when the vehicle is moving at a relatively high speed, the input intervals of the sensor signal pulses may be too short for the anti-skid control system to resolve. As accurate sampling of input timing is essential for the proposed approach, errors in the recorded input time data will cause errors or malfunction of the anti-skid brake control system. One possible source of error in sampling the input timing is accidentally missing one or more sensor signal pulses. Such errors are particularly likely to occur when the vehicle and wheel speeds are relatively high and therefore the intervals between adjacent sensor signal pulses are quite short.
U.S. Pat. No. 4,408,290, issued on Oct. 4, 1983 to the common inventor of this invention is intended to perform the foregoing input time data sampling for use in calculation of acceleration and deceleration. In the disclosure of the applicant's prior invention, an acceleration sensor acts on the variable-frequency pulses of a speed sensor signal to recognize any variation of the pulse period thereof and to produce an output indicative of the magnitude of the detected variation to within a fixed degree of accuracy. The durations of groups of pulses are held to within a fixed range by adjusting the number of pulses in each group. The duration of groups of pulses are measured with reference to a fixed-frequency clock pulse signal and the measurement periods of successive groups of equal numbers of pulses are compared. If the difference between pulse group periods is zero or less than a predetermined value, the number of pulses in each group is increased in order to increase the total number of clock pulses during the measurement interval. The number of pulses per group is increased until the difference between measured periods exceeds the predetermined value or until the number of pulses per group reaches a predetermined maximum. Acceleration data calculation and memory control procedure are designed to take into account the variation of the number of pulse per group.
The applicant's prior invention in effective for expanding intervals for sampling the input time data of the sensor pulse signals and for enabling the anti-skid control system to resolve variations in the wheel speeds.
In such known conventional systems, it is possible to cause error in calculation of a wheel speed data due to noise components contained in the sensor signal or so forth. As the wheel speed data is one of the most important essential data for performing anti-skid control, error in calculation of the wheel speed data may cause serious malfunction of the anti-skid control.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an anti-skid control system which can avoid significant error in wheel speed data calculation and thus improve accuracy and reliability of the system.
Another and more specific object of the present invention is to provide an anti-skid brake control system including means for detecting errors in wheel speed data and for producing a back-up signal having a value approximately corresponding to wheel speed to eliminate such error components.
In order to accomplish the above-mentioned and another objects, an anti-skid control system according to the present invention features a wheel speed processing step in which a newly derived wheel speed value is compared with wheel speed value derived in the immediately preceding calculation. When the newly derived wheel speed value deviates from the previously derived wheel speed by more than a predetermined value, a back-up signal is produced and output as a replacement for the new wheel speed data.
The back-up signal value is selected to the approximate the actual current wheel speed as closely as possible. For example, the last wheel speed data may be taken as the back-up signal value to replace the current, erroneous wheel speed value. Alternatively, the back-up signal value may be derived based on the old wheel speed data and wheel acceleration or deceleration derived at a timing corresponding to deriving of the old wheel speed.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given below and from the accompanying drawings of the preferred embodiments of the present invention, which, however, should not be taken to limit the invention to the specific embodiments, but are for explanation and understanding only.
FIG. 1 is a schematic block diagram of the general design of the preferred embodiment of an anti-skid brake control system according to the present invention;
FIG. 2 is a perspective illustration of the hydraulic circuits of the anti-skid brake system according to the present invention;
FIG. 3 is a circuit diagram of the hydraulic circuits performing the anti-skid control according to the present invention;
FIG. 4 is an illustration of the operation of an electromagnetic flow control valve employed in the hydraulic circuit, which valve has been shown in an application mode for increasing the fluid pressure in a wheel cylinder;
FIG. 5 is a view similar to FIG. 4 but of the valve in a hold mode in which the fluid pressure in the wheel cylinder is held at a substantially constant value;
FIG. 6 is a view similar to FIG. 4 but of the valve in a release mode in which the fluid pressure in the wheel cylinder is reduced;
FIG. 7 is a perspective view of a wheel speed sensor adapted to detect the speed of a front wheel;
FIG. 8 is a side elevation of a wheel speed sensor adapted to detect the speed of a rear wheel;
FIG. 9 is an explanatory illustration of the wheel speed sensors of FIGS. 7 and 8;
FIG. 10 shows the waveform of an alternating current sensor signal produced by the wheel speed sensor;
FIG. 11 is a timing chart for the anti-skid control system;
FIG. 12 is a block diagram of the preferred embodiment of a controller unit in the anti-skid brake control system according to the present invention;
FIG. 13 is a flowchart of a main program of a microcomputer constituting the controller unit of FIG. 12;
FIG. 14 is a flowchart of an interrupt program executed by the controller unit;
FIG. 15 is a flowchart of a main routine in the main program of FIG. 13;
FIG. 16 is a flowchart of an output calculation program for deriving EV and V signals for controlling operation mode of the electromagnetic valve according to the valve conditions of FIGS. 4, 5 and 6;
FIGS. 17 and 18 are diagrams of execution timing of the output calculation program in relation to the main program;
FIG. 19 is a table determining the operation mode of the actuator 16, which table is accessed in terms of the wheel acceleration and deceleration and the slip rate;
FIG. 20 is a flowchart of the wheel speed deriving routine used as part of the output calculation program of FIG. 16;
FIG. 21 is a diagram of the relationship between the sensor signal input times and the wheel speed derived therefrom;
FIG. 22 is a block diagram of another embodiment of the controller unit in the preferred embodiment of the anti-skid brake control system according to the present invention.
FIG. 23 is a circuit diagram of the wheel speed calculation circuit of the anti-skid control system of FIG. 22;
FIG. 24 is a circuit diagram of a midofication of the wheel speed calculation circuit of FIG. 23; and
FIG. 25 is a chart diagram of the procedure for deriving a back-up signal value by means of the wheel speed calculation circuit of FIG. 23.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This application is one of eighteen mutually related co-pending patent applications in the United States, filed on the same day. All of the eighteen applications have been filed by the common applicant to this application and commonly assigned to the assignee of this application. The other seventeen applications are identified below:
__________________________________________________________________________Basic JapanesePatent Appln No.Serial No. Title of the Invention__________________________________________________________________________Showa 58-70891 AN AUTOMOTIVE ANTI-SKID BRAKE601,326, filed April 17,1984 CONTROL SYSTEM WITH SAMPLING INPUT TIME DATA OF WHEEL SPEED SENSOR SIGNALSShowa 58-70892 METHOD AND SYSTEM FOR SAMPLING INPUT601,375, filed April 17,1984 TIME DATA FOR WHEEL SPEED SENSOR IN AN AUTOMOTIVE ANTI-SKID BRAKE CONTROL SYSTEMShowa 58-70893 AUTOMOTIVE ANTI-SKID CONTROL SYSTEM601,317, filed April 17,1984 WITH CONTROL OF SAMPLING OF INPUT TIME DATA OF WHEEL SPEED SENSOR SIGNALS AND METHOD THEREFORShowa 58-70894 ANTI-SKID CONTROL SYSTEM FOR AUTO-601,317, filed April 17,1984 MOTIVE BRAKE SYSTEM WITH SAMPLE CONTROL FOR SAMPLING INPUT TIMING OF SENSOR SIGNAL PULSES WITH REQUIRED PROCESS IDENTIFICATION AND METHOD FOR SAMPLINGShowa 58-70895 ANTI-SKID BRAKE CONTROL SYSTEM601,294, filed April 17,1984 INCLUDING A PROCEDURE OF SAMPLING OF INPUT TIME DATA OF WHEEL SPEED SENSOR SIGNALS AND METHOD THEREFORShowa 58-70896 ANTI-SKID BRAKE CONTROL SYSTEM601,344, filed April 17,1984 INCLUDING WHEEL DECELERATION CALCU- LATION WITH SHORTER LAB-TIME AND METHOD FOR PERFORMING CALCULATIONShowa 58-70897 ANTI-SKID BRAKE CONTROL SYSTEM WITH601,338, filed April 17,1984 SAMPLE CONTROL OF SENSOR SIGNAL INPUT TIME DATA, AND METHOD THEREFORShowa 58-70898 ANTI-SKID BRAKE CONTROL SYSTEM WITH601,337, filed April 17,1984 CONTROL OF SAMPLING TIMING OF INPUT TIMING VALUES OF WHEEL SPEED SENSOR SIGNAL PULSESShowa 58-70899 ANTI-SKID BRAKE CONTROL SYSTEM FOR601,330, filed April 17,1984 AUTOMOTIVE VEHCLEShowa 58-70900 ANTI-SKID BRAKE CONTROL SYSTEM WITH601,364, filed April 17,1984 REDUCED DURATION OF WHEEL ACCELE- RATION AND DECELERATION CALCULATIONShowa 58-84088 ANTI-SKID BRAKE CONTROL SYSTEM WITH601,363, filed April 17,1984 OPERATIONAL MODE CONTROL AND METHOD THEREFORShowa 58-84087 & ANTI-SKID BRAKE CONTROL SYSTEM WITH58-84091 OPERATION CONTROL FOR A PRESSURE601,329, filed April 17,1984 REDUCTION FLUID PUMP IN HYDRAULIC BRAKE CIRCUITShowa 58-84082 METHOD AND SYSTEM FOR DERIVING WHEEL601,318, filed April 17,1984 ROTATION SPEED DATA FOR AUTOMOTIVE ANTI-SKID CONTROLShowa 58-84085 METHOD AND SYSTEM FOR DERIVING WHEEL601,345, filed April 17,1984 ACCELERATION AND DECELERATION IN AUTOMOTIVE ANTI-SKID BRAKE CONTROL SYSTEMShowa 58-84092 ANTI-SKID BRAKE CONTROL SYSTEM AND601,293, filed April 17,1984 METHOD FEATURING VEHICLE BATTERY PROTECTIONShowa 58-84090 ANTI-SKID BRAKE CONTROL SYSTEM601,258, filed April 17,1984, INCLUDING FLUID PUMP AND DRIVEnow Patent No. 4,569,560 CIRCUIT THEREFORissued February 11, 1986;Showa 58-102919 & ANTI-SKID BRAKE CONTROL SYSTEM WITH58-109308 A PLURALITY OF INDEPENDENTLY601,295, filed April 17,1984 OPERATIVE DIGITAL CONTROLLERS__________________________________________________________________________
Disclosures of other seventeen applications as identified above are hereby incorporated by reference for the sake of disclosure.
Referring now to the drawings, particularly to FIG. 1, the preferred embodiment of an anti-skid control system according to the present invention includes a control module 200 including a front-left controller unit (FL) 202, a front-right controller unit (FR) 204 and a rear controller unit (R) 206. The controller unit 202 comprises a microprocessor and is adapted to control brake pressure applied to a front left wheel cylinder 30a of a front left hydraulic brake system 302 of an automotive hydraulic brake system 300. Similarly, the controller unit 204 is adapted to control brake pressure applied to the wheel cylinder 34a of a front right wheel (not shown) in the front right hydraulic brake system 304 and the controller unit 206 is adapted to control brake pressure applied to the rear wheel cylinders 38a of the hydraulic rear brake system 306. Respective brake systems 302, 304 and 306 have electromagnetically operated actuators 16, 18 and 20, each of which controls the pressure of working fluid in the corresponding wheel cylinders. By means of the controlled pressure, the wheel cylinders 30a, 34a and 38a apply braking force to brake disc rotors 28, 32 and 36 mounted on the corresponding wheel axles for rotation with the corresponding vehicle wheels via brake shoe assemblies 30, 34 and 38.
Though the shown brake system comprises disc brakes, the anti-skid control system according to the present invention can also be applied to drum-type brake systems.
The controller units 202, 204 and 206 are respectively associated with actuator drive circuits 214, 216 and 218 to control operations of corresponding actuators 16, 18 and 20. In addition, each of the controller units 202, 204 and 206 is connected to a corresponding wheel speed sensor 10, 12 and 14 via shaping circuits 208, 210 and 212 incorporated in the controller 200. Each of the wheel speed sensors 10, 12 and 14 is adapted to produce an alternating-current sensor signal having a frequency related to or proportional to the rotation speed of the corresponding vehicle wheel. Each of the A-C sensor signals is converted by the corresponding shaping circuit 208, 210 and 212 into a rectangular pulse signal which will be hereafter referred to as "sensor pulse signal". As can be appreciated, since the frequency of the A-C sensor signals is proportional to the wheel speed, the frequency of the sensor pulse signal should correspond to the wheel rotation speed and the pulse intervals thereof will be inversely proportional to the wheel rotation speed.
The controller units 202, 204 and 206 operate independently and continuously process the sensor pulse signal to derive control signals for controlling the fluid pressure in each of the wheel cylinders 30a, 34a and 38a in such a way that the slip rate R at each of the vehicle wheels is optimized to shorten the distance required to stop the vehicle, which distance will be hereafter referred to as "braking distance".
In general, each controller unit 202, 204 and 206 monitors receipt of the corresponding sensor pulses so that it can derive the pulse interval between the times of receipt of successive sensor pulses. Based on the derived pulse interval, the controller units 202, 204 and 206 calculate instantaneous wheel speed V w and instantaneous wheel acceleration or deceleration a w . From these measured and derived values, a target wheel speed V i is derived, which is an assumed value derived from the wheel speed at which a slip is assumed to be zero or approximately zero. The target wheel speed V i varies at a constant decelerating rate derived from variation of the wheel speed. The target wheel speed thus corresponds to a vehicle speed which itself is based on variation of the wheel speed. Based on the difference between the instantaneous wheel speed V w and the target wheel speed V i , a slip rate R is derived. The controller units 202, 204 and 206 determine the appropriate operational mode for increasing, decreasing or holding the hydraulic brake pressure applied to the wheel cylinders 30a, 34a and 38 a. The control mode in which the brake pressure is increased will be hereafter referred to as "application mode". The control mode in which the brake pressure is decreased will be hereafter referred to as "release mode". The mode in which the brake pressure is held essentially constant will be hereafter referred to as "hold mode". The anti-skid control operation consists of a loop of the application mode, hold mode, release mode and hold mode. This loop is repeated throughout the anti-skid brake control operation cyclically. One cycle of the loop of the control variation will be hereafter referred to as "skid cycle".
FIG. 2 shows portions of the hydraulic brake system of an automative vehicle to which the preferred embodiment of the anti-skid control system is applied. The wheel speed sensors 10 and 12 are respectively provided adjacent the brake disc rotor 28 and 32 for rotation therewith so as to produce sensor signals having frequencies proportional to the wheel rotation speed and variable in accordance with variation of the wheel speed. On the other hand, the wheel speed sensor 14 is provided adjacent a propeller shaft near the differential gear box or drive pinion shaft 116 for rotation therewith. (See FIG. 8) Since the rotation speeds of the left and right rear wheels are free to vary independently depending upon driving conditions due to the effect of the differential gear box 40, the rear wheel speed detected by the rear wheel speed sensor 14 is the average of the speeds of the left and right wheels. Throughout the specification, "rear wheel speed" will mean the average rotation speed of the left and right rear wheels.
As shown in FIG. 2, the actuator unit 300 is connected to a master wheel cylinder 24 via primary and secondary outlet ports 41 and 43 thereof and via pressure lines 44 and 42. The master wheel cylinder 24 is, in turn, associated with a brake pedal 22 via a power booster 26 which is adapted to boost the braking force applied to the brake pedal 22 before applying same to the master cylinder. The actuator unit 300 is also connected to wheel cylinders 30a, 34a and 38a via brake pressure lines 46, 48 and 50.
The circuit lay-out of the hydraulic brake system circuit will be described in detail below with reference to FIG. 3 which is only an example of the hydraulic brake system to which the preferred embodiment of the anti-skid control system according to the present invention can be applied, and so it should be appreciated that it is not intended to limit the hydraulic system to the embodiment shown. In FIG. 3, the secondary outlet port 43 is connected to the inlet ports 16b and 18b of electromagnetic flow control valves 16a and 18a, the respective outlet ports 16c and 18c of which are connected to corresponding left and right wheel cylinders 30a and 34a, via the secondary pressure lines 46 and 48. The primary outlet port 41 is conencted to the inlet port 20b of the electromagnetic valve 20a, the outlet port 20c of which is connected to the rear wheel cylinders 38a, via a primary pressure line 50. The electromagnetic valves 16a, 18a and 20a also have drain ports 16d, 18d and 20d. The drain ports 16d and 18d are connected to the inlet port 72a of a fluid pump 90 via drain passages 80, 82 and 78. The fluid pump 90 is associated with an electric motor 88 to be driven by the latter which is, in turn, connected to a motor relay 92, the duty cycle of which is controlled by means of a control signal from the control module 200. While the motor relay 92 is energized to be turned ON, the motor 88 is in operation to drive the fluid pump 90. The drain port 20d of the electromagnetic flow control valve 20a is connected to the inlet port 58a of the fluid pump 90 via a drain passage 64.
The outlet ports 72b and 58b are respectively connected to the pressure lines 42 and 44 via a return passages 72c and 58c. The outlet ports 16c, 18c and 20c of respective electromagnetic flow control valves 16a, 18a and 20a are connected to corresponding wheel cylinders 30a, 34a and 38a via braking lines 46, 48 and 50. Bypass passages 96 and 98 are provided to connect the braking pressure lines 46 and 48, and 50 respectively to the pressure lines 42 and 44, bypassing the electromagnetic flow control valves.
Pump pressure check valves 52 and 66 are installed in the pressure lines 42 and 44. Each of the pump pressure check valves 66 and 52 is adapted to prevent the working fluid pressurized by the fluid pump 90 from transmitting pressure surges to the master cylinder 24. Since the fluid pump 90 is designed for quick release of the braking pressure in the braking pressure lines 46, 48 and 50 and thus releasing the wheel cylinders 30a, 34a and 38a from the braking pressure, it is driven upon release of the brake pedal. This would result in pressure surges in the working fluid from the fluid pump 90 to the master cylinder 24 if the pump pressure check valves 66 and 52 were not provided. The pump pressure check valves 66 and 52 serve as one-way check valves allowing fluid flow from the master cylinder 24 to the inlet ports 16b, 18b and 20b of the electromagnetic valves 16a, 18a and 20a. Pressure accumulators 70 and 56 are installed in the pressure lines 42 and 44, which pressure accumulators serve to accumulate fluid pressure generated at the outlet ports 72b and 58b of the fluid pump 90 while the inlet ports 16b, 18b and 20b are closed. Toward this end, the pressure accumulators 70 and 56 are connected to the outlet ports 72b and 58b of the fluid pump 90 via the return passages 72c and 58c. Outlet valves 68 and 54 are one-way check valves allowing one-way fluid communication from the fluid pump to the pressure accumulators. These outlet valves 68 and 54 are effective for preventing the pressure accumulated in the pressure accumulators 70 and 56 from surging to the fluid pump when the pump is deactivated. In addition, the outlet valves 68 and 54 are also effective to prevent the pressurized fluid flowing through the pressure lines 42 and 44 from flowing into the fluid pump 90 through the return passages 72c and 58c.
Inlet check valves 74 and 60 are inserted in the drain passages 78 and 64 for preventing surge flow of the pressurized fluid in the fluid pump 90 to the electromagnetic flow control valves 16a, 18a and 20a after the braking pressure in the wheel cylinders is released. The fluid flowing through the drain passages 78 and 64 is temporarily retained in fluid reservoirs 76 and 62 connected to the former.
Bypass check valves 86, 85 and 84 are inserted in the bypass passages 98 and 96 for preventing the fluid in the pressure lines 42 and 44 from flowing to the braking pressure lines 46, 48 and 50 without first passing through the electromagnetic flow control valves 16a, 18a and 20a. On the other hand, the bypass check valves 86, 85 and 84 are adapted to permit fluid flow from the braking pressure line 46, 48 and 50 to the pressure lines 42 and 44 when the master cylinder 24 is released and thus the line pressure in the pressure lines 42 and 44 becomes lower than the pressure in the braking pressure lines 46, 48 and 50.
The electromagnetic flow control valves 16a, 18a and 20a are respectively associated with the actuators 16, 18 and 20 to be controlled by means of the control signals from the control module 200. The actuators 16, 18 and 20 are all connected to the control module 200 via an actuator relay 94, which thus controls the energization and deenergization of them all. Operation of the electromagnetic valve 16a in cooperation with the actuator 16 will be illustrated with reference to FIGS. 4, 5 and 6, in particular illustrating the application mode, hold mode and release mode, respectively.
It should be appreciated that the operation of the electromagnetic valves 18a and 20a are substantially the same as that of the valve 16a. Therefore, disclosure of the valve operations of the electromagnetic valves 18a and 20a is omitted in order to avoid unnecessary repetition and for simplification of the disclosure.
APPLICATION MODE
In this position, the actuator 16 remains deenergized. An anchor of the electromagnetic valve 16a thus remains in its initial position allowing fluid flow between the inlet port 16b and the outlet port 16c so that the pressurized fluid supplied from the master cylinder 24 via the pressure line 42 may flow to the left front wheel cylinder 30a via the braking pressure line 46. In this valve position, the drain port 16d is closed to block fluid flow from the pressure line 42 to the drain passage 78. As a result, the line pressure in the braking pressure line 46 is increased in proportion to the magnitude of depression of the brake pedal 22 and thereby the fluid pressure in the left front wheel cylinder 30a is increased correspondingly.
In this case, when the braking force applied to the brake pedal is released, the line pressure in the pressure line 42 drops due to return of the master cylinder 24 to its initial position. As a result, the line pressure in the braking pressure line 46 becomes higher than that in the pressure line 42 and so opens the bypass valve 85 to permit fluid flow through the bypass passage 98 to return the working fluid to the fluid reservoir 24a of the master cylinder 24.
In the preferring construction, the pump pressure check valve 66, normally serving as a one-way check valve for preventing fluid flow from the electromagnetic valve 16a to the master cylinder 24, becomes wide-open in response to drop of the line pressure in the pressure line below a given pressure. This allows the fluid in the braking pressure line 46 to flow backwards through the electromagnetic valve 16a and the pump pressure check valve 66 to the master cylinder 24 via the pressure line 42. This function of the pump pressure check valve 66 facilitates full release of the braking pressure in the wheel cylinder 30a.
For instance, the bypass valve 85 is rated at a given set pressure, e.g. 2 kg/cm 2 and closes when the pressure difference between the pressure line 42 and the braking pressure line 46 drops below the set pressure. As a result, fluid pressure approximating the bypass valve set pressure tends to remain in the braking pressure line 46, preventing the wheel cylinder 30a from returning to the fully released position. In order to avoid this, in the shown embodiment, the one-way check valve function of the pump pressure check valve 66 is disabled when the line pressure in the pressure line 42 drops below a predetermined pressure, e.g. 10 kg/cm 2 . When the line pressure in the pressure line 42 drops below the predetermined pressure, a bias force normally applied to the pump pressure check valve 66 is released, freeing the valve to allow fluid flow from the braking pressure line 46 to the master cylinder 24 via the pressure line 42.
HOLD MODE
In this control mode, a limited first value, e.g. 2A of electric current serving as the control signal is applied to the actuator 16 to position the anchor closer to the actuator 16 than in the previous case. As a result, the inlet port 16b and the drain port 16d are clsoed to block fluid communication between the pressure line 42 and the braking pressure line 46 and between the braking pressure line and the drain passage 78. Therefore, the fluid pressure in the braking pressure line 46 is held at the level extant at the moment the actuator is operated by the control signal.
In this case, the fluid pressure applied. through the master cylinder flows through the pressure check valve 66 to the pressure accumulator 70.
RELEASING MODE
In this control mode, a maximum value, e.g. 5A of electric current serving as the control signal is applied to the actuator 16 to shift the anchor all the way toward the actuator 16. As a result, the drain port 16d is opened to establish fluid communication between the drain port 16d and the outlet port 16c. At this time, the fluid pump 90 serves to facilitate fluid flow from the braking pressure line 46 to the drain passage 78. The fluid flowing through the drain passage is partly accumulated in the fluid reservoir 76 and the remainder flows to the pressure accumulator 70 via the check valves 60 and 54 and the fluid pump 90.
It will be appreciated that, even in this release mode, the fluid pressure in the prssure line 42 remains at a level higher or equal to that in the braking pressure line 46, so that fluid flow from the braking pressure line 46 to the pressure line 42 via the bypass passage 98 and via the bypass check valve 85 will never occur.
In order to resume the braking pressure in the wheel cylinder (FL) 30a after once the braking pressure is reduced by positioning the electromagnetic valve 16a in the release position, the actuator 16 is again deenergized. The electromagnetic valve 16a is thus returns to its initial position to allow the fluid flow between the inlet port 16b and the outlet port 16c so that the pressurized fluid may flow to the left front wheel cylinder 30a via the braking pressure line 46. As set forth the drain port 16d is closed to block fluid flow from the pressure line 42 to the drain passage 78.
As a result, the pressure accumulator 70 is connected to the left front wheel cylinder 30a via the electromagnetic valve 16a and the braking pressure line 46. The pressurized fluid in the pressure accumulator 70 is thus supplied to the wheel cylinder 30a so as to resume the fluid pressure in the wheel cylinder 30a.
At this time, as the pressure accumulator 70 is connected to the fluid reservoir 76 via the check valves 60 and 54 which allow fluid flow from the fluid reservoir to the pressure acumulator, the extra amount of pressurized fluid may be supplied from the fluid reservoir.
The design of the wheel speed sensors 10, 12 and 14 employed in the preferred embodiment of the anti-skid control system will be described in detail with reference to FIGS. 7 to 9.
FIG. 7 shows the structure of the wheel speed sensor 10 for detecting the rate of rotation of the left front wheel. The wheel speed sensor 10 generally comprises a sensor rotor 104 adapted to rotate with the vehicle wheel, and a sensor assembly 102 fixedly secured to the shim portion 106 of the knuckle spindle 108. The sensor rotor 104 is fixedly secured to a wheel hub 109 for rotation with the vehicle wheel.
As shown in FIG. 9, the sensor rotor 104 is formed with a plurality of sensor teeth 120 at regular angular intervals. The width of the teeth 120 and the grooves 122 therebetween are equal in the shown embodiment and define a unit angle of wheel rotation. The sensor assembly 102 comprises a magnetic core aligned with its north pole (N) near the sensor rotor 104 and its south pole (S) distal from the sensor rotor. A metal element 125 with a smaller diameter section 125a is attached to the end of the magnetic core 124 nearer the sensor rotor. The free end of the metal element 125 faces the sensor teeth 120. An electromagnetic coil 126 encircles the smaller diameter section 125a of the metal element. The electromagnetic coil 126 is adapted to detect variations in the magnetic field generated by the magnetic core 124 to produce an alternating-current sensor signal as shown in FIG. 10. That is, the metal element and the magneitc core 124 form a kind of proximity switch which adjusts the magnitude of the magnetic field depending upon the distance between the free end of the metal element 125 and the sensor rotor surface. Thus, the intensity of the magnetic field fluctuates in relation to the passage of the sensor teeth 120 and accordingly in relation to the angular velocity of the wheel.
It should be appreciated that the wheel speed sensor 12 for the right front wheel has the substantially the same structure as the set forth above. Therefore,
explanation of the structure of the right wheel speed sensor 12 will be omitted in order to avoid unnecessary repetition in the disclosure and in order to simplify the description.
FIG. 8 shows the structure of the rear wheel speed sensor 14. As with the aforementioned left front wheel speed sensor 10, the rear wheel speed sensor 14 comprises a sensor rotor 112 and a sensor assembly 102. The sensor rotor 112 is associated with a companion flange 114 which is, in turn, rigidly secured to a drive shaft 116 for rotation therewith. Thus, the sensor rotor 112 rotates with the drive shaft 116. The sensor assembly 102 is fixed to a final drive housing or a differential gear box (not shown).
Each of the sensor assemblies applied to the left and right front wheel speed sensors and the rear wheel sensor is adapted to output an alternating-current sensor signal having a frequency proportional to or corresponding to the rotational speed of the corresponding vehicle wheel. The electromagnetic coil 126 of each of the sensor assemblies 102 is connected to the control module 200 to supply the sensor signals thereto.
As set forth above, the control module 200 comprises the controller unit (FL) 202, the controller unit (FR) 204 and the controller unit (R) 206, each of which comprises a microcomputer. Therefore, the wheel speed sensors 10, 12 and 14 are connected to corresponding controller units 202, 204 and 206 and send their sensor signals thereto. Since the structure and operation of each of the controller units is substantially the same as that of the others, the structure and operation of only the controller unit 202 for performing the anti-skid brake control for the front left wheel cylinder will be explained in detail.
FIG. 11 is a timing chart of the anti-skid conttrol performed by the controller unit 202. As set forth above, the alternating-current sensor signal output from the wheel speed sensor 10 is converted into a rectangular pulse train, i.e. as the sensor pulse signal mentioned above. The controller unit 202 monitors occurrences of sensor pulses and measures the intervals between individual pulses or between the first pulses of groups of relatively-high-frequency pulses. Pulses are so grouped that the measured intervals will exceed a predetermined value, which value will be hereafter referred to as "pulse interval threshold".
The wheel rotation speed V w is calculated in response to each sensor pulse. As is well known, the wheel speed is generally inversely proportional to the intervals between the sensor pulses and accordingly, the wheel speed V 2 is derived from the interval between the last sensor pulse input time and the current sensor pulse input time. A target wheel speed is designated V i and the resultant wheel speed is designated V w . In addition, the slip rate is derived from the rate of change of the wheel speed and an projected speed V v which is estimated from the wheel speed at the moment the brakes are applied based on the assumption of a continuous, linear deceleration without slippage. In general, the target wheel speed V i is derived from the wheel speed of the last skid cycle during which the wheel deceleration rate was equal to or less than a given value which will be hereafter referred to as "deceleration threshold a ref ", and the wheel speed of the current skid cycle, and by estimating the rate of change of the wheel speed between wheel speeds at which the rate of deceleration is equal to or less than the deceleration threshold. In practice, the first target wheel speed V i is derived based on the projected speed V v which corresponds to a wheel speed at the initial stage of braking operation and at which wheel deceleration exceeds a predetermined value, e.g. -1.2G, and a predetermined deceleration rate, for example 0.4G. The subsequent target wheel speed V i is derived based on the projected speeds V v in last two skid cycles. For instance, the deceleration rate of the target wheel speed V i is derived from a difference of the projected speeds V v in the last two skid cycle and a period of time in which wheel speed varies from the first projected speed to the next projected speed. Based on the last projected speed and the deceleration rate, the target wheel speed in the current skid cycle is derived.
The acceleration and deceleration of the wheel is derived based on the input time of three successive sensor pulses. Since the interval of the adjacent sensor signal pulses corresponds to the wheel speed, and the wheel speed is a function of the reciprocal of the interval by comparing adjacent pulse-to-pulse intervals, a value corresponding to the variation or difference of the wheel speed may be obtained. The resultant interval may be divided by the period of time of the interval in order to obtain the wheel acceleration and deceleration at the unit time. Therefore, the acceleration or deceleration of the wheel is derived from the following equation: ##EQU1## where A, B and C are the input times of the sensor pulses in the order given.
On the other hand, the slip rate R is a rate of difference of wheel speed relative to the vehicle speed which is assumed as substantially corresponding to the target wheel speed. Therefore, in the shown embodiment, the target wheel speed V i is taken as variable or parameter indicative of the assumed or projected vehicle speed. The slip rate R can be obtained by dividing a difference between the target wheel speed V i and the intantaneous wheel speed V w by the target wheel speed. Therefore, in addition, the slip rate R is derived by solving the following equation: ##EQU2##
Finally, the controller unit 202 determines the control mode, i.e., release mode, hold mode and application mode from the slip rate R and the wheel acceleration or deceleration a w .
General operation of the controller unit 202 will be briefly explained herebelow with reference to FIG. 11. Assuming the brake is applied to at t 0 and the wheel deceleration a w exceeds the predetermined value, e.g. 1.2G at a time t 1 , the controller unit 202 starts to operate at a time t 1 . The first sensor pulse input time (t 1 ) is held int the controller unit 202. Upon receipt of the subsequent sensor pulse at a time t 2 , the wheel speed V w is calculated by deriving the current sensor pulse period (dt=t 2 -t 1 ). In response to the subsequently received sensor pulses at time t 3 , t 4 . . . , the wheel speed values V w2 , V w3 . . . are calculated.
On the other hand, at the time t 1 , the instantaneous wheel speed is taken as the projected speed V v . Based on the projected speed V v and the predetermined fixed value, e.g. 0.4G, the target wheel speed V i decelerating at the predetermined deceleration rate 0.4G is derived.
In anti-skid brake control, the braking force applied to the wheel cylinder is to be so adjusted that the peripheral speed of the wheel, i.e. the wheel speed, during braking is held to a given ratio, e.g. 85% to 80% of the vehicle speed. Therefore, the slip rate R has to be maintained below a given ratio, i.e., 15% to 10%. In the preferred embodiment, the control system controls the braking force so as to maintain the slip rate at about 15%. Therefore, a reference value R ref to be compared with the slip rate R is determined at a value at 85% of the projected speed V v . As will be appreciated, the reference value is thus indicative of a slip rate threshold, which will be hereafter referred to "slip rate threshold R ref " throughout the specification and claims, and varies according to variation of the target wheel speed.
In practical brake control operation performed by the preferred embodiment of the anti-skid control system according to the present invention, the electric current applied to the actuator attains a limited value, e.g., 2A to place the electromagnetic valve 30a in the hold mode as shown in FIG. 5 when the wheel speed remains inbetween the target wheel speed V i and the slip rate threshold R ref . When the slip rate derived from the target wheel speed V i and the wheel speed V w becomes equal to or larger than the slip rate threshold R ref , then the supply current to the actuator 16 is increased to a maximum value, e.g. 5A to place the electromagnetic valve in the release mode as shwon in FIG. 6. By maintaining the release mode, the wheel speed V w is recovered to the target wheel speed. When the wheel speed is thus recovered or resumed so that the slip rate R at that wheel speed becomes equal to or less than the sip rate threshold R ref , then the supply current to the actuator 16 is dropped to the limited value, e.g. 2A to return the electromagnetic valve 30a to the hold mode. By holding the reduced fluid pressure in the wheel cylinder, the wheel speed V w is further resumed to the target wheel speed V i . When the wheel speed V w is resumed equal to or higher than the targt wheel speed V i , the supply current is further dropped to zero for placing the electromagnetic valve in the application mode as shown in FIG. 4. The electromagnetic valve 30a is maintained in the application mode until the wheel speed is decelerated at a wheel speed at which the wheel deceleration becomes equal to or slightly more than the deceleration threshold R ref -1.2G. At the same time, the projected speed V v is again derived with respect to the wheel speed at which the wheel decleration a w becomes equal to or slightly larger than the deceleration threshold a ref . From a difference of speed of the last projected speed and the instant projected speed and the period of time from a time obtaining the last projected speed to a time obtaining the instant projected speed, a deceleration rate of the target wheel speed V i is derived. Therefore, assuming the last projected speed is V v1 , the instant projected speed is V v2 , and the period of time is T v , the target wheel speed V i can be obtained from the following equation:
V.sub.i =V.sub.v2 -(V.sub.v1 -V.sub.v2)/T.sub.v ×t.sub.e
where t e is an elapsed time from the time at which the instant projected speed V v2 is obtained.
Based on the input timing to t 1 , t 2 , t 3 , t 4 . . . , deceleration rate a w is derived from the foregoing equation (1). In addition, the projected speed V v is estimated as a function of the wheel speed V w and rate of change thereof. Based on the instantaneous wheel speeds V w1 at which the wheel deceleration is equal to or less than the deceleration threshold a ref and the predetermined fixed value, e.g. 0.4G for the first skid cycle of control operation, the target wheel speed V i is calculated. According to equation (2), the slip rate R is calculated, using successive wheel speed values V w1 , V w2 , V w3 . . . as parameters. The derived slip rate R is compared with the slip rate threshold R ref . As the wheel speed V w drops below the projected speed V v at the time t 1 , the controller unit 202 switches the control mode from the application mode to the hold mode. Assuming also that the slip rate R exceeds the slip rate threshold at the time t 4 , then the controller unit 202 switches the control mode to the release mode to release the fluid pressure at the wheel cylinder.
Upon release of the brake pressure in the wheel cylinder, the wheel speed V w recovers, i.e. the slip rate R drops until it is smaller than the slip rate threshold at time t 7 . The controller unit 202 detects when the slip rate R is smaller than the slip rate threshold R ref and switches the control mode from release mode to the hold mode.
By maintaining the brake system in the hold mode in which reduced brake pressure is applied to the wheel cylinder, the wheel speed increases until it reaches the projected speed as indicated by the intersection of the dashed line (V v ) and the solid trace in the graph of V w in FIG. 11. When the wheel speed V w becomes equal to the target wheel speed V i (at a time t 8 ), the controller unit 202 switches the control mode from the hold mode to the application mode.
As can be appreciated from the foregoing description, the control mode will tend to cycle through the control modes in the order application mode, hold mode, release mode and hold mode, as exemplified in the period of time from t 1 to t 8 . This cycle of variation of the control modes will be referred to hereafter as "skid cycle". Practically speaking, there will of course be some hunting and other minor deviations from the standard skid cycle.
The projected speed V v , which is meant to represent ideal vehicle speed behavior, at time t 1 can be obtained directly from the wheel speed V w at that time since zero slip is assumed. At the same time, the deceleration rate of the vehicle will be assumed to be a predetermined fixed value or the appropriate one of a family thereof, in order to enable calculation of the target wheel speed for the first skid cycle operation. Specifically, in the shown example, the projected speed V v at the time t 1 will be derived from the wheel speed V w1 at that time. Using the predetermined deceleration rate, the projected speed will be calculated at each time the wheel deceleration a w in the application mode reaches the deceleration threshold a ref .
At time t 9 , the wheel deceleration a w becomes equal to or slightly larger than the decelerationn threshold a ref , then the second projected speed V v2 is obtained at a value equal to the instantaneous wheel speed V w at the time t 9 . According to the above-mentioned equation, the deceleration rate da can be obtained
da=(V.sub.v1 -V.sub.v2)/(t.sub.9 -t.sub.1)
Based on the derived deceleration rate da, the target wheel speed V i ' for the second skid cycle of control operation is derived by:
V.sub.i '=V.sub.v2 -da×t.sub.e
Based on the derived target wheel speed, the slip rate threshold R ref for the second cycle of control operation is also derived. As will be appreciated from FIG. 11, the control mode will be varied during the second cycle of skid control operation, to hold mode at time t 9 at which the wheel deceleration reaches the deceleration threshold a ref as set forth above, to release mode at time t 10 at which the slip rate R reaches the slip rate threshold R ref , to hold mode at time t 11 at which the slip rate R is recovered to the slip rate threshold R ref , and to application mode at time t 12 at which the wheel speed V w recovered or resumed to the target wheel speed V i '. Further, it should be appreciated that in the subsequent cycles of the skid control operations, the control of the operational mode of the electromagnetic valve as set forth with respect to the second cycle of control operation, will be repeated.
Relating the above control operations to the structure of FIGS. 3 through 6, when application mode is used, no electrical current is applied to the actuator of the electromagnetic valve 16a so that the inlet port 16b communicates with the outlet port 16c, allowing fluid flow between the pressure passage 42 and the brake pressure line 46. A limited amount of electrical current (e.g. 2A) is applied at times t 1 , t 7 , t 9 and t 11 , so as to actuate the electromagnetic valve 16a to its limited stroke position by means of the actuator 16, and the maximum current is applied to the actuator as long as the wheel speed V w is not less than the projected speed and the slip rate is greater than the slip rate threshold R ref . Therefore, in the shown example, the control mode is switched from the application mode to the hold mode at time t 1 and then to the release mode at time t 4 . At time t 7 , the slip rate increases back up to the slip rate threshold R ref , so that the control mode returns to the hold mode, the actuator driving the electromagnetic valve 16a to its central holding position with the limited amount of electrical current as the control signal. When the wheel speed V w finally returns to the level of the target wheel speed V i at time t 8 , the actuator 16 supply current is cut off so that the electromagnetic valve 16a returns to its rest position in order to establish fluid communication between the pressure line 42 and the braking pressure line 46 via inlet and outlet ports 16b and 16c.
Referring to FIG. 12, the controller unit 202 includes an input interface 230, CPU 232, an output interface 234, RAM 236 and ROM 238. The input interface 230 includes an interrupt command generator 229 which produces an interrupt command in response to every sensor pulse. In ROM, a plurality of programs including a main program (FIG. 13), an interrupt program (FIG. 15), an sample control program (FIG. 19), a timer overflow program (FIG. 20) and an output calculation program (FIG. 23) are stored in respectively corresponding address blocks 244, 246, 250, 252 and 254.
The input interface also has a temporary register for temporarily holding input timing for the sensor pulses. RAM 236 similarly has a memory block holding input timing for the sensor pulses. The contents of the memory block 240 of RAM may be shifted whenever calculations of the pulse interval, wheel speed, wheel acceleration or deceleration, target wheel speed, slip rate and so forth are completed. One method of shifting the contents is known from the corresponding disclosure of the U.S. Pat. No. 4,408,290. The disclosure of the U.S. Pat. No. 4,408,290 is hereby incorporated by reference. RAM also has a memory block 242 for holding pulse intervals of the input sensor pulses. The memory block 242 is also adapted to shift the contents thereof according to the manner similar to set forth in the U.S. Pat. No. 4,408,290.
An interrupt flag 256 is provided in the controller unit 202 for signalling interrupt requests to the CPU. The interrupt flag 256 is set in response to the interrupt command from the interrupt command generator 229. A timer overflow interrupt flag 258 is adapted to set an overflow flag when the measured interval between any pair of monitored sensor pulses exceeds the capacity of a clock counter.
In order to time the arrival of the sensor pulses, a clock is connected to the controller unit 202 to feed time signals indicative of elapsed real time. The timer signal value is latched whenever a sensor pulse is received and stored in either or both of the temporary register 231 in the input interface 230 and the memory block 240 of RAM 236.
The operation of the controller unit 202 and the function of each elements mentioned above will be described with reference to FIGS. 13 to 30.
FIG. 13 illustrates the main program for the anti-skid control system. Practically speaking, this program will generally be executed as a background job, i.e. it will have a lower priority than most other programs under the control of the same processor. Its first step 1002 is to wait until at least one sample period, covering a single sensor pulse or a group thereof, as described in more detail below, is completed as indicated when a sample flag FL has a non-zero value. In subsequent step 1004, the sample flag FL is checked for a value greater than one, which would indicate the sample period is too short. If this is the case, control passes to a sample control program labelled "1006" in FIG. 13 but shown in more detail in FIG. 19. If FL=1, then the control process is according to plan, and control passes to a main routine explained later with reference to FIG. 15. Finally, after completion of the main routine, a time overflow flag OFL is reset to signify successful completion of another sample processing cycle, and the main program ends.
FIG. 14 shows the interrupt program stored in the memory block 246 of ROM 238 and executed in response to the interrupt command generated by the interrupt command generator 229 whenever a sensor pulse is received. It should be noted that a counter value NC of an auxiliary counter 233 is initially set to 1, a register N representing the frequency divider ratio is set at 1, and a counter value M of an auxiliary counter 235 is set at -1. After starting execution of the interrupt program, the counter value NC of the auxiliary counter 233 is decremented by 1 at a block 3002. The auxiliary counter value NC is then checked at a block 3004 for a value greater than zero. For the first sensor pulse, since the counter value NC is decremented by 1 (1-1=0) at the block 3002 and thus is zero, the answer of the block 3004 is NO. In this case, the clock counter value to is latched in a temporary register 231 in the input interface 230 at a block 3006. The counter value NC of the auxiliary counter 233 is thereafter assigned the value N in a register 235, which register value N is representative of frequency dividing ratio determined during execution of the main routine explained later, at a block 3008. The value M of an auxiliary counter 235 is then incremented by 1. The counter value M of the auxiliary counter 235 labels each of a sequence of sample periods covering an increasing number of sensor pulses. After this, the sample flag FL is incremented by 1 at a block 3012. After the block 3012, interrupt program ends, returning control to the main program or back to block 3002, whichever comes first.
On the other hand, when the counter value NC is non-zero when checked at the block 3004, this indicates that not all of the pulses for this sample period have been received, and so the interrupt program ends immediately.
This interrupt routine thus serves to monitor the input timing t of each pulse sampling period, i.e. the time t required to receive NC pulses, and signals completion of each sample period (M=0 through M=10, for example) for the information of the main program.
Before describing the operation in the main routine, the general method of grouping the sensor pulses into sample periods will be explained to facilitate understanding of the description of the operation in the main routine.
In order to enable the controller unit 202 to accurately calculate the wheel acceleration and deceleration a w , it is necessary that the difference between the pulse intervals of the single or grouped sensor pulses exceeding a given period of time, e.g. 4 ms. In order to obtain the pulse interval difference exceeding the given period of time, 4 ms, which given period of time will be hereafter referred to as "pulse interval threshold S", some sensor pulses are ignored so that the recorded input timing t of the sensor pulse groups can satisfy the following formula:
dT=(C-B)-(B-A)≧S(4 ms.) (3)
where A, B and C are the input times of three successive sensor pulse groups.
The controller unit 202 has different sample modes, i.e. MODE 1, MODE 2, MODE 3 and MODE 4 determining the number of sensor pulses in each sample period group. As shown in FIG. 16, in MODE 1 every sensor pulse input time is recorded and therefore the register value N is 1. In MODE 2, every other sensor pulse is ignored and the register value N is 2. In MODE 3, every fourth sensor pulse is monitored, i.e. its input time is recorded, and the register value N is 4. In MODE 4 every eighth sensor pulse is sampled and the register value N is then 8.
The controller unit 202 thus samples the input timing of three successive sensor pulses to calculate the pulse interval difference dT while operating in MODE 1. If the derived pulse interval difference is equal to or greater than the pulse interval threshold S, then sensor pulses will continue to be sampled in MODE 1. Otherwise, the input timing of every other sensor pulse is sampled in MODE 2 and from the sampled input timing of the next three sensor pulses sampled, the pulse interval difference dT is calculated to again be compared with the pulse interval threshold S. If the derived pulse interval difference is equal to or greater than the pulse interval threshold S, we remain in MODE 2. Otherwise, every four sensor pulses are sampled in MODE 3. The input timings of the next three sampled sensor pulses are processed to derive the pulse interval difference dT. The derived pulse interval difference dT is again compared with the pulse interval threshold S. If the derived pulse interval difference is equal to or greater than the pulse interval threshold S, the MODE remains at 3 and the value N is set to 4. On the other hand, if the derived pulse interval difference dT is less than the pulse interval threshold S, the mode is shifted to MODE 4 to sample the input timing of every eighth sensor pulse. In this MODE 4, the value N is set at 8.
Referring to FIG. 15, the main routine serves to periodically derive an updated wheel acceleration rate value a w . In general, this is done by sampling larger and larger groups of pulses until the difference between the durations of the groups is large enough to yield an accurate value. In the main routine, the sample flag FL is reset to zero at a block 2001. Then the counter value M of the auxiliary counter 233, indicating the current sample period of the current a w calculation cycle, is read out at a block 2002 to dictate the subsequent program steps.
Specifically, after the first sample period (M=φ), the input timing t temporarily stored in the temporary register 231 corresponding to the sensor pulse number (M=0) is read out and transferred to a memory block 240 of RAM at a block 2004, which memory block 240 will be hereafter referred to as "input timing memory". Then control passes to the block 1008 of the main program. When M=2, the corresponding input timing t is read out from the temporary register 231 and transferred to the input timing memory 240 at a block 2006. Then, at a block 2008, a pulse inteval Ts between the sensor pulses of M=1 is derived from the two input timing values in the input timing memory 240. That is, the pulse interval of the sensor pulse (M=1) is derived by:
Ts=t.sub.1 -t.sub.0
where
t 1 is input time of the sensor pulse M1; and
t 0 is input time of the sensor pulse M0.
The derived pulse interval T s of the sensor pulse M1 is then compared with a reference value, e.g. 4 ms., at a block 2010. If the pulse interval T s is shorter than the reference value, 4 ms., control passes to a block 2012 wherein the value N and the pulse interval T s are multiplied by 2. The doubled timing value (2T s ) is again compared with the reference value by returning to the block 2010. The blocks 2010 and 2012 constitute a loop which is repeated until the pulse interval (2nT s ) exceeds the reference value. when the pulse interval (2nT 2 ) exceeds the reference value at the block 2010, a corresponding value of N (2N) is automatically selected. This N value represents the number of pulses to be treated as a single pulse with regard to timing.
After setting the value of N and thus deriving the sensor pulse group size, then the auxiliary counter value NC is set to 1, at a block 2016. The register value N is then checked for a value of 1, at a block 2018. If N=1, then the auxiliary counter value M is set to 3 at a block 202 and otherwise control returns to the main program. When the register value N equals 1, the next sensor pulse, which would normally be ignored, will instead be treated as the sensor pulse having the sample period number M=3.
In the processing path for the sample period number M=3, the corresponding input timing is read from the corresponding address of the temporary register 231 and transferred to the input timing memory 240, at a block 2024. The pulse interval T 2 between the sensor pulses at M=1 and M=3 is then calculated at a block 2026. The derived pulse interval T 2 is written in a storage section of a memory block 242 of RAM 236 for a current pulse interval data, which storage section will be hereafter referred at as "first pulse interval storage" and which memory block 242 will be hereafter referred to as "pulse interval memory". After the block 2026, control returns to the main program to await the next sensor pulse, i.e. the sensor pulse for sample period number M=4.
When the sensor pulse for M=4 is received, the value t of the temporary register 231 is read out and transferred to the input timing memory 240 at block 2028. Based on the input timing of the sensor pulses for M=3 and M=4, the pulse interval T 3 is calculated at a block 2030. The pulse interval T 3 derived at the block 2030 is then written into the first pulse interval storage of the pulse interval memory. At the same time, the pulse interval data T 2 previously stored in the first pulse interval storage is transferred to another storage section of the pulse interval memory adapted to store previous pulse interval data. This other storage section will be hereafter referred to as "second pulse interval storage". Subsequently, at a block 2032 the contents of the first and second storages, i.e. the pulse interval data T 2 and T 3 are read out. Based on the read out pulse interval data T 2 and T 3 , a pulse interval difference dT is calculated at block 2032 and compared with the pulse interval threshold S to determine whether or not the pulse interval difference dT is large enough for accurate calculation of wheel acceleration or deceleration a w . If so, process goes to the block 2040 to calculate the wheel acceleration or deceleration according to the equation (1). The register value N is then set to 1 at the block 2044 and thus MODE 1 is selected. In addition sample period number M is reset to -1, and the a 2 derivation cycle starts again. On the other hand, if at the block 2032 the pulse interval difference dT is too small to calculate the wheel acceleration or deceleration a w , then the value N is multiplied by 2 at a block 2034. Due the updating of the value N, the sample mode of the sensor pulses is shifted to the next mode.
By shifting the sample mode to MODE 2, every other sensor pulse is sampled. Therefore, assuming the sample mode is shifted to MODE 2 during processing of the sensor pulse of M=3, the sensor pulse is input following the sensor pulse for M=3 will be ignored by the interrupt program as set forth above. In this case, the sensor pulse C 2 following the sensor pulse c 1 is given the sample period number M=5 and its input timing is recorded. Shifting of the sample mode at the blocks 2032 and 2034 will be repeated until the pulse interval difference dT becomes large enough for accurate calculation of the wheel acceleration and deceleration a w at the block 2040.
As set forth above, by setting the counter value NC of the auxiliary counter 233 to 1 at the block 2016, the input timing of the sensor pulse received immediately after initially deriving the sample mode at the blocks 2010, 2012 and 2014 will be sampled as the first input timing to be used for calculation of the wheel acceleration and deceleration. This may be contrasted with the procedure taken in the known art.
FIG. 16 shows the output program for deriving the wheel speed V w , wheel acceleration and deceleration a w and slip rate R, selecting the operational mode, i.e. application mode, hold mode and release mode, and outputting an inlet signal EV and/or an outlet signal AV depending upon the selected operation mode of the actuator 16.
When the application mode is selected the inlet signal EV goes HIGH and the outlet signal EV goes HIGH. When the release mode is selected, the inlet signal EV goes LOW and the outlet signal AV also goes LOW. When the selected mode is the hold mode, the inlet signal EV remains HIGH while the outlet signal AV goes LOW. These combinations of the inlet signal EV and the outlet signal AV correspond to the actuator supply current levels shown in FIG. 11 and thus actuate the electromagnetic valve to the corresponding positions illustrated in FIGS. 4, 5 and 6.
The output program is stored in the memory block 254 and adapted to be read out periodically, e.g. every 10 ms, to be executed as an interrupt program. The output calculation program is executed in the time regions shown in hatching in FIGS. 25 and 26.
During execution of the output calculation program, the pulse interval T is read out from a memory block 241 of RAM which stores the pulse interval, at a block 5002. As set forth above, since the pulse interval T is inversely proportional to the wheel rotation speed V w , the wheel speed can be derived by calculating the reciprocal (1/T) of the pulse interval T. This calculation of the wheel speed V w is performed at a block 5004 in the output program. After the block 5004, the target wheel speed V i is calculated at a block 5006. The manner of deriving the target wheel speed V i has been illustrated in the U.S. Pat. Nos. 4,392,202 to Toshiro MATSUDA, issued on July 5, 1983, 4,384,330 also to Toshiro MATSUDA, issued May 17, 1983 and 4,430,714 also to Toshiro MATSUDA, issued on Feb. 7, 1984, which are all assigned to the assignee of the present invention. The disclosure of the above-identified three U.S. Patents are hereby incorporated by reference for the sake of disclosure. As is obvious herefrom, the target wheel speed V i is derived as a function of wheel speed deceleration as actually detected. For instance, the wheel speed V w at at which the wheel deceleration a w exceeds a predetermined value -b is taken a one reference point for deriving the target wheel speed V i . The wheel speed at
which the wheel deceleration a w also exceeds the predetermined value -b, is taken as the other reference point. In addition, the period of time between the points a and b is measured. Based on the wheel speed V w1 and V w2 and the measured period P, the deceleration rate dV i is derived from:
dV.sub.i =(V.sub.w1 -V.sub.w2)/P (4)
This target wheel speed V i is used for skid control in the next skid cycle.
It should be appreciated that in the first skid cycle, the target wheel speed V i cannot be obtained. Therefore, for the first skid cycle, a predetermined fixed value will be used as the target wheel speed V i .
At a block 5008 (FIG. 16), the slip rate R is calculated according to the foregoing formula (2). Subsequently, the operational mode is determined on the basis of the wheel acceleration and deceleration a w and the slip rate R, at a block 5010. FIG. 19 shows a table used in determining or selecting the operational mode of the actuator 16 and which is accessed according to the wheel acceleration and deceleration a w and the slip rate R. As can be seen, when the wheel slip rate R is in the range of 0 to 15%, the hold mode is selected when the wheel acceleration and deceleration a w is lower than -1.0G and the application mode is selected when the wheel acceleration and deceleration a w is in the range of -1.0G to 0.6G. On the other hand, when the slip rate R remains above 15%, the release mode is selected when the wheel acceleration and deceleration a w is equal to or less than 0.6G, and the hold mode is selected when the wheel acceleration and deceleration is in a range of 0.6G to 1.5G. When the wheel acceleration and deceleration a w is equal to or greater than 1.5G, the application mode is selected regardless of the slip rate.
According to the operational mode selected at the blcok 5010, the signal levels of the inlet signal EV and the outlet signal AV are determined so that the combination of the signal levels corresponds to the selected operation mode of the actuator 16. The determined combination of the inlet signal EV and the outlet signal AV are output to the actuator 16 to control the electromagnetic valve.
The wheel speed deriving routine executed at the block 5004 of the output calculation program of FIG. 16 is illustrated in FIG. 20.
After starting the wheel speed deriving routine, the sensor pulse interval T n stored in the memory block 242 of RAM 236 is read out at a block 5004-1. Based on the read out sensor pulse interval T n , the wheel speed V wn corresponding to the read out sensor pulse interval T n is derived from the formula V wn =k 1 /T n (where k 1 is a constant determined in accordance with the ratio of the diameter of the wheel sensor rotor and the diameter of the wheel), at a block 5004-2.
The wheel speed V wn derived during the current cycle of program execution will be referred to as "new wheel speed" and the wheel speed V wn-1 derived in the preceding cycle of program execution is referred to as "old wheel speed". It should be noted that the new and old wheel speeds V wn and V wn-1 are stored in a shiftable memory block 243 of RAM 236. The memory block 243 has first and second sections 243-1 and 243-2 respectively adapted to hold the instant and old wheel speeds.
Returning to FIG. 20, after performing the calculation at the block 5004-2, the newly derived wheel speed V wn is written into the first section 243-1 of the memory block 243, at a block 5004-3. At a block 5004-4, a wheel speed flag FLV is checked. If the flag FLV is not set, the new wheel speed V wn and the old wheel speed V wn-1 are compared at a block 5004-5. In practice, a difference of the new and old wheel speeds dV (=V wn -V wn-1 ) is compared with a given threshold dV ref , at the block 5004-5. If the difference dV is equal to or less than the given threshold dV ref , then the old wheel speed V wn-1 stored in the second section 243-2 of the memory block 243 is cleared at a block 5004-6 and at the same time, the new wheel speed V wn is shifted from the first section 243-1 to the second section 243-2. Thereafter, the content of the second section 243-2 of the memory block 243 is output at a block 5004-7.
On the other hand, if the difference dV is greater than the given threshold dV ref at the block 5004-5, then the wheel speed flag FLV is set at a block 5004-8. The new wheel speed V wn stored in the first section 243-1 is then cleared at a block 5004-9. The old wheel speed V wn-1 stored in the second 243-2 is output in place of the new wheel speed at a block 5004-10. Thereafter, the old wheel speed V wn-1 stored in the second section 243-1 of the memory block 243 is cleared at a block 5004-11.
If the wheel speed flag FLV is set when checked at the block 5004-12, then the wheel speed flag FLV is reset at a block 5004-12. The new wheel speed V wn held in the first section 243-1 is shifted to the second section 243-2 at a block 5004-13. Thereafter, the new wheel speed V wn stored in the second section 243-2 is output as the new wheel speed data at a block 5004-14.
After outputting wheel speed data at the blocks 5004-7, 5004-11 or 5004-14, control returns to the output calculation program.
The procedure executed by the wheel speed deriving routine set forth above will be explained with reference to FIG. 18. Assuming sensor signal pulses are at the time t n-1 , t n and t n+1 , the sensor pulse intervals T n1 and T n2 are respectively (t n -t n-1 ) and (t n+1 -t n ). From these sensor pulse intervals, wheel speed values V w1 and V w2 are derived at times t 1 and t n+1 respectively. As shown in broken lines in FIG. 21, if the derived wheel speed V w2 has a value significantly different from the value of the wheel speed V w1 , is ignored and replaced with the preceding wheel speed value V w1 .
As will be appreciated from FIG. 20, the memory block 243 is empty after the old wheel speed is cleared at the block 5004-11 so that the next derived wheel speed value V w3 will always be output as the next wheel speed data in the subsequent cycle of the V w derivation routine.
Since it is not possible for the wheel speed to vary significantly within such a short period of time, e.g. 10 ms., even when a substantial difference between the old and new wheel speeds is detected and the new wheel speed is ignored, this will never affect the performance of the anti-skid control system seriously. Under these circumstances, it may be possible to use an old wheel speed data in the current cycle of anti-skid control operation, in case where the new wheel speed is deviates from the old wheel speed data by more than the given threshold dV ref .
FIG. 22 shows another embodiment of the controller unit 202 in the preferred embodiment of the anti-skid control system according to the present invention. In practice the circuit shown in FIG. 22 performs the same procedure in controlling the actuator 16 and each block of the circuit performs by the substantially corresponding to that performed by the foregoing computer flowchart.
In FIG. 22, the wheel speed sensor 10 is connected to a shaping circuit 260 provided in the controller unit 202. The shaping circuit 260 produces the rectangular sensor pulses having a pulse interval inversely proportional to the wheel speed V w . The sensor pulse output from the shaping circuit 260 is fed to a pulse pre-scaler 262 which counts the sensor pulses to produce a sample command for sampling input timing when the counter value reaches a predetermined value. The predetermined value to be compared with the counter value in the pulse pre-scaler 262 is determined such that the intervals between the pairs of three successive sample commands will be sufficiently different to allow calculation of the wheel acceleration and deceleration rate.
The sample command is fed to a flag generator 264. The flag generator 264 is responsive to the sample command to produce a flag signal. The flag signal of the flag generator 264 is fed to a flag counter 266 which is adapted to count the flag signals and output a counter signal having a value representative of its counter value.
At the same time, the sample command of the pulse pre-scaler 262 is fed to a latching circuit 268 which is adapted to latch the signal value of a clock counter signal from a clock counter 267 counting the clock pulse output by a clock generator 11. The latched value of the clock counter signal is representative of the input timing of the sensor pulse which activates the pulse pre-scaler 262 to produce the sample command. The latching circuit 268 sends the input timing indicative signal having a value corresponding to the latched clock counter signal value, to a memory controller 274. The memory controller 274 is responsive to a memory command input from an interrupt processing circuit 272 which in turn is responsive to the flag counter signal to issue a memory command which activates the memory controller 274 to transfer the input timing indicative signal from the latching circuit 268 to a memory area 276. The memory 276 sends the stored input timing indicative signal to a sample controller 270 whenever the input timing signal value corresponding to the latched value of the latching circuit 268 is written therein. The sample controller 270 peforms operation substantially corresponding to that performed in the blocks 2008, 2010, 2012, 2032 and 2034 in FIG. 15, i.e. it determines number of sensor pulses in each group to be ignored. The sample controller 270 outputs a pulse number indicative signal to the pulse pre-scaler 262, which pulse number indicative signal has a value approximating the predetermined value to be compared with the counter value in the pulse pre-scaler 262.
The memory 276 also feeds the stored input timing indicative signal to a wheel acceleration and deceleration calculation circuit 278 and a pulse interval calculation circuit 280. The wheel acceleration and deceleration calculation circuit 278 first calculates a pulse interval difference between pairs of three successively sampled sensor pulses. The obtained pulse interval difference is compared with a reference value so as to distinguish if the pulse interval difference is great enough to allow calculation of the wheel acceleration and deceleration a w . If the obtained pulse interval difference is greater than the reference value, then the wheel acceleration and deceleration calculation circuit 278 performs calculation of the wheel acceleration and decerelation according to the foregoing formula (1) If the obtained pulse interval difference is smaller than the reference value, the wheel acceleration and deceleration calculation circuit 278 shifts the operational mode thereof in a manner substantially corresponding to the procedure disclosed with reference to FIG. 16, so as to achieve a pulse interval difference large enough to permit the wheel acceleration and deceleration calculation. On the other hand, the pulse interval calculation circuit 280 peforms calculations to obtain the pulse interval between the current pulse and the immediate preceding pulse and sends a pulse interval indicative signal to a memory 282. The memory 282 sends a stored pulse interval indicative signal to a wheel speed calculation circuit 284 which is associated with a 10 ms timer 292. The 10 ms time 292 produces a timer signal every 10 ms to activate the wheel speed calculation circuit 284. The wheel speed calculation circuit 284 is responsive to the timer signal to perform calculation of the wheel speed V w by calculating the reciprocal value of the pulse interval indicative signal from the memory 282. The wheel speed calculation circuit 284 thus produces a wheel speed indicative signal to be fed to a target wheel speed calculation circuit 288 and to a slip rate calculation circuit 290 which is also associated with the 10 ms timer to be activated by the timer signal every 10 ms.
The target wheel speed calculation circuit 288 is adapted to detect the wheel speed V w at which the wheel acceleration and deceleration a w calculated by the wheel acceleration and deceleration calculating circuit 278 exceeds than a predetermined deceleration rate -b. The target wheel speed calculation circuit 288 measures the interval between times at which the wheel deceleration exceeds the predetermined deceleration value. Based on the wheel speed at the foregoing times and the measured period of time, the target wheel speed calculation circuit 288 derives a decelerating ratio of the wheel speed to produce a target wheel speed indicative signal. The target wheel indicative signal of the target wheel speed calculation circuit 288 and the wheel speed indicative signal from the wheel speed calculation circuit 284 are fed to a slip rate calculation circuit 290.
The slip rate calculation circuit 290 is also responsive to the timer signal from the 10 ms timer 282 to perform calculation of the slip rate R based on the wheel speed indicative signal from the wheel speed calculation circuit 284 and the target wheel speed calculation circuit 288, in accordance with the formula (2).
The slip rate calculation circuit 290 and the wheel acceleration and deceleration calculation circuit 278 are connected to an output unit 294 to feed the acceleration and deceleration indicative signal and the slip rate control signal thereto. The output unit 294 determines the operation mode of the actuator 16 based on the wheel acceleration and deceleration indicative signal value and the slip rate indicative signal value according to the table of FIG. 26. The output unit 294 thus produces the inlet and outlet signals EV and AV with a combination of signal levels corresponding to the selected operation mode of the actuator.
On the other hand, the wheel speed calculation circuit 284 is also connected to the flag counter 266 to feed a decrementing signal whenever the calculation of the wheel speed is completed and so decrement the counter value of the flag counter by 1. The flag counter 266 is also connected to a comparator 295 which is adapted to compare the counter value of the flag counter with a reference value, e.g. 2. When the counter value of the flag counter 266 is greater than or equal to the reference value, the comparator 25 outputs a comparator signal to an overflow detector 296. The overflow detector 296 is responsive to the comparator signal to feed a sample mode shifting command to be fed to the pulse pre-scaler 262 to shift the sample mode to increase the number of the sensor pulses in each sample group.
On the other hand, the clock counter 267 is connected to an overflow flag generator 297 which detects when the counter value reaches the full count of the clock counter to produce an overflow flag signal. The overflow flag signal of the overflow flag generator 297 is fed to an overflow flag counter 298 which is adapted to count the overflow flag signals and send an overflow counter value indicative signal to a judgment circuit 299. The judgment circuit 299 compares the overflow counter indicative signal value with a reference value e.g. 2. The judgment circuit 299 produces a reset signal when the overflow counter indicative signal value is equal to or greater than the reference value. The reset signal resests the wheel acceleration and deceleration calculation circuit 278 and the wheel speed calculation circuit 284 to zero. On the other hand, the overflow flag counter is connected to the wheel speed calculation circuit 284 and is responsive to the decrementing signal output from the wheel speed calculation circuit as set forth above to be reset in response to the decrementing signal.
FIG. 23 is a block diagram of the wheel speed V w calculation circuit 284 of FIG. 22. The wheel speed calculation circuit 284 generally comprises an arithmetic circuit 284-1 connected to the memory 276 to receive the input timing data of the sampled sensor pulses. The arithmetic circuit 284-1 calculates the signal-to-signal interval T n1 , T n1 , T n2 . . . and the wheel speed V w1 , V w2 respectively corresponding to the signal-to-signal intervals T n1 , T n2 . . . . The arithmetic circuit 284-1 sends a signal indicative of the derived wheel speed V wn to a first memory 284-2 to store the derive wheel speed as the new wheel speed value V wn . The first memory 284-2 is associated with a second memory 284-3 which holds the old wheel speed value V wn-1 . The first memory transfers the stored value to the second memory in response to a transfer command from a transfer command generator 284-8 which is, in turn, connected to an output circuit 284-4 and responsive to a signal from the latter to produce the transfer command.
The first and second memories 284-2 and 284-3 are connected for output to a comparator circuit 284-5 which calculates the difference between the new and old wheel speeds (V wn -V wn-1 ) and compares the difference dV with the given threshold dV ref . The comparator circuit 284-5 produces an abnormal state indicative signal when the difference dV is greater than the given threshold dV ref as is the case in FIG. 21. The abnormal-state-indicative signal is sent to a toggle flip-flop circuit 284-6. The T-flip-flop circuit 284-6 is initialized to its reset state but is responsive to successive abnormal-state-indicative signals to change to its set state and then back again. The flip-flop circuit 284-6 feeds a set signal to a memory selector switch 284-7. The memory selector switch 284-7 is normally positioned to transmit the new wheel speed value V wn in the first memory 284-2 to the output circuit 284-4. The memory selector switch 284-7 is responsive to the set signal from the flip-flop circuit 284-6 to reverse its switch position and send the old wheel speed value V wn-1 to the output circuit 284-4.
In the next cycle of wheel speed calculation by the arithmetic circuit 284-1, new wheel speed value V wn+1 is derived. The new wheel speed value V wn+1 is then stored in the first memory 284-1. Since the second memory 284-3 holds an erroneous old wheel speed value V wm , the new wheel speed V wn+1 (see FIG. 21) will deviate excessively from the old value V wn , so that the comparator circuit 284-5 will again output the abnormal-state-indicative signal to the flip-flop circuit 284-6. The flip-flip circuit 284-6, currently set, is responsive to the abnormal-state-indicative signal to be reset. Since the set signal of the flip-flop circuit 284-6 thus ends, the memory selector switch 284-7 returns to its normal position to transmit the new wheel speed value V wn+1 in the first memory 284-2 to the output circuit.
The output circuit 284-4 may include a buffer for temporarily latching the output signal value. The output circuit 284-4 may detect when the memory selector switch 284-7 is in the second-mentioned position and at such times output the value stored in its buffer as the wheel speed data.
It should be noted that the given threshold dV ref to be compared with the difference of the new and old wheel speed (d=|V wn -V wn-1 |) may be adjusted in accordance with vehicle driving conditions, and will be based on empirically obtained values.
FIG. 24 shows a modification of the wheel speed calculation circuit of FIG. 23. In this modification, the wheel speed calculation circuit is so associated with the wheel acceleration calculation circuit 278 as to adjust the wheel speed value to be output through the output circuit on the basis of the wheel acceleration value a w derived at a timing corresponding to the derivation of the old wheel speed value, when the new wheel speed value is detected to be erroneous.
As shown in FIG. 24, the memory selector switch 284-7 is connected for input to the first memory 284-1 and a back-up signal generator 284-9, the latter of which is designed to output a back-up signal having a value derived from the old wheel speed value V wn-1 and the acceleration value a wn-1 derived at the same time as the old wheel speed value V wn-1 . In order to receive the wheel acceleration value, the back-up signal generator 284-9 is connected to the wheel acceleration calculation circuit 278 which comprises an arithmetic circuit 278-1, a first memory which holds the new wheel acceleration value a wn , a second memory 278-3 which holds the old wheel acceleration value a wn-1 and an output correction circuit 278-4 which is adapted to correct the acceleration output value in a manner similar to that performed for the wheel speed data. The back-up signal generator 284-9 is also connected to the memory 276 to receive input timing data in order to derive the period T between the pulses which triggered the derivations of the old and new wheel speed values.
As the in the wheel speed calculation circuit above, the wheel acceleration calculation circuit is adapted to shift the acceleration data from first memory 278-2 to the second memory 27-3 every time the acceleration data is output.
It should be appreciated that since both the wheel speed calculation circuit 284 and the wheel acceleration calculation circuit 278 are adapted to shift data from their first memories 284-2 and 278-2 to their second memories 284-3 and 278-3 whenever their arithmetic circuits 284-1 and 278-1 output the corresponding data, the derivation timing of the wheel speed and the wheel acceleration may essentially correspond. Namely, the wheel acceleration value a wn-1 corresponds to the wheel speed value V wn-1 .
Assuming the wheel speed value V wn is erroneous, the comparator circuit 284-5 will produce the abnormal-state-indicative signal in response thereto. The flip-flop 284-6 is set in response to the abnormal-state-indicative signal, shifting the memory selector switch to its reverse position to connect the output circuit 284-4 to the back-up signal generator 284-9. The back-up signal generator 284-9 receives the old wheel speed V wn-1 corresponding to the old wheel speed from the second memory 278-3 of the wheel acceleration and deceleration calculation circuit 278 and the input timing data representative of the interval between the sensor pulses in response to which the old and new wheel speed values were derived. The back-up circuit 284-9 calculates the back-up signal value according to the following equation:
V.sub.w '=V.sub.wn-1 +a.sub.w ×T
The back-up signal is then fed to the output circuit 284-4 through the memory selector switch 284-7. Thus, the back-up signal value is output by the output circuit as the new wheel speed value.
It is also possible to write the back-up signal value into the second memory 284-3 as the old wheel speed value or into the buffer provided in the output circuit. In the latter case, the back-up signal value may be read out of the buffer as long as the memory selector switch 284-7 remains at its reverse position, i.e., until the next abnormal-state-indicative signal output by the compartor circuit.
Assume that wheel speed values V wn-1 , V wn and V wn+1 are derived from the input timing data t n-2 , t n-1 , t n and t n+1 , shown in FIG. 25. Wheel speed and acceleration are calculated essentially simultaneously from the same timing values. For instance, the wheel acceleration a wn-1 is derived from the input timing data t n-2 , t n-1 and t n , as shown in FIG. 25. If the wheel speed V w derived from the input timing data t n and t n+1 is deviant from the old wheel speed V wn-1 , as shown in FIG. 22 in broken lines, the abnormal-state-indicative signal is produced by the comparator circuit 284-5. In response to the abnormal-state-indicative signal, the projected actual change in wheel speed dV over the period of time T is derived from the wheel acceleration a wn-1 and added to the old wheel speed V wn-1 to derive the back-up signal.
Since the wheel acceleration may not change at a significant rate over one cycle of wheel speed calculation, the back-up signal value thus derived will approximately correspond to the wheel speed which would be calculated if the wheel sensor signal were accurate.
As set forth above, according to the present invention, errors in calculation of wheel speeds are satisfactorily and successfully avoided. This ensures accurate anti-skid control. Therefore, the invention fulfills all of the objects and advantages sought thereto.
|
An anti-skid control system for automotive hydraulic brakes screens out clearly erroneous sensor signals and/or values derived directly from sensor signals and used as anti-skid control parameters. Values for wheel speed, wheel acceleration and other brake-related factors are derived from a wheel rotation sensor signal. When the difference between successively derived wheel speed values exceeds a predetermined value, thus indicating a level of wheel acceleration which can only be an artifact due to an erroneous sensor reading, the latter wheel speed value is replaced with a back-up value. The back-up value is chosen to approximate the actual wheel speed as closely as possible, either by using the previously derived, and presumably accurate, wheel speed value or by adding to the latter a factor projecting the wheel acceleration.
| 1
|
BACKGROUND OF THE INVENTION
It is common practice, particularly in maintenance operations, to use integrally-formed plastic barrels for holding trash and carrying it to various places. It is also known to provide such a barrel with a pair of wheels for ease in moving it from one place to another. While such wheeled trash barrels are very convenient, they suffer from the disability that they cannot be nested. The nesting operation becomes important in shipping, since otherwise a large number of containers would occupy a very large volume that is inconsistent with their value. Also, in displaying such trash barrels at the retail level, would be desirable to nest them to save both storage and display space. The prior art wheeled barrels could not be assembled at the factory and, when received at the retail store, placed on the sale floor immediately without a secondary operation. These and other difficulties experienced with the prior art devices have been obviated in a novel manner by the present invention.
It is, therefore, an outstanding object of the present invention to provide a trash barrel which normally rests securely on a floor surface, but on occassion can be wheeled from one place to another.
Another object of the invention is the provision of a trash barrel which is provided with wheels and which, nevertheless, may be nested with similar containers.
A further object of the present invention is the provision of a wheeled trash barrel which is simple in construction, which is inexpensive to manufacture, and which is capable of a long life of useful service with a minimum of maintenance.
With these and other objects in view, as will be apparent to those skilled in the art, the invention resides in the combination of parts set forth in the specification and covered by the claims appended hereto.
SUMMARY OF THE INVENTION
In general, the present invention consists of a trash barrel having a single-piece plastic container with tapered sidewalls and a bottom wall. The bottom wall is formed with a downwardly-extending pedestal along one side adapted to engage the ground and with an abutment extending laterally from the pedestal directly across the bottom wall. A pair of wheels is rotatably mounted on opposite sides of the abutment. The wheels are generally tangential to a ground plane including the lower surface of the pedestal. The wheels are also generally tangential to a plane of extension of a side wall, so that the wheels lie entirely within an envelope defined by the side wall surfaces and the ground surface.
More specifically, the abutment is formed with an edge surface that curves from a side wall to the pedestal, so that, when the container is tilted about the axis of the wheels, all portions of the container are lifted and only the wheels contact the ground.
BRIEF DESCTIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of its structural forms, as illustrated by the accompanying drawings, in which:
FIG. 1 is a perspective view of a trash barrel embodying the principles of the present invention,
FIG. 2 is a side elevational view of the trash barrel,
FIG. 3 is a front elevational view of the trash barrel, and
FIG. 4 is a bottom plan view of the trash barrel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, wherein are best shown the general features of the invention, the trash barrel, indicated generally by the reference numeral 10, is shown as comprising a single-piece plastic container 11 having tapered sidewalls 12, 13, 14, and 15 terminating in a bottom wall 16. The bottom wall 16 is formed with a downwardly-extending pedestal 17 extending along the sidewall 14 and adapted to engage the ground 22. The bottom wall 16 is also formed with an abutment 18 which extends laterally from the pedestal across the bottom wall. A pair of wheels 19 and 21 are rotatably mounted on the opposite sides of the abutment.
Referring now to FIG. 2, it can be seen that the wheels are generally tangential to the ground plane 22, including the lower surface 23 of the pedestal 17. The wheels are also generally tangential to a plane A--A which constitutes an extension of the sidewall 12. The wheels, therefore, are entirely within an envelope defined by the outer surface of the sidewalls and the ground surface 22. The five planes which define the envelope within which the wheels 19 and 21 are enclosed, are shown in the drawings as planes A--A, B--B, C--C and D--D, as well as the ground surface 22.
Referring now to FIGS. 2, 3, and 4, it can be seen that the abutment 18 is formed with an edge surface 24 that curves from the sidewall 12 to the pedestal 17. When the container 11 is tilted about the axis of the wheels 19 and 21, all portions of the container are lifted from the ground 22 and only the wheels contact the ground.
The bottom wall 16 is formed with four lower sidewalls 25, 26, 27 and 28 which might be considered generally as extensions of the previously-mentioned sidewalls 15, 14, 13 and 12, respectively. However, the outer surfaces of these lower sidewalls are spaced inwardly of and parallel to their corresponding sidewalls. A handle 29 is mounted on the upper portion of the sidewall 12 that extends above the wheels 19 and 21. This is so that the act of pulling the handle 29 causes the container 11 to tilt about the wheel axis and to lift the pedestal 17 from the ground. A cover 30 is provided to fit snugly over the top edge of the container 11.
The operation and the advantages of the present invention will now be readily understood in view of the above description. The fact that the sidewalls 12, 13, 14 and 15 of the container 11 are tapered allows the container to be nestable with similar containers. The fact that the wheels 19 and 21 lie entirely within the silhoutte of the container means that the nesting operation can be carried out while still maintaining the effectiveness of having a wheel available for transport of the trash barrel. This function is possible because of the use of the curved surface 24 in the abutment 18 which permits tilting of the container about the wheel axis. In addition, the nesting capability is rendered more effective by the use of the recess in the bottom wall 16 of the container. This is formed by placing the bottom lower sidewalls 25, 26, 27 and 28 in a location which is spaced inwardly and parallel to their respective upper sidewalls. Naturally, the cover 30 is removed before the nesting operation is attempted. One of the advantages of the invention is that the wheels can be assembled with the container at the factory. There is no loss of "packing cube" when it is assembled. The arrangement also allows the weight of the container and contents to be spread along the sidewalls and not at a principal point, such as the bottom of the container, where with thin-walled containers it would cause damage. The wheels do not rest on the bottom of the next lower container; on the contrary, the weight of each container is carried on the side walls of the container under it. In other words, the containers, when nested, are supported by the sidewalls of the previous container and the wheels do not touch the bottom of the supporting container.
It can be seen, then, that the present invention has the advantage that it is capable of being nested for storage, for transport in large quantities, and for display at a point of sale. The function of being able to roll the container from one place to another is not lost because of the nesting capability. This is due to the novel shape of the bottom wall 16, of the pedestal 17, and the abutment 18 which form the bottom wall. A commercial embodiment of the invention, a 32 gallon barrel, is capable of being shipped in a lot of 800 pieces in a 900 cubic foot truck, or of 1550 pieces in a 4400 cubic foot railroad car. The container was made from a high-density polyethlene blended with ultra-violet inhibitor to prevent cracking in the sunlight.
It is obvious that minor changes may be made in the form and construction of the invention without departing from the material spirit thereof. It is not, however, desired to confine the invention to the exact form herein shown and described, but it is desired to include all such as properly come within the scope claimed.
|
Barrel consisting of a container manufactured in one piece of plastic with a bottom wall formed to provide a pedestal for resting on the ground as well as recesses to receive a pair of wheels, the container being tapered and the wheels being entirely included with an envelope of the surface of the container so that it is nestable with a similar container.
| 8
|
This is a continuation-in-part application of U.S. application Ser. No. 09/141,959, filed Aug. 28, 1998 (pending) which is a continuation-in-part of U.S. application Ser. No. 09/063,651, filed Apr. 20, 1998 (abandoned). The disclosures of these two related patent applications are hereby fully incorporated by reference herein.
FIELD OF THE INVENTION
The present invention generally relates to applicators or fiberization dies for applying thermoplastic materials to a substrate or for producing nonwoven materials.
BACKGROUND OF THE INVENTION
Thermoplastic materials, such as hot melt adhesive, are dispensed and used in a variety of situations including the manufacture of diapers, sanitary napkins, surgical drapes as well as many others. This technology has evolved from the application of linear beads or fibers of material and other spray patterns, to air-assisted applications, such as spiral and meltblown depositions of fibrous material.
Often, the applicators will include one or more dispensing modules for applying the intended deposition pattern. Many of these modules include valve components to operate in an on/off fashion. One example of a dispensing module is disclosed in U.S. Pat. No. 6,089,413, assigned to the assignee of the present invention, and the disclosure of which is hereby fully incorporated by reference herein. This module includes valve structure which changes the module between ON and OFF conditions relative to the dispensed material. In the OFF condition, the module enters a recirculating mode. In the recirculating mode, the module redirects the pressurized material from the liquid material inlet of the module to a recirculation outlet which, for example, leads back into a supply manifold and prevents the material from stagnating. Many other modules or valves have also been used to provide selective metering and/or on/off control of material deposition.
Various dies or applicators have also been developed to provide the user with some flexibility in dispensing material from a series of modules. For short lengths, only a few dispensing modules are mounted to an integral manifold block. Longer applicators may be assembled by adding additional modules to the manifold. Additional flexibility may be provided by using different die tips or nozzles on the modules to permit a variety of deposition patterns across the applicator as well. The most common types of air-assisted dies or nozzles include meltblowing dies, spiral nozzles, and spray nozzles. Pressurized air used to either draw down or attenuate the fiber diameter in a meltblowing application, or to produce a particular deposition pattern, is referred to as process air. When using hot melt adhesives, or other heated thermoplastic materials, the process air is typically also heated so that the process air does not substantially cool the thermoplastic material prior to deposition of the material on the substrate or carrier. Therefore, the manifold or manifolds used in the past to direct both thermoplastic material and process air to the module include heating devices for bringing both the thermoplastic material and process air to an appropriate application temperature.
In the above-incorporated patent applications, various embodiments of modular applicators are disclosed which allow a user to more easily configure the applicator according to their needs. Generally, these applicators include a plurality of manifold segments disposed in side-by-side relation, with each manifold segment including a dispensing module or valve and a positive displacement pump. Material, such as hot melt adhesive, flows through the side-by-side manifold segments to each pump. The pumps individually direct the material to each corresponding dispensing module. Heated process air is also directed through each manifold segment to the die tip or nozzle of the module and impacts the dispensed material to achieve a desired effect on the deposition pattern. A separate recirculating module is provided so that the material discharged from the pump flows to the recirculation module if the fiberization die module is shut off or closed. The recirculated flow ensures that flow through the pump is uninterrupted. These related applications disclose applicators having a single integral drive shaft extending through side-by-side positive displacement gear pumps or, alternatively, a segmented drive shaft which allows the manifold segments to be removed or added without the need for disassembling the entire manifold. In each case, the number of manifold segments and modules define the effective dispensing length of the applicator.
Despite the various progress made in the technology, there is still a need to increase the speed and efficiency at which an applicator may be configured and maintained or repaired. There is also a continuing desire to reduce the cost and complexity associated with these applicators.
SUMMARY OF THE INVENTION
The present invention generally provides a modular applicator for dispensing liquid including a plurality of manifold segments coupled in side-by-side relation. Each manifold segment includes a liquid supply passage and a liquid discharge passage. A plurality of pumps are respectively mounted in a removable manner to the plurality of manifold segments. Each of the pumps includes an inlet communicating with the liquid supply passage of the corresponding manifold segment, an outlet communicating with the liquid discharge passage of the corresponding manifold segment and a pumping mechanism for pumping the liquid from the inlet to the outlet. A drive motor is coupled to each of the pumps for operating each of the associated pumping mechanisms.
More specifically, the plurality of pumps are preferably gear pumps with one of the gears being a drive gear. A shaft is coupled between the drive motor and each of the drive gears to simultaneously operate each of the pumps. The system further includes a plurality of on/off dispensing modules respectively coupled with the manifold segments. These dispensing modules may be pneumatically operated valves and, for operational purposes, the manifold segments include air distribution passages for delivering pressurized control air to each of the pneumatically operated valves. An air control valve may be mounted to one or more of the manifold segments to selectively supply the pressurized control air to an associated one or more of the pneumatically operated valves. The manifold segments further include liquid distribution passages for delivering the liquid from one of the manifold segments to another of the manifold segments through opposed side surfaces thereof. Likewise, process air distribution passages also communicate between adjacent manifold segments for supplying heated process air to each of the modules. A pair of heating rods extend through each of the manifold segments for heating liquid and process air sections thereof. The liquid and process air sections of each manifold segment are thermally separated by one or more insulators, such as slots and/or bores.
The dispensing modules are preferably recirculating modules and appropriate passages are provided in each associated manifold segment to ensure that liquid is recirculated back into the manifold segment if the module is in an OFF position. The preferred liquid dispensing system also has the advantage that the pumps may be removed from the manifold segment without decoupling the manifold segments from one another. In this regard, the common drive shaft may be disengaged from one or more pumps by pulling the drive shaft out of one end of the manifold and, once disengaged, the appropriate pump or pumps may be removed and either repaired or replaced as necessary.
Various additional advantages and features of the invention will become more readily apparent to those of ordinary skill in the art upon review of the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially exploded perspective view illustrating the preferred dispensing applicator of the present invention.
FIG. 2 is an exploded perspective view showing the end plates of the manifold assembly.
FIG. 3 is a partially exploded perspective view showing one of the gear pumps.
FIG. 4 is an exploded perspective view illustrating a first manifold segment.
FIG. 5 is an exploded perspective view illustrating a second manifold segment.
FIG. 6 is a perspective view of a gasket positioned between one of the manifold segments and a corresponding one of the air control valves.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a preferred applicator constructed in accordance with the inventive concepts. Applicator 10 includes a dispensing assembly 12 comprised of individual side-by-side manifold segments 14 , dispensing modules 16 , air control valves 18 and gear pumps 20 . In general, a pressurized liquid is introduced into manifold segments 14 and is metered by gear pumps 20 individually associated with each manifold segment 14 to each corresponding dispensing module 16 . Air control valves 18 selectively supply pressurized control air through the attached manifold segment 14 to the corresponding module 16 to operate module 16 between open and closed (ON and OFF) positions. Dispensing module 16 is preferably a recirculating module, such as the module disclosed in U.S. Pat. No. 6,089,413 incorporated above.
In the illustrated embodiment of applicator 10 , each manifold segment 14 includes an identical dispensing module 16 , air control valve 18 , which may be a conventional spool operated solenoid valve, and gear pump 20 . From the description to follow, it will be appreciated that the plurality of dispensing modules may be controlled by less than a corresponding number of air control valves 18 . Also, one or more gear pumps 20 may be removed and replaced with a substitution block (not shown) which diverts liquid material back into the corresponding manifold segment 14 and does not direct the liquid material into a corresponding dispensing module 16 . Thus, dispensing assembly 12 may be configured in many different manners depending on the application needs and desires of the user. Except as noted herein, each assembly comprised of a manifold segment 14 , a dispensing module 16 , an air control valve 18 and a gear pump 20 is preferably identical.
As further shown in FIG. 1, dispensing assembly 12 includes a pair of end plates 30 , 32 sandwiching the dispensing portion of assembly 12 therebetween. A DC servo motor 34 and conventional right angle gear box 36 are provided to simultaneously drive each gear pump 20 coupled with manifold segments 14 . A filter block 40 is secured to end plate 30 and contains a removable filter element (not shown) accessible by turning a handle 42 coupled with a threaded cap 44 . The filter element within block 40 filters liquid material introduced through an input 50 before directing that material through end plate 30 and into the adjacent manifold segment 14 for distribution to each gear pump 20 and ultimately each module 16 . Filter block 40 includes a pre-filter transducer port 52 and a post-filter transducer port 54 . These ports 52 , 54 allow pressure transducers to be coupled upstream and downstream of the filter element to allow measurement of the pressure differential and thereby allow detection of a clogged filter condition which necessitates cleaning or replacement. A pressure relief valve 56 is provided to relieve liquid pressure within dispensing assembly 12 during, for example, maintenance and repair. A pair of cordsets 60 , 62 and corresponding heater rods 60 a , 62 a are provided to respectively heat the process air section and liquid section of each manifold segment 14 . Rods 60 a , 62 a are respectively inserted through holes 64 and 66 in end plate 30 and holes 67 , 69 which align in each manifold segment 14 . A plug 70 is threaded into one side of the liquid supply passage in filter block 40 with the other side aligning with the liquid supply passage of the adjacent manifold segment 14 as will be discussed below. Fasteners 74 couple filter block 40 to end plate 30 .
Referring to FIG. 2, end plates 30 , 32 are shown in greater detail with certain components illustrated in exploded view for clarity. Each end plate 30 , 32 includes a control air input port 82 , 84 and a pair of control air exhaust ports 86 , 88 and 92 , 94 which receive threaded exhaust filters 96 , 98 and 102 , 104 . Port 84 includes a plug 106 , although it will be appreciated that this supply port 84 may instead include an input fitting 108 as shown with the opposite end plate 30 , depending on the needs of the user. A supply port 84 a and exhaust ports 92 a , 94 a communicate with the control air input 84 and exhaust ports 92 , 94 in the top of each end plate as shown in end plate 32 . In addition, two additional ports 107 , 109 are provided on the inside facing surface of each end plate and are used to direct control air to the adjacent manifold segment as will be described below. Each end plate 30 , 32 also includes a plurality of threaded fastener holes 110 and counterbored fastener receiving holes 112 . Fasteners 114 are used to secure the respective end plate 30 , 32 to the adjacent manifold segment 14 (FIG. 1 ).
Process air is supplied into either of the end plates 30 , 32 through a bore 120 or 122 . The other bore is plugged. The bores 120 , 122 lead to a process air slot 124 as shown on inner face 32 a of plate 32 . Although not shown, plate 30 has the same slot on its inner face. Process air therefore supplied to slot 124 and this slot 124 communicates with a series of radially spaced bores 126 in each manifold segment 14 surrounding the process air heating rod 60 a (FIG. 1 ). Each slot 126 redirects air in a serpentine fashion through the bores 126 such that it is uniformly heated as it traverses back-and-forth along the length of the connected manifold segments 14 and heater rod 60 a . Another slot 128 also directs the process air in this serpentine fashion. The final bore 126 in the serpentine air flow path communicates with a slot 130 which leads to an air supply passage 132 . The air supply passage 132 extends through each of the connected manifold segments 14 and a perpendicular bore 136 in each manifold segment 14 communicates with the corresponding module 16 to provide the process air to the nozzle region 16 a.
A liquid material input passage 140 communicates with the liquid supply passage of filter block 40 and with the respective inputs of the manifold segments in a serial fashion as will be discussed below. The input port 142 in the opposite end plate 30 is plugged. A cover plate 150 is attached to each end plate 30 , 32 with each plate 150 secured by sets of fasteners 152 and sealed by an O-ring 154 . Only the cover plate 150 associated with end plate 32 is shown in FIG. 2 for clarity although it will be appreciated that an identical cover plate assembly is used on end plate 30 . A shoulder bearing 156 is provided in a hole 159 for the drive shaft (not shown in FIG. 2) coupled with each gear pump 20 . When cover plate 150 is removed, the drive shaft may be pulled out of one or more of the gear pumps 20 to allow removal of that gear pump 20 from the corresponding manifold segment 14 . A similar bearing 158 is provided in a hole for the drive shaft and a pair of roll pins 162 , 164 are provided in the opposite end plate 30 .
A process air sensor port 170 and a liquid sensor port 172 are provided in bores 174 , 176 extending through edge portions 178 , 180 of each end plate 30 , 32 with the remaining bores 184 , 186 of the end plates 30 , 32 receiving plugs (not shown), as necessary. Ports 170 , 172 receive temperature sensors 188 , 189 for respectively measuring the temperatures of the process air section, i.e., lower section of each end plate 30 , 32 and the liquid section, i.e., upper section of each end plate 30 , 32 . The upper and lower sections are divided by insulators which, in this preferred embodiment, comprise pairs of slots 190 , 192 and 194 , 196 and pairs of holes 202 , 204 and 206 , 208 . These air spaces therefore provide thermal insulation between the upper section and lower section and allow these respective sections to be maintained at different operating temperatures. It will be appreciated that other types of insulators and insulating materials may be used as well.
As further shown in FIG. 3, each gear pump 20 comprises a conventional sandwiched construction of three plates 220 , 222 , 224 containing a pair of gears 230 , 232 . One gear is an idler gear 230 , while the other gear is a driven gear 232 which receives a drive shaft 234 having a hexagonal cross section. It will be appreciated that drive shaft 234 extends through each gear pump 20 and is received in a complimentary hexagonally-shaped bore of each drive gear 232 . A static seal 240 contains any liquid which would otherwise tend to seep out of gear pump 20 . A rupture disc assembly 242 is provided for providing pressure relief in the event of a significant over-pressure condition. On the back side of each gear pump 20 , one port 244 is threaded to receive a temperature sensor (not shown). This is especially useful during start-up to ensure that each gear pump 20 is heated to the application temperature before operation. This threaded port 244 may also receive an extractor tool (not shown) for removing the gear pump 20 from the associated manifold segment 14 during repair or replacement without having to dissemble or decouple the manifold segments 14 from one another. The second bore 248 receives a plug assembly 250 , which may be removed to then allow insertion of a pressure transducer (not shown) for reading output liquid pressure.
Referring now to FIGS. 4 and 5, each manifold segment 14 a , 14 b is identical, except for the fastener configurations used to fasten manifold segments 14 a , 14 b together. In this regard, manifold segment 14 a includes four counterbored fastener holes 258 for receiving four fasteners 260 , while the corresponding holes 262 in an adjacent manifold segment 14 b are threaded to receive the threaded portions of fasteners 260 . Likewise, manifold segment 14 b includes four counterbored fastener holes 264 for receiving four fasteners 268 and the threaded portions of these fasteners 268 are received in threaded holes 270 in an adjacent manifold segment 14 a as shown in FIG. 4 . As previously described, a plurality of radially spaced bores 126 direct process air in a serpentine, back-and-forth manner along the length of dispenser assembly (FIG. 1) so that the process air is heated as it traverses back-and-forth alongside the heater rod 60 a contained in hole 67 . A slot 280 and a hole 282 , as well as a pair of recesses 284 , 286 are provided for thermally isolating the lower process air section of each manifold segment 14 , 14 b from the upper liquid section of each manifold segment 14 a , 14 b in a manner similar to that discussed in connection with the end plates 30 , 32 . The recess 290 in the back side of each manifold segment 14 a , 14 b receives a gear pump 20 . A diverter plate 298 (only one shown) is secured to each manifold segment 14 a , 14 b with a fastener 300 and may be configured to direct the liquid in various manners. In the preferred embodiment shown, liquid is directed from liquid material input passage 140 into aligned supply bores 301 in a manifold segments 14 a , 14 b . The liquid is then directed into an internal passage (not shown) and into a bore 302 in each diverter plate 298 . Bore 302 communicates with a supply passage 303 in the associated gear pump 20 (FIG. 1) connected gear pump 20 (FIG. 1) and exits from the gear pump 20 through a discharge passage 305 of gear pump 20 and into a bore 304 communicating with a discharge passage 306 at a front edge portion 308 of the manifold segment 14 a . Passage 306 supplies the pressurized liquid to the associated dispensing module 16 . Another passage 307 is a recirculation passage which receives liquid from the associated dispensing module 16 when the module 16 is OFF. Passage 307 communicates with supply passage 301 . Each gear pump 20 is held on with a clamp 320 and fastener 322 . Clamp 320 includes upper and lower angled surfaces 320 a , 320 b acting as cam surfaces to engage complimentary surfaces at lower edges of the gear pump 20 and the manifold segment 14 a , respectively. Another bore 326 in the clamp 320 is provided for receiving a bayonet process air sensor (not shown) as described in connection with FIG. 2 .
As further shown in FIGS. 4 and 5, two passages 332 , 334 are provided on front edge 308 of each manifold segment 14 a , 14 b . Passages 332 , 334 supply pressurized control air to the associated dispensing module 16 for pneumatically actuating a piston within module 16 between open and closed positions. Referring to FIG. 6A, for the preferred embodiment in which each manifold segment 14 (FIG. 1) is controlled by a separate air control valve 18 , a gasket 340 is placed between manifold segment 14 and air control valve 18 . Gasket 340 includes a lower surface 342 and an upper surface 344 . An air supply hole 346 is centrally located and communicates with air supply port 82 . Hole 346 is flanked by air distribution passages 348 , 350 which respectively communicate with passages 332 , 334 after assembly onto manifold segment 14 . Respective air exhaust passages 352 , 354 respectively communicate with exhaust ports 92 a , 94 a after assembly. More specifically referring to FIGS. 4 and 5, holes 346 , 348 , 350 , 352 , 354 respectively align with holes or passages 356 , 358 , 360 , 362 , 364 on top of the associated manifold segment 14 a or 14 b . Manifold segments 14 a , 14 b further include an air supply port 374 which communicates with passage 356 and exhaust ports 376 , 380 which respectively communicate with passages 362 , 364 . Passages 370 , 372 are also provided for an optional manifold segment to manifold segment distribution of control air if only one air control valve 18 is to be used to operate a plurality of dispensing modules 16 .
While the present invention has been illustrated by a description of various preferred embodiments and while these embodiments has been described in some detail, it is not the intention of the Applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The various features of the invention may be used alone or in numerous combinations depending on the needs and preferences of the user. This has been a description of the present invention, along with the preferred methods of practicing the present invention as currently known. However, the invention itself should only be defined by the appended claims, wherein we claim:
|
A modular applicator for dispensing liquid including a plurality of manifold segments, a plurality of removable pumps, and a drive motor coupled to each pump. The manifold segments are coupled in side-by-side relation and each includes a liquid supply passage and a liquid discharge passage. Each pump includes an inlet communicating with the liquid supply passage, an outlet communicating with the liquid discharge passage and a pumping mechanism for pumping the liquid from the inlet to the outlet. The drive motor is coupled to each pump to simultaneously operate each pumping mechanism and dispense the liquid from a plurality of dispensing modules coupled with each manifold segment. The dispensing modules are recirculating modules which direct the liquid back into the corresponding manifold segment when they are in closed positions.
| 3
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an vital sign box housing a plurality of vital sensors such as an electrocardiograph and a blood pressure monitor.
[0003] 2. Description of the Related Art
[0004] Recently, in connection with high concern about health and the coming of super aged society, for the grip of health conditions, for example, electrocardiographs and blood pressure monitors that can measure electrocardio and blood pressure in home have been developed. Medical care equipment such an electrocardiograph or a blood pressure monitor is called a vital sensor, and the vital sensor utilized in home is miniaturized, and hence can be carried. Furthermore, vital sign boxs, each of which houses such a plurality of miniaturized vital sensors in one housing, have been also developed. FIG. 36 is a perspective view showing an vital sign box used in Medi Data that is an online medical check system developed by SECOM Co. Ltd./SECOM home medical care system Co., Ltd.
[0005] In addition, in connection with the diffusion of multimedia, systematization of home medical care, telemedicine, and remote house visit is requested.
[0006] As a system for such requests, the above-described Medi Data. of SECOM Co., Ltd./SECOM home medical care system Co., Ltd. is known. Medi Data is a system that the above-described vital sign box is connected to a nurse center via a communication line, for example, a patient in home medical care measures the Patient's own blood pressure with using a vital sensor contained in the vital sign box to transmit the measurement to the nurse center. Furthermore, in the nurse center, the measurement is received and stored, and the transition of the measurements is reported to a doctor, who performs telemedicine with using a telephone and the like on the basis of the measurements that the doctor are reported.
[0007] In addition, as another system performing the home medical care and telemedicine, a home medical care support system by Fukuda Denshi Co., Ltd. is also known. The system consists of home terminal equipment that is installed in home and to which a plurality of vital sensors and a camera to take a picture of patient's appearance such as a face and the like in home medical care are connected, and transmits the patient's images via a communication line with measurements measured by the vital sensors to a center. The center grips not only the measurements measured by the vital sensors, but also the patient's appearance. In addition, by providing a camera in the center and letting faces of a doctor and a nurse in the center know the patient, it is possible to remove the patient's anxiety for the telemedicine. Furthermore, by providing each talking unit in the home terminal equipment and the center, it is possible to perform communication by voice.
[0008] However, a camera for taking a picture of patient's appearance such as a face and the like is not provided in the conventional vital sign box used in Medi Data that is an online medical check system made by SECOM Co., Ltd./SECOM home medical care system Co., Ltd. On the other hand, in the home medical care support system made by Fukuda Denshi Co., Ltd., a camera can be connected to home terminal equipment. But, since the camera is used with being fixed in substance and is not a handy type camera, after it is fixed once, it is possible just to take a picture of an object in a viewing angle range to some extent. Nevertheless, it is not possible to take a picture of, for example, a patient's face sometimes, and to take a picture of the patient's foot locally in another time.
[0009] In addition, in the above-described conventional vital sign boxs, an input of a measurement measured by each vital sensor is performed by manually inputting the measurement with using a ten-key pad after a user confirms the measurement. The manual input of the measurement using the ten-key pad in this manner is troublesome work for a user, and a mishit may be performed. Furthermore, there is also a possibility of false inputting a measurement.
[0010] Moreover, each of the above-described conventional vital sign boxs includes memory to record measurements measured by each vital sensor, and a display for displaying, for example, the transition of measurements for 30 days in a graph. Nevertheless, daily drifts of measurements may not be expressed clearly in the graph displayed in the display. For example, in case a display area is too large in comparison with the largeness of drifts or a display scale is not suitable, daily drifts of measurements are not expressed clearly.
[0011] In addition, in a conventional vital sign box, although it is possible to display a measurement measured by each vital sensor in a display, for example, a user having poor eyesight may feel resistance to looking at a displayed measurement. Thus, depending on a user or a using status, it may be more convenient to let the user auditorily inform the measurement by sound than to visually display the measurement in a display.
[0012] Furthermore, in the above-described conventional vital sign box, it is possible to transmit a measurement, measured by each vital sensor, to an administration section such as a nurse center via a communication line. Nevertheless, since, for example, a camera for taking a picture of an affected part and the like of a patient in home medical care is not provided, it is not possible to transmit such an image to the administration section.
[0013] Furthermore, in the above-described conventional vital sign box, it is possible to transmit a measurement, measured by each vital sensor, to an administration section such as a nurse center via a communication line. Nevertheless, in case of telemedicine, after having received a measurement, it is necessary for a doctor and a nurse in the administration section to inquire a user of the vital sign box, who transmitted the measurement, about health conditions with a telephone or the like. However, if answers to inquiry items have been transmitted to the administration section with the measurements, measured by each vital sensor, beforehand, it becomes unnecessary for a doctor and a nurse in the administration section to inquire the sender. Hence they can have a time margin for medical practice.
SUMMARY OF THE INVENTION
[0014] An object of the present invention is to provide an vital sign box which has means of being able to take a picture of an object with changing the object and/or an imaging angle flexibly, in consideration of a subject that, in a conventional vital sign box, a camera taking a picture of an object is not provided, and even if home terminal equipment has a capability for connecting a camera, it is not possible to flexibly change an imaging object and/or an imaging angle.
[0015] In addition, another object of the present invention is to provide an vital sign box, having vital sensors which can input measurements into memory without letting a user manually input the measurements, in consideration of a subject that, in a conventional vital sign box, a use is made to manually input the measurements when inputting the measurements, measured by the vital sensors, into memory.
[0016] Furthermore, still another object of the present invention is to provide an vital sign box, having a display to clearly display drifts of measurements which have been measured by the vital sensors and have been recorded in a predetermined period, in consideration of a subject that, in a display of a conventional vital sign box, the drifts of the measurements measured and recorded in the predetermined period may not be clearly displayed.
[0017] Moreover, a further object of the present invention is to provide an vital sign box having a speaker, outputting measurements, measured by vital sensors, with using sound, in consideration of a subject that measurements measured by vital sensors are not outputted by sound in a conventional vital sign box.
[0018] In addition, a still further object of the present invention is to provide an vital sign box not only having means of taking a picture of an object but also being able to transmit an image of the object, that is taken by the imaging means, to a communication partner, in consideration of a subject that, in a conventional vital sign box, for example, a camera taking a picture of an affected part and the like of a patient in home medical care is not provided. Furthermore, an object of the present invention is also to provide an vital sign box that receives information from a communication partner and can perform bi-directional communication.
[0019] Moreover, another object of the present invention is also to provide an vital sign box that inquires a user of the vital sign box about health conditions, in consideration of a subject that a conventional vital sign box does not inquire the user of the vital sign box about health conditions.
[0020] The 1 st invention of the present invention (corresponding to claim 1 ) is an vital sign box comprising: a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body; an camera taking a picture of a predetermined object; and a housing containing the plurality of vital sensors and the camera.
[0021] The 2 nd invention of the present invention (corresponding to claim 2 ) is the vital sign box according to 1 st invention, further comprising a base that is rotatable, can be fixed at a predetermined angle, and houses the camera at the time of detachment.
[0022] The 3 rd invention of the present invention (corresponding to claim 3 ) is the vital sign box according to 1 st invention, wherein the camera is rotatable, and can be fixed at a predetermined angle.
[0023] The 4 th invention of the present invention (corresponding to claim 4 ) is the vital sign box according to 1 st invention, wherein the camera is detachable.
[0024] The 5 th invention of the present invention (corresponding to claim 5 ) is the vital sign box according to 4 th invention, wherein the camera is a fixed focus type camera.
[0025] The 6 th invention of the present invention (corresponding to claim 6 ) is the vital sign box according to 5 th invention, wherein the camera comprises:
[0026] a string-like or rod-like body that indicates whether distance between the imaging object and a predetermined section of the camera becomes predetermined length, and is attached at the predetermined section of the camera, and has predetermined length;
[0027] instruction receiving means of receiving an imaging instruction of the imaging object; and
[0028] imaging means of taking a picture of the imaging object when the instruction receiving means receives the imaging instruction.
[0029] The 7 th invention of the present invention (corresponding to claim 7 ) is the vital sign box according to 5 th invention, wherein the camera comprises:
[0030] range-finding means of detecting distance between the imaging object and the predetermined section of the camera;
[0031] comparing means of comparing distance, detected by the range-finding means, with predetermined length;
[0032] result output means of outputting a comparison result, obtained by the comparing means, by a sound and/or an image;
[0033] instruction receiving means of receiving an imaging instruction of the imaging object; and
[0034] imaging means of taking a picture of the imaging object when the instruction receiving means receives the imaging instruction.
[0035] The 8 th invention of the present invention (corresponding to claim 8 ) is the vital sign box according to 5 th invention wherein the camera comprises:
[0036] range-finding means of detecting distance between the imaging object and a predetermined section of the camera;
[0037] comparing means of comparing distance, detected by the range-finding means, with predetermined length; and
[0038] imaging means of taking a picture of the imaging object when distance, detected by the range-finding means, substantially coincides with the predetermined length.
[0039] The 9 th invention of the present invention (corresponding to claim 9 ) is the vital sign box according to 1 st invention, wherein the camera has a lighting section emitting light to the object.
[0040] The 10 th invention of the present invention (corresponding to claim 10 ) is the vital sign box according to 1 st invention, further comprising a display displaying an object whose image is taken by the camera.
[0041] The 11 th invention of the present invention (corresponding to claim 11 ) is an vital sign box comprising:
[0042] a plurality of vital sensors that measures predetermined biological, chemical, or physical conditions of a living body, and transmits measurements, obtained by the measurement, with using an electric wave;
[0043] a reception sensor receiving measurements from the plurality of vital sensors;
[0044] memory recording measurements received by the reception sensor; and
[0045] a housing containing the plurality of vital sensors, the reception sensor, and the memory.
[0046] The 12 th invention of the present invention (corresponding to claim 12 ) is the vital sign box according to 11 th invention, wherein the electric wave is an infrared ray having a predetermined wavelength.
[0047] The 13 th invention of the present invention (corresponding to claim 13 ) is an vital sign box comprising: a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body; and a housing with a lid that contains at least the plurality of vital sensors, wherein the lid has a shank that becomes a substantially shaft when the lid is opened and closed;
[0048] wherein the shank is provided in the housing so that a main body of the housing has a front section and a rear section to the shank; and
[0049] wherein the lid can be fixed in a status that the lid stands to a bottom section of the vital sign box with using the shank when the vital sign box is used.
[0050] The 14 th invention of the present invention (corresponding to claim 14 ) is the vital sign box according to 13 th invention further comprising a display that is provided and fixed inside the lid of the housing, and displays measurements measured by the vital sensors.
[0051] The 15 th invention of the present invention (corresponding to claim 15 ) is an vital sign box comprising: a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body; a display displaying measurements measured by the vital sensors; and a housing with a lid that contains the plurality of vital sensors and the display.
[0052] The 16 th invention of the present invention (corresponding to claim 16 ) is the vital sign box according to 15 th invention, wherein the display is movable;
[0053] wherein the housing has a display fixing section to fix the display; and
[0054] wherein the display lies in a bottom section of the housing at the time of non-use and can be fixed in a status that the display stands to the bottom section of the housing with using the display fixing section at the time of use.
[0055] The 17 th invention of the present invention (corresponding to claim 17 ) is an vital sign box comprising:
[0056] a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body;
[0057] memory recording measurements measured by the vital sensors;
[0058] a display that displays measurements measured by the vital sensors, and/or a plurality of measurements recorded in the memory, and determines a display range and/or a display scale with each of the measurements, which are displayed, being as a reference; and
[0059] a housing that contains the plurality of vital sensors, the memory, and the display.
[0060] The 18 th invention of the present invention (corresponding to claim 18 ) is the vital sign box according to 17 th invention wherein each of the measurement to be a reference is a newest measurement and the item to be determined is a display range.
[0061] The 19 th invention of the present invention (corresponding to claim 19 ) is the vital sign box according to 17 th invention, wherein, when at least one of the plurality of vital sensors measures upper and lower limits of the predetermined condition substantially at the same time, the display simultaneously displays the measurements, which are measured and are upper and lower limits, and/or a plurality of measurements, which are recorded in the memory, with classifying the measurements into the upper limits and the lower limits whose display areas are divided separately.
[0062] The 20 th invention of the present invention (corresponding to claim 20 ) is an vital sign box comprising:
[0063] a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body;
[0064] a speaker outputting measurements, measured by the vital sensors, by sound; and
[0065] a housing containing the plurality of vital sensors, and the speaker.
[0066] The 21 st invention of the present invention (corresponding to claim 21 ) is a vital sign box comprising:
[0067] a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body;
[0068] an camera taking a picture of a predetermined object;
[0069] memory recording measurements measured by the vital sensors and/or objects whose images are taken by the camera;
[0070] a communication terminal of transmitting all or part of measurements measured by the vital sensors, an object whose image is taken by the camera, measurements recorded in the memory, and objects recorded in the memory; and
[0071] a housing containing the plurality of vital sensors, the camera, the memory, and the communication terminal.
[0072] The 22 nd invention of the present invention (corresponding to claim 22 ) is the vital sign box according to 21 st invention, wherein the communication terminal receives predetermined information from a communication partner, and wherein the vital sign box comprises a display that is contained in the housing, and not only displays all or part of measurements measured by the vital sensors, an object whose image is taken by the camera, measurements recorded in the memory, and objects recorded in the memory, but also displays information from the communication partner inputted by the communication terminal.
[0073] The 23 rd invention of the present invention (corresponding to claim 23 ) is the vital sign box according to 22 nd invention, wherein one of information from the communication partner, which is displayed in the display, is arrowhead information for specifying a predetermined position of the display, and the arrowhead is displayed in the display with all or part of measurements measured by the vital sensors, an object whose image is taken by the camera, measurements recorded in the memory, and objects recorded in the memory that are displayed in the display.
[0074] The 24 th invention of the present invention (corresponding to claim 24 ) is the vital sign box according to 23 rd invention wherein the arrowhead information is coordinate information of the position when the arrowhead is let to be displayed in the display, and the display has shape information of the arrowhead to be displayed and displays the arrowhead on the basis of the coordinate information from the communication partner.
[0075] The 25 th invention of the present invention (corresponding to claim 25 ) is an vital sign box comprising:
[0076] a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body;
[0077] a power supply section that is provided so as not to contact with the vital sensors and supplies electric power from the outside of the vital sign box to all or part of the plurality of vital sensors with using an electromagnetic wave by electromagnetic induction; and
[0078] a housing containing the plurality of vital sensors, and the power supply section.
[0079] The 26 th invention of the present invention (corresponding to claim 26 ) is an vital sign box comprising:
[0080] a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body;
[0081] a microphone inputting sound;
[0082] a communication terminal transmitting sound inputted by the microphone; and
[0083] a housing containing the plurality of vital sensors, the microphone, and the communication terminal.
[0084] The 27 th invention of the present invention (corresponding to claim 27 ) is an vital sign box comprising:
[0085] a display displaying inquiry items to a user;
[0086] an inquiry result input section of inputting an inquiry result to inquiries in the display;
[0087] a communication terminal transmitting the inquiry result inputted by the inquiry result input section; and
[0088] a housing containing the display, the inquiry result input section, and the communication terminal.
[0089] The 28 th invention of the present invention (corresponding to claim 28 ) is the vital sign box according to 27 th invention, wherein the communication terminal is a device inputting predetermined information from a communication partner to whom the inquiry result is sent and the display also displays information from the communication partner that is inputted by the communication terminal.
[0090] The 29 th invention of the present invention (corresponding to claim 29 ) is the vital sign box according to 27 th invention wherein the communication terminal is a device inputting predetermined information from a communication partner to whom the inquiry result is sent, and the vital sign box further comprises a speaker that is contained in the housing and outputs information from the communication partner, which is inputted by the communication terminal, with using sound.
[0091] The 30 th invention of the present invention (corresponding to claim 30 ) is an vital sign box comprising:
[0092] a speaker outputting inquiry items to a user by sound;
[0093] an inquiry result input section inputting an inquiry result to inquiries from the speaker;
[0094] a communication terminal transmitting the inquiry result inputted by the inquiry result input section; and
[0095] a housing containing the speaker, the inquiry result input section, and the communication terminal.
[0096] The 31 st invention of the present invention (corresponding to claim 31 ) is the vital sign box according to 30 th invention wherein the communication terminal is a device inputting predetermined information from a communication partner to whom the inquiry result is sent, and the speaker also outputs information from the communication partner, which is inputted by the communication terminal, with using sound.
[0097] The 32 nd invention of the present invention (corresponding to claim 32 ) is the vital sign box according to 30 th invention, wherein the communication terminal is a device inputting predetermined information from a communication partner to whom the inquiry result is sent, and the vital sign box further comprises the display that is contained in the housing and displays information from the communication partner that is inputted by the communication terminal.
[0098] The 33 rd invention of the present invention (corresponding to claim 33 ) is the vital sign box according to any one of 1 st , 11 th , 13 th , 15 th , 17 th , 20 th , 21 st , 25 th , 26 th , 27 th , and 30 th inventions, wherein the housing has a lid; wherein a clamp for closing the lid and fixing the lid to the main body of the housing is provided in each of a main body of the housing and the lid; and wherein a handle is provided in the main body of the housing.
[0099] The 34 th invention of the present invention (corresponding to claim 34 ) is the vital sign box according to any one of 1 st to 32 nd inventions, further comprising a password input section of inputting a password of a user, wherein measurements measured by the vital sensors, and/or an object whose image is taken by the camera are managed with being associated with a password inputted in the password input unit.
[0100] The 35 th invention of the present invention (corresponding to claim 35 ) is the vital sign box according to any one of 1 st to 32 nd inventions, wherein all or part of the plurality of vital sensors and/or the camera each have an electric power storage section storing electric power.
[0101] The 36 th invention of the present invention (corresponding to claim 36 ) is the vital sign box according to any one of 1 st to 32 nd inventions, further comprising a display displaying usage of an vital sign box.
[0102] The 37 th invention of the present invention (corresponding to claim 37 ) is the vital sign box according to 36 th invention, wherein all or part of the usage is displayed by an image.
[0103] The 38 th invention of the present invention (corresponding to claim 38 ) is the vital sign box according to 37 th invention, wherein the image is a graphic image of measurements measured by a vital sensor.
[0104] The 39 th invention of the present invention (corresponding to claim 39 ) is the vital sign box according to 36 th invention, wherein the display is a touch panel type liquid crystal display and changes display contents by a predetermined portion of the liquid crystal display being touched by a user.
[0105] The 40 th invention of the present invention (corresponding to claim 40 ) is the vital sign box according to any one of 1 st to 32 nd inventions, further comprising a speaker outputting usage of an vital sign box by sound.
[0106] The 41 st invention of the present invention (corresponding to claim 41 ) is the vital sign box according to 40 th invention, further comprising: a display displaying usage of an vital sign box; and a change instruction input section of inputting an instruction for changing an output of the usage from an output where sound from the speaker is used to an output where display in the display is used.
[0107] The 42 nd invention of the present invention (corresponding to claim 42 ) is the vital sign box according to any one of 10 th , 14 th , 15 th , 17 th , 22 nd , 27 th , 32 nd , 36 th , and 41 st inventions, wherein the display is a touch panel type display having a software keyboard function.
[0108] The 43 rd invention of the present invention (corresponding to claim 43 ) is the vital sign box according to any one of 10 th , 14 th , 15 th , 17 th , 22 nd , 27 th , 32 nd , 36 th , and 41 st inventions, wherein at least part of the housing consists of metallic material, and the vital sign box comprises a connecting section that consists of metallic material and connects a heating section, generating heat in connection with image display to the display, with a metallic material section of the housing.
[0109] The 44 th invention of the present invention (corresponding to claim 44 ) is the vital sign box according to any one of 20 th , 30 th , and 40 th inventions, wherein at least part of the housing consists of metallic material, and the vital sign box comprises a connecting section that consists of metallic material and connects a heating section, generating heat in connection with a sound output from the speaker, with a metallic material section of the housing.
[0110] The 45 th invention of the present invention (corresponding to claim 45 ) is the vital sign box according to any one of 21 st , 26 th , 27 th , and 30 th inventions, wherein at least part of the housing consists of metallic material, and the vital sign box comprises a connecting section that consists of metallic material and connects a heating section, generating heat in connection with information communication in the communication terminal, with a metallic material section of the housing.
[0111] The 46 th invention of the present invention (corresponding to claim 46 ) is a medium that bears a program and/or data for letting a computer execute all or part of functions of the vital sign box according to any one of 36 th to 41 st inventions, the medium with which a computer can perform processing.
[0112] The 47 th invention of the present invention (corresponding to claim 47 ) is an information aggregation, wherein the information aggregation is a program and/or data for letting a computer execute all or part of functions of the vital sign box according to any one of 36 th to 41 st inventions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0113] [0113]FIG. 1 is a perspective view of an vital sign box when a lid of the vital sign box according to a first embodiment of the present invention is opened;
[0114] [0114]FIG. 2 is a side view of the vital sign box when the lid of the vital sign box according to the first embodiment of the present invention is opened;
[0115] [0115]FIG. 3 is a top view of the vital sign box when viewing the vital sign box, the lid of which is opened, according to the first embodiment of the present invention from an arrow A in FIG. 2;
[0116] [0116]FIG. 4 is a front view showing the inside of the lid of the vital sign box when the lid of the vital sign box according to the first embodiment of the present invention is opened substantially vertically to a bottom face of the vital sign box and an camera provided in the vital sign box is also stood substantially vertically to the bottom face of the vital sign box;
[0117] [0117]FIG. 5 is a drawing showing a display screen on which the vital sign box according to the first embodiment of the present invention lets a user input the user's name and password in order to specify the user;
[0118] [0118]FIG. 6 is an explanatory diagram for explaining that a display 10 of the vital sign box according to the first embodiment of the present invention displays the contents shown in FIG. 5, and if a “Grandfather” portion in the display 10 is touched by a user, the “Grandfather” portion is displayed with blinking;
[0119] [0119]FIG. 7 is a diagram showing a display screen for letting a user of the vital sign box according to the first embodiment of the present invention input the user's name;
[0120] [0120]FIG. 8 is a diagram showing a display screen for letting a user of the vital sign box according to the first embodiment of the present invention input a password;
[0121] [0121]FIG. 9 is a diagram showing a display screen on which the vital sign box according to the first embodiment of the present invention lets a user select any one of the use of each vital sensor or an camera 5 , display of data stored in memory 9 , or communication with a hospital;
[0122] [0122]FIG. 10 is an explanatory diagram for explaining that a display 10 of the vital sign box according to the first embodiment of the present invention displays the contents shown in FIG. 9, and if a “Measurement/Record” portion in the display 10 is touched by a user, the “Measurement/Record” portion is displayed with blinking;
[0123] [0123]FIG. 11 is a diagram showing a display screen on which the vital sign box according to the first embodiment of the present invention lets a user select whether the user uses any one of each vital sensor and the camera 5 ;
[0124] [0124]FIG. 12 is a diagram showing an example of a chart of a measurement result of body temperature measured by an earhole clinical thermometer 3 included in the vital sign box according to the first embodiment of the present invention;
[0125] [0125]FIG. 13 is a diagram showing another example of a chart of a measurement result of body temperature measured by the earhole clinical thermometer 3 included in the vital sign box according to the first embodiment of the present invention, which is different from the example in FIG. 12;
[0126] [0126]FIG. 14 is a diagram showing an example of charts of measurement results of blood pressure measured by a blood pressure monitor 2 included in the vital sign box according to the first embodiment of the present invention;
[0127] [0127]FIG. 15 is a diagram showing another example of charts of measurement results of blood pressure measured by the blood pressure monitor 2 included in the vital sign box according to the first embodiment of the present invention, which is different from the example in FIG. 14;
[0128] [0128]FIG. 16 is a diagram showing an example of a chart of a measurement result of pulse rates measured by the blood pressure monitor 2 included in the vital sign box according to the first embodiment of the present invention;
[0129] [0129]FIG. 17 is a diagram showing another example of a chart of a measurement result of pulse rates measured by the blood pressure monitor 2 included in the vital sign box according to the first embodiment of the present invention, which is different from the example in FIG. 16;
[0130] [0130]FIG. 18 is a diagram showing an example of an electrocardiogram measured by the electrocardiograph 1 of the vital sign box according to the first embodiment of the present invention;
[0131] [0131]FIG. 19 is an explanatory diagram of a display area when objects, whose pictures are taken by an camera 5 of the vital sign box according to the first embodiment of the present invention, are displayed in a display 10 ;
[0132] [0132]FIG. 20 is an explanatory diagram of a display area when an object, whose picture is taken by an camera 5 of the vital sign box according to the first embodiment of the present invention is displayed in a display 10 with being magnified;
[0133] [0133]FIG. 21 is a diagram showing an example of a chart of a measurement result of blood glucose levels measured by a glucose meter 4 included in the vital sign box according to the first embodiment of the present invention;
[0134] [0134]FIG. 22 is a diagram showing another example of a chart of a measurement result of blood glucose levels measured by the glucose meter 4 included in the vital sign box according to the first embodiment of the present invention, which is different from the example in FIG. 21;
[0135] [0135]FIG. 23 is a diagram showing an example of a chart of a measurement result of body weight measured by a scale that can perform data transmission to the vital sign box according to the first embodiment of the present invention;
[0136] [0136]FIG. 24 is a diagram showing another example of a chart of a measurement result of body weight measured by the scale that can perform data transmission to the vital sign box according to the first embodiment of the present invention, which is different from the example in FIG. 23;
[0137] [0137]FIG. 25 is a drawing showing a display screen for letting a user input a name and a telephone number of a communication partner in order to specify the communication partner of the vital sign box according to the first embodiment of the present invention;
[0138] [0138]FIG. 26 is a drawing showing inquiry items that are displayed in the display 10 included in the vital sign box according to the first embodiment of the present invention, and about which a user is asked;
[0139] [0139]FIG. 27 is a drawing showing a display screen for letting a user of the vital sign box according to the first embodiment of the present invention input a name and a telephone number of a communication partner;
[0140] [0140]FIG. 28 is a drawing showing a display screen for letting a user of the vital sign box according to the first embodiment of the present invention input a telephone number of a communication partner;
[0141] [0141]FIG. 29 is a drawing showing a display screen first displayed in the display 10 of the vital sign box and a personal computer of a communication partner after the vital sign box according to the first embodiment of the present invention and the personal computer of the communication partner could communicate with each other;
[0142] [0142]FIG. 30 is a drawing showing a display screen where an arrow is displayed in the display 10 of the vital sign box and the personal computer of the communication partner while the vital sign box according to the first embodiment of the present invention and the personal computer of the communication partner are communicating;
[0143] [0143]FIG. 31 is a drawing showing a display screen that is displayed in the display 10 of the vital sign box according to the first embodiment of the present invention and is displayed for instructing a user to turn off the vital sign box;
[0144] [0144]FIG. 32 is a side view of an vital sign box when a lid of the vital sign box according to the first embodiment of the present invention is opened, which is different from the vital sign box shown in FIG. 2;
[0145] [0145]FIG. 33 is a side view of an vital sign box when a lid of the vital sign box according to the first embodiment of the present invention is opened, which is different from each vital sign box shown in FIGS. 2 and 32;
[0146] [0146]FIG. 34 is a configuration of a power supply section 17 supplying electric power to each vital sensor and the camera 5 of the vital sign box according to the first embodiment of the present invention with using an electromagnetic wave generated by electromagnetic induction;
[0147] [0147]FIG. 35 is a configuration of another power supply section 17 supplying electric power to each vital sensor and the camera 5 of the vital sign box according to the first embodiment of the present invention with using an electromagnetic wave generated by electromagnetic induction, which is different from the power supply section 17 in FIG. 34; and
[0148] [0148]FIG. 36 is a perspective view showing a conventional vital sign box used in Medi Data that is an online medical check system developed by SECOM Co., Ltd./SECOM home medical care system Co., Ltd.
Description of Symbols 1 Electrocardiograph 1a Contact section for a left arm 1b Contact section for a right arm 2 Blood Pressure Monitor 3 Earhole clinical thermometer 4 Blood glucose meter 4a Blood-collecting needle 4b Sensor chip 4c Connection jack 5 Electronic camera 6 Base 6a Connecting section 7 LED 8 Reception sensor 9 Memory 10 Display 11 Speaker 12 Microphone 13 Communication terminal 14 Housing 15 Lid 16 Shank 17 Power supply section
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0149] Hereinafter, embodiments of the present invention will be described with reference to drawings.
[0150] Embodiment 1
[0151] First of all, the configuration of an vital sign box of a first embodiment of the present invention will be described.
[0152] [0152]FIG. 1 is a perspective view of the vital sign box when a lid of the vital sign box according to the first embodiment of the present invention is opened. FIG. 2 is a side view of the vital sign box when the lid of the vital sign box according to the first embodiment of the present invention is opened. FIG. 3 is a top view of the vital sign box when viewing the vital sign box, the lid of which is opened, according to the first embodiment of the present invention from an arrow A in FIG. 2. FIG. 4 is a front view showing the inside of the lid of the vital sign box when the lid of the vital sign box according to the first embodiment of the present invention is opened substantially vertically to a bottom face of the vital sign box and an camera provided in the vital sign box is also stood substantially vertically to the bottom face of the vital sign box.
[0153] As shown in FIGS. 1 to 4 , the vital sign box according to the first embodiment of the present invention consists of an electrocardiograph 1 , a blood pressure monitor 2 , an earhole clinical thermometer 3 , a blood glucose meter 4 , an camera 5 , a base 6 , an LED 7 , a reception sensor 8 , memory 9 , a display 10 , a speaker 11 , a microphone 12 , a communication terminal 13 , and a housing 14 .
[0154] The electrocardiograph 1 is means of measuring electrocardio, and, as shown in FIG. 3, consists of a clip-like contact section for a left arm 1 a and a contact section for a right arm 1 b that contact to left and right arms of a human body respectively. Those contact section for a left arm 1 a and contact section for a right arm 1 b are connected to a main body of the vital sign box with connection cords, and are means of transmitting measurements to the LED 7 through the connection cords with using electrical signals. In addition, inside the contact section for a left arm 1 a and contact section for a right arm 1 b, a circuit for measuring electrocardio is built in, and the circuit is utilized in electrocardio measurement.
[0155] The blood pressure monitor 2 is means of measuring blood pressure and a pulse rate, and is a handy type meter. Furthermore, the blood pressure monitor 2 is means that is not connected to the main body of the vital sign box with a connection cord but transmits a measurement to the reception sensor 8 with using an infrared ray having a predetermined wavelength.
[0156] The earhole clinical thermometer 3 is means of measuring body temperature, and is a handy type meter similarly to the blood pressure monitor 2 . Furthermore, the earhole clinical thermometer 3 is means that is not connected to the main body of the vital sign box with a connection cord but transmits a measurement to the reception sensor 8 with using an infrared ray having a predetermined wavelength.
[0157] The blood glucose meter 4 is means of measuring sugar density in blood, and has a blood-collecting needle 4 a, a sensor chip 4 b, and a connection jack 4 c. Furthermore, when being housed in the housing 14 , the blood glucose meter 4 , blood-collecting needle 4 a, sensor chip 4 b, and connection jack 4 c are housed separately. Moreover, the blood glucose meter 4 is a handy type meter, and the sensor chip 4 b is mounted and used when a blood glucose level is measured. The blood glucose meter 4 measures a blood glucose level of the blood collected by the blood-collecting needle 4 a with utilizing the sensor chip 4 b. In addition, when measured data is transmitted to the main body of the vital sign box, the blood glucose meter 4 is connected to the connection jack 4 c, and furthermore, the connection jack 4 c is connected to the main body of the vital sign box. The measured data is transmitted from the blood glucose meter 4 to the LED 7 in the main body of the vital sign box through the connection jack 4 c with using an electrical signal. The blood-collecting needle 4 a is means of gathering blood from a human body, the sensor chip 4 b is means of measuring a blood glucose level of the blood collected by the blood-collecting needle 4 a, and the connection jack 4 c connects the blood glucose meter 4 to the main body of the vital sign box.
[0158] In addition, the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , and blood glucose meter 4 are used as an example of vital sensors according to the vital sign box of the present invention, the vital sensors which are described in claims 1 , 11 , 13 , 15 , 17 , 20 , 21 , 25 and 26 .
[0159] The camera 5 is means of taking a picture of a predetermined object, has a lighting section lighting the object, and is detachable from the base 6 .
[0160] The base 6 has a connecting section 6 a, is connected to the housing 14 through the connecting section 6 a, is rotatable with the connecting section 6 a as a fulcrum, and not only can be fixed at a predetermined angle, but also is means of containing the camera 5 .
[0161] The LED 7 is means of converting each measurement, transmitted with using electrical signals from the electrocardiograph 1 and blood glucose meter 4 , into an infrared ray having a predetermined wavelength and transmitting each measurement to the reception sensor 8 .
[0162] The reception sensor 8 is means of receiving each infrared ray having a predetermined wavelength from the blood pressure monitor 2 , earhole clinical thermometer 3 , and LED 7 .
[0163] The memory 9 is installed with being embedded in the housing 14 , and is means of not only recording each measurement on the basis of the infrared ray received by the reception sensor 8 , but also recording an image of an object recorded by the camera 5 .
[0164] The display 10 is means of displaying each measurement measured by the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , and blood glucose meter 4 , an object, a picture of which is taken by the camera 5 , and usage of the vital sign box according to the first embodiment of the present invention. The display 10 is a touch panel type liquid crystal display, and hence changes display contents when each of predetermined portions is touched.
[0165] The speaker 11 is means of outputting each measurement measured by the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , and blood glucose meter 4 or usage of the vital sign box according to the first embodiment of the present invention with using sound.
[0166] Microphone 12 is means of collecting sound of voice and the like of a user of the vital sign box according to the first embodiment of the present invention.
[0167] The communication terminal 13 is means of transmitting each measurement measured by the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , and blood glucose meter 4 , and an object recorded by the camera 5 to a communications partner with using a communication line.
[0168] The housing 14 is means of having the lid 15 and containing all of the above-described sections from the electrocardiograph 1 to the terminal 13 . The lid 15 has the shank 16 that substantially becomes a shaft when the lid 15 is opened and closed, and not only is installed in the housing 14 through the shank 16 , but also can be fixed at a predetermined angle of gradient to the housing 14 . In addition, it is assumed that the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , blood glucose meter 4 , camera 5 , base 6 , LED 7 , reception sensor 8 , and memory 9 are contained in a main body of the housing 14 , that the display 10 , speaker 11 , and microphone 12 are provided inside the lid 15 , and that the communication terminal 13 is provided outside the main body of the housing 14 .
[0169] In addition, as show in FIG. 1, in the housing 14 and lid 15 each, clamps 20 a, 20 b, 21 a, and 21 b are attached for closing the lid 15 and fixing the lid 15 to the housing 14 . Furthermore, a handle 22 for easily carrying the vital sign box of the first embodiment when the lid 15 is closed and is fixed to the housing 14 is provided in the housing 14 .
[0170] Moreover, although being not shown in FIGS. 1 to 4 , a program recording medium that stores a program to let the display 10 and speaker 11 output the usage of the vital sign box is built in the vital sign box according to the first embodiment of the present invention.
[0171] In addition, it is made that the vital sign box of the first embodiment of the present invention can receive data from a scale that is different from the vital sign box and can transmit a measurement to the vital sign box with using an infrared ray having a predetermined wavelength. It is made that the LED 7 receives data from the scale at that time.
[0172] Furthermore, it is assumed that the vital sign box according to the first embodiment of the present invention is connected to a personal computer in a hospital through the communication terminal 13 .
[0173] Moreover, although having been explained once, FIG. 3 will be explained again. FIG. 3 is a top view showing the main body of the housing 14 when the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , blood glucose meter 4 , camera 5 , base 6 , LED 7 , reception sensor 8 , and memory 9 are contained in the main body of the housing 14 and the lid 15 is opened.
[0174] Next, the operation of the vital sign box according to the first embodiment of the present invention will be described.
[0175] First of all, a user switches on the vital sign box, and opens the lid 15 of the housing 14 as shown in FIGS. 1 and 2.
[0176] When the vital sign box is turned on, the display 10 provided inside the lid 15 begins displaying the usage of the vital sign box on the basis of the program stored in the program recording medium. In addition, similarly, on the basis of the program stored in the program recording medium, the speaker 11 begins outputting the usage of the vital sign box by sound.
[0177] [0177]FIG. 5 shows display contents that are first displayed in the display 10 after the vital sign box was switched on. FIG. 5 is a drawing showing a display screen on which the vital sign box lets a user input the user's name and password in order to specify the user. By the way, the reason why a user is specified is for the vial sign box to associate a measurement measured by each vital sensor and an image a picture of which is taken by the camera 5 with each user, and to manage the measurement and image every user. In addition, in connection to it, the reason is also to protect the privacy of the measurement and the shot image of each user is protected. Furthermore, when the display 10 displays contents shown in FIG. 5, the user touches a portion of any one of “Grandfather,” “Grandmother,” “Registration wait 3 ,” and “Registration wait 4 ” in the display 10 . By the way, the display of the “Grandfather” and “Grandmother” means that names and passwords of the “Grandfather” and “Grandmother” have been already registered. In addition, the display of the “Registration wait 3 ” and “Registration wait 4 ” means that names and passwords of users are not registered.
[0178] Then, if the user is the “Grandfather” or “Grandmother” and the user's name and password have been registered beforehand, the user touches an adequate portion, furthermore touches a “password” to input the user's password, and goes to the next step shown in FIG. 9. On the other hand, if the user is not the “Grandfather” or “Grandmother” but the user's name and password are not registered, the user touches a portion of any one of the “Registration wait 3 ” and “Registration wait 4 .” The user touches the “Registration wait 3 ” or “Registration wait 4 ” so as to use the vital sign box many times later and to let the vital sign box manage measurements measured by each vital sensor and/or images taken by the camera 5 . When the user touches the “Registration wait 3 ” or “Registration wait 4 ,” the display 10 displays the contents shown in FIG. 7, and lets the user register the user's name with letting the user utilize the touch panel. If the user touches a “Confirm” portion after registration, the display 10 displays the contents shown in FIG. 8 to let the user register, for example, four character password with letting the user use the touch panel again. In this manner, if the user is made to register the user's name and password, the name and password are managed by the vital sign box after that with being associated with the “Registration wait 3 ” or “Registration wait 4 ” that was touched before the registration of the name and password. In addition, if the name and password are registered, the display 10 displays the contents shown in FIG. 9.
[0179] If the user operates according to the display of the display 10 as described above, the display 10 displays the contents shown in FIG. 9.
[0180] In addition, for the convenience of explanation, it is assumed that the user of the vital sign box is a “Grandfather.” Therefore, in this case, when the display 10 displays the contents shown in FIG. 5, the user touches the “Grandfather” portion in the display 10 . When the “Grandfather” portion is touched in this manner, the display 10 displays the “Grandfather” portion with blinking as shown in FIG. 6. In addition, in FIG. 6, it is assumed that slanted lines of the portion displaying the “Grandfather” portion denote that the portion displaying the “Grandfather” blinks. In addition, it is assumed for the convenience of the following explanation as described above that the user of the vital sign box is the “Grandfather.” Nevertheless, it is assumed that, even if the user is not the “Grandfather” but the user touches the “Grandmother,” “Registration wait 3 ,” or “Registration wait 4 ” when the display 10 displays the contents shown in FIG. 5, the display 10 displays and blinking the touched portion. Furthermore, also in the following description, it is assumed that, if a predetermined portion of the display 10 is touched by a user, the display 10 displays and blinking the touched portion.
[0181] Moreover, although the usage of the vital sign box only by the display of the display 10 is explained in the above description, it is made that the usage is explained simultaneously with using sound from the speaker 11 . Similarly, also in the following explanation, it is assumed that the usage of the vital sign box is explained not only in the display of the display 10 , but also by a sound output from the speaker 11 .
[0182] In addition, in the above description, the display 10 corresponds to a password input section of the present invention according to claim 34 .
[0183] Furthermore, as explained when the configuration of vital sign box according to the first embodiment of the present invention is described, the display 10 is a touch panel type liquid crystal display. Hence, for a user, the display 10 is convenient because it is not necessary to use a ten-key pad or a mouse when the user changes the display contents of the display 10 .
[0184] By the way, FIG. 9 is a drawing showing a display screen for letting a user select any one of using each vital sensor or the camera 5 of the vital sign box, letting the display 10 display the data that is stored as measurements and pictures in the memory 9 , and communicating with a personal computer in a hospital that is connected to the vital sign box.
[0185] In this manner, it is assumed that, when the contents shown in FIG. 9 is displayed by the display 10 , first of all, the user uses each vital sensor and the camera 5 . At this time, the user touches a “Measurement/Record” in the display 10 , and the display 10 displays the “Measurement/record” portion with blinking the “Measurement/record” portion as shown in FIG. 10 if the “Measurement/Record” portion is touched. After that, the display 10 changes the display contents to the contents shown in FIG. 11. In addition, in FIG. 10, it is assumed that slanted lines of the portion displaying the “Measurement/Record” denote that the portion displaying the “Measurement/Record” blinks, similarly slanted lines of the portion displaying the “Grandfather” in FIG. 6.
[0186] By the way, FIG. 11 is a diagram showing a display screen on which the vital sign box lets a user select whether the user uses any one of each vital sensor and the camera 5 . The “Temperature,” “Blood pressure,” “Electrocardio,” “Camera,” “Blood glucose level,” and “Body weight” that are shown in FIG. 11 correspond to the earhole clinical thermometer 3 , blood pressure monitor 2 , electrocardiograph 1 , camera 5 , and blood glucose meter 4 in the vital sign box respectively. They are displayed with images obtained by graphing measurements measured by respective vital sensors. In addition, because the “Pulse rate” shown in FIG. 11 is measured by the blood pressure monitor 2 , the “Pulse rate” corresponds to the blood pressure monitor 2 . Furthermore, the “Body weight” corresponds to the scale outside the vital sign box.
[0187] By the way, it is assumed that, when the contents shown in FIG. 11 are displayed by the display 10 , first of all, a user is going to measure the “Temperature.” At this time, the user touches the “Temperature” in the display 10 , takes out the earhole clinical thermometer 3 from the vital sign box, and measures body temperature by contacting the earhole clinical thermometer 3 to the user's earhole. Since being a cordless vital sensor, the earhole clinical thermometer 3 is convenient for a user to handle the thermometer 3 . Then, when finishing the measurement of the body temperature, the user presses a send switch provided in the earhole clinical thermometer 3 . When the send switch is pressed, the earhole clinical thermometer 3 transmits a measurement to the reception sensor 8 with using an infrared ray having a predetermined wavelength. In this manner, by letting a user press the send switch to transmit a measurement, it is possible to prevent the mishit or an input of a devious value that can be generated when letting the user input a measurement with using the ten-key pad. In addition, for a user, it becomes unnecessary to perform such troublesome work that the user inputs the measurement with using the ten-key pad. Next, when receiving the measurement from the earhole clinical thermometer 3 , the reception sensor 8 not only outputs information as such to the speaker 11 , but also outputs the information of the measurement to the memory 9 . Then, the speaker 11 outputs such information that the reception sensor 8 has received the measurement from the earhole clinical thermometer 3 by sound. For example, the speaker 11 outputs such a sentence that “The measurement is received.” by sound. In this manner, if the receipt information of a measurement is outputted by sound, a user can confirm that a measured measurement is received by the main body of the vital sign box. On the other hand, when receiving the measurement from the reception sensor 8 , the memory 9 not only lets the display 10 display the measurement in a number as shown in FIG. 12, but also lets the display 10 display the measurements for last five days including the measurement inputted from the reception sensor 8 . At that time, the display 10 displays a final measurement on a graph, in other words, the latest measurement with blinking the measurement. In FIG. 12, it is assumed that a measurement on November 11 is the final measurement, the final measurement is displayed as a black dot, and the black dot portion is displayed with blinking. In addition, the display 10 displays the graph with letting the final measurement be a reference and determining a predetermined range between a certain higher value and a certain lower value than the final measurement as a display range. For example, the display range is a range having the width of 3.5° C. between the final measurement +1.5° C./−2° C., and is determined so that each measurement in the display period is displayed in a substantially central part of the display screen. Thus, since fluctuations do not become clear if the display range becomes larger than the fluctuations of measurements, the display range is determined so that the fluctuations of the measurements become clear. In this manner, by letting a final measurement be a reference and determining a predetermined range between a certain higher value and a certain lower value than the final measurement as a display range, the fluctuations of daily measurements become clear. In addition, the display 10 displays with adjusting a display scale in order to make fluctuations of measurements clear. Furthermore, as show in FIG. 12, when displaying a graph of measurements for past five days including the final measurement, the display 10 displays a “30-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 30 days including the final measurement may be displayed as a graph. In addition, when the user touches the “30-day display” portion, the display 10 , as shown in FIG. 13, displays the measurements for the last 30 days, including the final measurement, in the graph. Also, in regard to the graphical representation, in order that each measurement in the display period can be displayed in a substantially central part of the display screen, a display range is determined by making the final measurement value be a reference so that a predetermined range between a certain higher value and a certain lower value than the final measurement becomes the display range. In addition, a display scale is also determined so that fluctuations of measurements become clear. Furthermore, as show in FIG. 13, when displaying a graph of measurements for past 30 days including the final measurement, the display 10 displays a “5-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 5 days including the final measurement are redisplayed as a graph. When the user touches the “5-day display” portion, the display 10 , as shown in FIG. 12, redisplays the measurements for the last 5 days in a graph. By the way, a measurement received by the reception sensor 8 is outputted as sound from the speaker 11 . Then, if the user confirms display contents in FIG. 12 or 13 and touches a “Return” portion, the display 10 displays contents shown in FIG. 11 once again.
[0188] Next, it is assumed that, when the contents shown in FIG. 11 are displayed in the display 10 , the user is going to measure “Blood pressure” and/or “Pulse rate.” At this time, the user touches the “Blood pressure” or “Pulse rate” in the display 10 , takes out the blood pressure monitor 2 from the vital sign box, and measures the blood pressure and pulse rate by wrapping the blood pressure monitor 2 around the user's arm. In addition, the blood pressure and pulse rate are measured at the substantially same time by the blood pressure monitor 2 . Since being a cordless vital sensor, the blood pressure monitor 2 is convenient for a user to handle the blood pressure monitor 2 . Then, when finishing the measurement of the blood pressure and pulse rate, the user presses a send switch provided in the blood pressure monitor 2 . When the send switch is pressed, the blood pressure monitor 2 transmits a measurement to the reception sensor 8 with using an infrared ray having a predetermined wavelength. In this manner, by letting a user press the send switch to transmit a measurement, it is possible to prevent the mishit or an input of a devious value that can be generated when letting the user input a measurement with using the ten-key pad. Next, when receiving the measurement from the blood pressure monitor 2 , the reception sensor 8 not only outputs information as such to the speaker 11 , but also outputs the information of the measurement to the memory 9 . Then, the speaker 11 outputs by sound such information that the reception sensor 8 has received the measurement from the blood pressure monitor 2 .
[0189] On the other hand, when receiving the measurement from the reception sensor 8 , the memory 9 not only lets the display 10 display the measurement in a number as shown in FIG. 14, but also lets the display 10 display the measurements for last five days, including the measurement inputted from the reception sensor 8 , in a graph. At that time, as shown in FIG. 14, the display 10 displays highest blood pressure level values and lowest blood pressure values independently in graphs in the same screen with dividing the display area. In addition, the display 10 displays final measurements on the graphs, in other words, the latest measurements with blinking the measurements. Furthermore, when displaying the graphs, the display 10 determines display ranges with the final measurement values as respective references. For example, the display range is a range having the width of 50 mmHg between the final measurement +15 mmHg/−35 mmHg, and is determined so that each measurement in the display period is displayed in a substantially central part of the display screen. Thus, since fluctuations do not become clear if the display range becomes larger than the fluctuations of measurements, the display range is determined so that the fluctuations of the measurements become clear. In this manner, by letting each final measurement be a reference and determining a predetermined range between a certain higher value and a certain lower value than each final measurement as each display range, the fluctuations of daily measurements become clear. In addition, the display 10 displays with adjusting each display scale in order to make fluctuations of measurements clear. Furthermore, as show in FIG. 14, when displaying each graph of measurements for past five days including each final measurement, the display 10 displays each “30-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 30 days including each final measurement are displayed as each graph. In addition, when the user touches the “30-day display” portion, the display 10 , as shown in FIG. 15, displays the measurements for the last 30 days, including each final measurement, in each graph. Also, in regard to the graphical representation, in order that each measurement in the display period can be displayed in a substantially central part of the display screen, each display range is determined by making the final measurement value be a reference so that each predetermined range between a certain higher value and a certain lower value than the final measurement becomes each display range. In addition, each display scale is also determined so that fluctuations of measurements become clear. Furthermore, as show in FIG. 15, when displaying each graph of measurements for past 30 days including each final measurement, the display 10 displays a “5-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 5 days including each final measurement are redisplayed as each graph. When the user touches the “5-day display” portion, the display 10 , as shown in FIG. 14, redisplays the measurements for the last 5 days in each graph. By the way, a measurement received by the reception sensor 8 is outputted as sound from the speaker 11 .
[0190] In this manner, if a screen showing the measurement result of blood pressure is displayed in the display 10 and display contents do not change from that status, for example, predetermined time of five seconds passes, the display 10 not only displays measurements in numbers about the measurement result of pulse rates as shown in FIG. 16, but also displays as a graph the measurements for past five days including the measurement inputted from the reception sensor 8 . At that time, the display 10 not only blinks and displays the final measurement, but also displays the graph after determining a display range with the final measurement as a reference so that each measurement in a display period is displayed in a substantially central part of the display screen. In addition, a display scale is also determined so that fluctuations of measurements become clear, and the graph is displayed. Furthermore, as show in FIG. 16, when displaying a graph of measurements of pulse rates for past five days including the final measurement, the display 10 displays a “30-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 30 days including the final measurement are displayed as a graph. In addition, when the user touches the “30-day display” portion, the display 10 , as shown in FIG. 17, displays the measurements for the last 30 days, including the final measurement, in the graph. Also, in regard to the graphical representation, in order that each measurement in the display period can be displayed in a substantially central part of the display screen, the display range is determined. In addition, a display scale is also determined so that fluctuations of measurements become clear. Furthermore, as show in FIG. 17, when displaying a graph of measurements for past 30 days including the final measurement, the display 10 displays a “5-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 5 days including the final measurement are redisplayed as a graph. When the user touches the “5-day display” portion, the display 10 , as shown in FIG. 16, redisplays the measurements of pulse rates for the last 5 days in a graph. In addition, a measurement of a pulse rate received by the reception sensor 8 is also outputted as sound from the speaker 11 .
[0191] Now, if a screen showing the measurement result of pulse rates is displayed in the display 10 and display contents do not change from that status, for example, predetermined time of five seconds passes, the display 10 changes display contents from the measurement result of the pulse rates to the contents shown in FIG. 14 about the measurement result of blood pressure. In this manner, if not receiving the user's instruction for changing the display of the measurement period of the graph within predetermined time, the display 10 changes display contents so as to switch between the measurement result of blood pressure and measurement result of pulse rates.
[0192] In any case, if the user confirms the display contents when the display 10 displays any one of FIGS. 14 to 17 , and touches a “Return” portion, the contents shown in FIG. 11 are displayed once again in the display 10 .
[0193] It is assumed that, when contents shown in FIG. 11 are next displayed in the display 10 , the user is going to measure “Electrocardio.” At this time, the user touches the “Electrocardio” in the display 10 , takes out the electrocardiograph 1 from the vital sign box, and measures the electrocardio by contacting the contact section for a left arm 1 a, and contact section for a right arm 1 b to left and right arms respectively. The user presses a send switch provided in the electrocardiograph 1 during the electrocardio measurement, and when the send switch is pressed, the electrocardiograph 1 transmits a measurement to the LED 7 through a connection cord with using an electrical signal. In this manner, by letting a user press the send switch to transmit a measurement, it is possible to prevent the mishit or an input of a devious value that can be generated when letting the user input a measurement with using the ten-key pad. The LED 7 converts each measurement, transmitted with using electrical signals from the electrocardiograph 1 , into an infrared ray having a predetermined wavelength and transmits the measurement to the reception sensor 8 . When receiving the measurement by the electrocardiograph 1 from the LED 7 in the infrared ray, the reception sensor 8 not only outputs information as such to the speaker 11 , but also outputs the information of the measurement to the display 10 and the memory 9 . Then, the speaker 11 outputs by sound such information that the reception sensor 8 has received the measurement from the electrocardiograph 1 . The display 10 , as shown in FIG. 18, displays an electrocardiographic waveform on the basis of the measurement received by the LED 7 , in real time for a predetermined period of, for example, 10 seconds. At that time, the display 10 displays the electrocardiographic waveform so that the electrocardiographic waveform is continuously displayed. In addition, if one electrocardio measuring period is, for example, 50 seconds, at the time of finishing the measurement the display 10 displays the waveform equivalent to the last predetermined time of predetermined electrocardio measuring time of, for example, the last ten seconds. In addition, so as to make fluctuations of the electrocardio clear when displaying, an electrocardiographic waveform, the display 10 displays an electrocardiogram so that a status of the fluctuations of the electrocardio is displayed in a substantially central part of the display screen. In addition, the display 10 displays the electrocardiogram with adjusting a display scale in order to make fluctuations of measurements clear. On the other hand, the memory 9 records waveform data for the last predetermined time in a predetermined electrocardio measuring time, for example, for last ten seconds, which is displayed at the time of finishing the measurement in the display 10 . Then, if the user confirms display contents in FIG. 18 and touches a “Return” portion, the display 10 displays contents shown in FIG. 11 once again.
[0194] Next, it is assumed that, when contents shown in FIG. 11 are displayed in the display 10 , the user is going to use the camera 5 . At this time, the user touches a “Camera” portion in the display 10 .
[0195] By the way, a main body of the housing 14 of the vital sign box is put on a predetermined mount and the like so that the height of a CCD of the camera 5 becomes substantially equal to the height of a central part of the user's face when the base 6 is stood substantially vertical to the bottom face of the vital sign box with using the connecting section 6 a while, as shown in FIG. 4, the camera 5 is housed in the base 6 . When the user is going to take a picture of the user's own face with the camera 5 , the user lets the camera 5 take a picture of the user's own face with practically vertically standing and fixing the base 6 to the bottom face of the vital sign box while the camera 5 is housed in the base 6 . Then, an image shot by the camera 5 is displayed as any one of camera images 1 to 4 in the display 10 that are shown in FIG. 19. By the way, the display 10 , as shown in FIG. 19, displays “Screen zoom” and “Screen erase” in the lower side of the screen when displaying the image of an object such as a face. When the user is going to enlarge any one of the camera images 1 to 4 , the user touches the image among the camera images 1 to 4 that the user is going to enlarge, and furthermore, touches the “Screen zoom” portion. When the “Screen zoom” portion is touched, the image among the camera images 1 to 4 that is touched by the user beforehand is enlarged and displayed in the display 10 as shown in FIG. 20. In case of finishing the zoom, when the user touches the “Return” portion in display contents that are shown in FIG. 20 and are displayed in the display 10 , the contents shown in FIG. 19 are displayed once again in the display 10 . In addition, if the user is going to erase any one of the camera images 1 to 4 , the user touches the image among the camera images 1 to 4 that the user is going to erase, and touches the “Screen erase” portion. The image is erased if the “Screen erase” is touched. Furthermore, when a user is going to record any image among the camera images 1 to 4 in the memory 9 , the user touches the image among the camera images 1 to 4 that the user is going to record. When the image that the user is going to record in the memory 9 is displayed in a frame of the camera image touched, the user presses a switch that is used to record an image and is provided in the camera 5 . In this manner, when the switch is pressed, the image at that timing is recorded in the memory 9 as a static image. In addition, since the camera 5 is connected to the main body of the vital sign box with a connecting cord, the image that is shot is outputted through the connecting cord to the display 10 and/or memory 9 . Furthermore, it is assumed that the memory 9 can record up to four images. Moreover, different four images that are taken by the camera 5 can be displayed in the display 10 simultaneously as shown in FIG. 19. Then, it is assumed that it is possible that, so as to display the fifth image different from the images displayed, for example, the fifth image enters into the frame of the camera image 1 , and other images are sequentially shifted and displayed as the image having been included in the frame of the camera image 1 enters into the frame of the camera image 2 and so on.
[0196] By the way, differently from the above-described status, there is a case that, for example, the main body of the housing 14 of the vital sign box is not put on the predetermined mount described above, and the height of the CCD of the camera 5 is not equal to the height of the central part of the user's face when the base 6 is stood substantially vertically to the bottom face of the vital sign box while the camera 5 is housed in the base 6 . Nevertheless, in case a user is going to take a picture of the user's own face with the camera 5 , the user takes a picture of the user's own face by rotating the base 6 with using the connecting section 6 a of the base 6 while the camera 5 is contained in the base 6 , and fixing the base 6 with inclining the base 6 at a predetermined angle to the bottom face of the vital sign box. The base 6 is rotatable and can be fixed at the predetermined angle of gradient. Hence, it is possible to take a picture of the user's own face and the like with the camera 5 without changing the user's posture by fixing the base 6 in a predetermined direction and at a predetermined angle of gradient.
[0197] In addition, the camera 5 is detachable from the base 6 . Hence, if a user is going to take a picture of, for example, the user's ankle instead of the user's face with the camera 5 , the user takes out the camera 5 from the base 6 , and can take a picture of the ankle with holding the camera 5 in user's hands and so on.
[0198] Furthermore, since having a lighting section for lighting an imaging object, the camera 5 can take a clear picture. In addition, since having a function capable of enlarging and shrinking an image, the camera 5 can take an image, which is enlarged or shrunk, and lets the display 10 display the image.
[0199] After that, if the user confirms display contents in FIG. 19 and touches a “Return” portion, the display 10 displays contents shown in FIG. 11 once again.
[0200] It is assumed that, when contents shown in FIG. 11 is next displayed in the display 10 , the user is going to measure a “Blood glucose level.” At this time, the user touches a “Blood glucoses” portion in the display 10 , and takes out the blood glucose meter 4 , blood-collecting needle 4 a, and sensor chip 4 b from the vital sign box to attach the sensor chip 4 b at a predetermined position of the blood glucosemeter 4 . Next, the user collects the user's own blood of about 5 μl (micro liter) with using the blood-collecting needle 4 b to drip the blood, which is collected, on the sensor chip 4 b. Then, the user measures sugar density in the blood with using the sensor chip 4 b attached on the blood glucose meter 4 . When finishing the measurement of the sugar density in the blood, the user connects the connection jack 4 c to the blood glucose meter 4 , and furthermore, connects the connection jack 4 c to the main body of the vital sign box to press the send switch provided in the blood glucose meter 4 . When the send switch is pressed, the blood glucose meter 4 transmits the measurement to the LED 7 , provided in the main body of the vital sign box, through the connection jack 4 c with using an electrical signal. The LED 7 converts the measurement, transmitted with using the electrical signal from the blood glucose meter 4 , into an infrared ray having a predetermined wavelength and transmits the measurement to the reception sensor 8 . When receiving the measurement by the blood glucose meter 4 from the LED 7 in the infrared ray, the reception sensor 8 not only outputs information as such to the speaker 11 , but also outputs the information of the measurement to the memory 9 . Then, the speaker 11 outputs by sound such information that the reception sensor 8 has received the measurement from the blood glucose meter 4 . On the other hand, when receiving the measurement from the reception sensor 8 , the memory 9 not only lets the display 10 display the measurement in a number as shown in FIG. 21, but also lets the display 10 display the measurements for last five days including the measurement inputted from the reception sensor 8 . At that time, the display 10 displays and blinks the final measurement. In addition, the display 10 displays the graph with letting the final measurement be a reference and defining a predetermined range between a certain higher value and a certain lower value than the final measurement as a display range. Furthermore, in order that each measurement in the display period can be displayed in a substantially central part of the display screen, the graph is displayed. In addition, the display 10 displays the graph with adjusting a display scale in order to make fluctuations of measurements clear. Furthermore, as show in FIG. 21, when displaying each graph of measurements for past five days including each final measurement, the display 10 displays each “30-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 30 days including each final measurement are displayed as each graph. In addition, when the user touches the “30-day display” portion, the display 10 , as shown in FIG. 22, displays the measurements for the last 30 days, including the final measurement, in the graph. Also, in regard to the graphical representation, in order that each measurement in the display period can be displayed in a substantially central part of the display screen, each display range is determined by making the final measurement value be a reference so that each predetermined range between a certain higher value and a certain lower value than the final measurement becomes each display range. In addition, a display scale is also determined so that fluctuations of measurements become clear. Furthermore, as show in FIG. 22, when displaying a graph of measurements for past 30 days including the final measurement, the display 10 displays a “5-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 5 days including the final measurement are redisplayed as a graph. When the user touches the “5-day display” portion, the display 10 , as shown in FIG. 21, redisplays the measurements for the last 5 days in a graph. By the way, a measurement received by the reception sensor 8 is outputted as sound from the speaker 11 . Then, if the user confirms display contents in FIG. 21 or 22 and touches a “Return” portion, the display 10 displays contents shown in FIG. 11 once again.
[0201] Next, it is assumed that, when contents shown in FIG. 11 are displayed in the display 10 , the user is going to measure “Body weight.” At this time, the user touches a “Body weight” portion in the display 10 . Then, the user measures the user's own body weight by mounting the scale outside the vital sign box, the scale that can transmit the measurement to the vital sign box with using an infrared ray having a predetermined wavelength. When finishing the measurement of the body weight, the scale transmits a measurement to the reception sensor 8 with using the infrared ray having the predetermined wavelength. When receiving the measurement from the scale, the reception sensor 8 not only outputs information as such to the speaker 11 , but also outputs the information of the measurement to the memory 9 . Then, the speaker 11 outputs by sound such information that the reception sensor 8 has received the measurement from the scale. On the other hand, when receiving the measurement from the reception sensor 8 , the memory 9 not only lets the display 10 display the measurement in a number as shown in FIG. 23, but also lets the display 10 display the measurements for last five days including the measurement inputted from the reception sensor 8 . At that time, the display 10 displays and blinks the final measurement. In addition, with letting the final measurement be a reference and determining a predetermined range between a certain higher value and a certain lower value than the final measurement as a display range, the display 10 displays the graph, so that each measurement in the display period can be displayed in a substantially central part of the display screen. In addition, the display 10 displays with adjusting a display scale in order to make fluctuations of measurements clear. Furthermore, as show in FIG. 23, when displaying each graph of measurements for past five days including each final measurement, the display 10 displays each “30-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 30 days including each final measurement are displayed as each graph. In addition, when the user touches the “30-day display” portion, the display 10 , as shown in FIG. 24, displays the measurements for the last 30 days, including the final measurement, in the graph. Also, in regard to the graphical representation, in order that each measurement in the display period can be displayed in a substantially central part of the display screen, each display range is determined by making the final measurement value be a reference so that each predetermined range between a certain higher value and a certain lower value than the final measurement becomes each display range. In addition, a display scale is also determined so that fluctuations of measurements become clear. Furthermore, as show in FIG. 24, when displaying a graph of measurements for past 30 days including the final measurement, the display 10 displays a “5-day display” portion for changing the display contents in the lower left corner of the display screen simultaneously so that the measurements for past 5 days including the final measurement are redisplayed as a graph. When the user touches the “5-day display” portion, the display 10 , as shown in FIG. 23, redisplays the measurements for the last 5 days in a graph. By the way, the measurement received by the reception sensor 8 is outputted as sound from the speaker 11 . Then, if the user confirms display contents in FIG. 23 or 24 and touches a “Return” portion, the display 10 displays contents shown in FIG. 11 once again.
[0202] As described above, when all or part of the respective vital sensors, camera 5 , and scale are used and the use is finished, the contents shown in FIG. 11 are displayed in the display 10 . At this time, the user touches the “Return” portion in FIG. 11, and when the “Return” is touched by the user, the display 10 displays the contents shown in FIG. 9.
[0203] It is assumed that, when contents shown in FIG. 9 are next displayed in the display 10 , the user lets the display 10 display measurements and/or shot images stored in the memory 9 . At this time, the user touches a “Display” in the display 10 , and the display 10 displays and blinks the “Display” portion when the “Display” portion is touched, and after that, changes the display contents to the contents shown in FIG. 11.
[0204] In addition, when the contents shown in FIG. 11 are displayed in the display 10 , the user determines which data of the “Temperature, “Blood pressure,” “Pulse rate,” “Electrocardio,” and “Blood glucose level” measured by respective vital sensors, images taken by the camera 5 , and the “Body weight” measured by the scale, that are stored in the memory 9 , is displayed in the display 10 . Then, the user touches an adequate portion among the “Temperature,” “Blood pressure,” “Pulse rate,” “Electrocardio,” “camera,” “Blood glucose level,” and “Body weight” in the display 10 that corresponds to the data determined. The display 10 reads measurements and graph(s), or data of shot images, which correspond to the portion touched by the user, from the memory 9 , and displays them. In addition, the data displayed in the display 10 is the data displayed in realtime in the display 10 at the time of measuring an object or taking a picture that are explained with using FIGS. 12 to 24 .
[0205] Furthermore, although there are two kinds of graphs of measurements relating to, for example, “Body weight” and the like as shown in FIGS. 12 and 13, first of all a 5-day graph shown in FIG. 12 is displayed in the display 10 . Then, similarly to the above description on the display method of measurements in a graph, by the user touching the “30-day display” portion displayed in the display 10 so as to let display 10 display the 30-day graph, the 30-day graph shown in FIG. 13 is displayed in the display 10 . In this manner, it is assumed that, in the case of letting the display 10 display data stored in the memory 9 and being able to display the data obtained by the respective vital sensors, camera 5 , or scale as two kinds of screens, which screen is to be displayed is determined similarly to the case of letting the display 10 display a measurement measured in realtime and a shot image.
[0206] In addition, when the user confirms the display contents of data, recorded in the memory 9 , in the display 10 , the user touches the “Return” portion of the screen to change the display contents in the display 10 to the contents shown in FIG. 11. Furthermore, the user touches the “Return” portion shown in FIG. 11 to change the contents shown in FIG. 9.
[0207] It is assumed that, when the contents shown in FIG. 9 are next displayed in the display 10 , the user is going to communicate with the personal computer connected to the vital sign box via a communications line. At this time, the user touches a “Telephone” portion in the display 10 , and the display 10 displays and blinks the “Telephone” portion when the “Telephone” portion is touched, and after that, changes the display contents to the contents shown in FIG. 25. FIG. 25 is a drawing showing a display screen for letting a user input a name and a telephone number of a communication partner in order to specify the communication partner of the vital sign box. When the display 10 displays the contents shown in FIG. 25, the user touches any one of “Matsushita Hospital,” “xx clinic,” “Registration wait 3 ,” and “Registration wait 4 ,” and “Misc.” portions. By the way, the display of the “Matsushita Hospital” and “xx clinic” means that names and telephone numbers of the “Matsushita Hospital” and “xx clinic” have been already registered. Furthermore, the display of the “Registration wait 3 ,” “Registration wait 4 ” and “Misc.” means that names and telephone numbers of communication partners have not been registered yet.
[0208] Then, if a communication partner is the “Matsushita Hospital” or “xx clinic” and the name and telephone number have been registered beforehand, the user touches the concerned portion. When the concerned portion is touched, the display 10 displays inquiry items to the user as shown in FIG. 26. The user replies to the inquiry items shown in FIG. 26, and when the answer is finished, the user touches a “Confirmed” portion. In addition, the display 10 is used as an inquiry result input unit of the present invention according to claim 27 . By the way, when the contents shown in FIG. 26 is displayed in the display 10 and the “Confirmed” portion is touched by the user, the vital sign boxs communicates with the communication partner through the communication terminal 13 , and the display in the display 10 goes to the next step shown in FIG. 29. On the other hand, if the communication partner is not the “Matsushita Hospital” or “xx clinic” and its name and telephone number are not registered, the user touches any one of the “Registration wait 3 ,” “Registration wait 4 ,” and “Misc.” portions. If considering to contacts many times to a specific communication partner in future, the user touches the “Registration wait 3 ” or “Registration wait 4 ” portion, or if not, the user touches the “Misc.” portion. If the user touches the “Registration wait 3 ” or “Registration wait 4 ,” the display 10 displays the contents shown in FIG. 27 to let the user register a name and a telephone number of the communication partner with letting the user utilize the touch panel. If the user touches the “Confirmed” portion after the registration, the vital sign box contacts to the communication partner through the communication terminal 13 , and the display 10 displays the contents at the next step. In this manner, by letting a user register a name and a telephone number of a communication partner, thereafter, the name and telephone number are associated with the “Registration wait 3 ” or “Registration wait 4 ” that is shown in FIG. 25 and touched before the registration of the name and telephone number, and are managed by the vital sign box. On the other hand, if the user touches the “Misc.” portion when the display 10 displays the contents shown in FIG. 25, the display 10 displays the contents shown in FIG. 28 to let the user input a telephone number of a communication partner with letting the user utilize the touch panel. If the user touches the “Confirmed” portion after the input, the vital sign box contacts to the communication partner through the communication terminal 13 , and the display 10 displays the contents at the next step.
[0209] In addition, as explained at the time of describing the configuration of an vital sign box of a first embodiment of the present invention, for the convenience of the following explanation, it is assumed that the communication partner of the vital sign box is the “Matsushita Hospital.”
[0210] Moreover, although the contact method to a communication partner only by the display in the display 10 is explained in the above description, it is assumed that the contact method to the communication partner is explained simultaneously with using sound from the speaker 11 . In this manner, as described above, also in the following explanation, it is assumed that the usage of the vital sign box is explained not only with the display in the display 10 , but also with a sound output from the speaker 11 .
[0211] By the way, it is assumed that a user of the vital sign box is a “Grandfather,” a communication partner of the vital sign box is the “Matsushita Hospital,” and the vital sign box can communicate with the personal computer in the “Matsushita Hospital” on the basis of the contact from the vital sign box. In the display 10 of the vital sign box, as shown in FIG. 29, data, which relates to the “Grandfather,” is measured by each vital sensor, and is graphed, among data stored in the memory 9 , newest images taken by the camera 5 , data that is measured by the scale and graphed, and the inquiry result are displayed separately with sharing an display area. Each graph in FIG. 29 is different from each graph shown in FIG. 11, and is obtained by graphing values that are shown in FIGS. 13, 15, 17 , 18 , 19 , 22 , and 24 and are actually measured. In addition, when displaying the contents shown in FIG. 29, the display 10 displays that the vital sign box becomes communicable with the personal computer in the “Matsushita Hospital” that is the communication partner. Furthermore, the speaker 11 also outputs by sound that the vital sign box becomes in the status of being able to communicate. In addition, at that time, the vital sign boxs inputs a face image of a doctor in the “Matsushita Hospital,” which is taken by a camera connected to the personal computer, from the personal computer of the communication partner through the communication terminal 13 . Then, the display 10 displays the doctor's image in the top right portion of the screen. In addition, the vital sign boxs transmits data displayed in the display 10 to the personal computer of the communication partner through the communication terminal 13 , and lets the contents, which are shown in FIG. 29 and displayed in the display 10 , displayed on a screen of the personal computer. Furthermore, the “Grandfather” who is a user of the vital sign box lets the camera 5 take a picture of the user's own face with fixing an angle of gradient of camera 5 at a predetermined angle. The vital sign box transmits the user's real time image, taken by the camera 5 , to the personal computer of the communication partner through the communication terminal 13 . In addition, at that time, the microphone 12 becomes in a status that the microphone 12 can collect sonic reflection of realtime voice of the “Grandfather,” and can transmit the voice to the personal computer of the communication partner through the communication terminal 13 . Furthermore, the display 10 becomes in a status that the display 10 can input information from the communication partner through the communication terminal 13 and can display the information. Moreover, the speaker 11 becomes in a status that the speaker 11 can input information such as the voice of the doctor in the communication partner through the communication terminal 13 and can output the information as sound. In this manner, by also using the vital sign box as a picture phone, the “Grandfather” that is a user of the vital sign box receives telemedicine from the doctor in the communication partner.
[0212] In addition, suppose that, when the “Grandfather” that is a user of the vital sign box receives telemedicine from the doctor in the communication partner, the doctor observes, for example, a graph of blood pressure in a screen of the personal computer and finds an abnormal indication. Then, when the doctor controls the screen to magnify only the graph in order to pay attention to the graph, not only the graph of blood pressure is magnified on the screen of the doctor's personal computer, but also the graph of blood pressure is magnified and displayed in the display 10 of the vital sign box by the zoom control being inputted into the vital sign box through the communication terminal 13 . Furthermore, when the doctor locates an arrowhead on the graph as shown in FIG. 30 in order to specify the abnormal point, coordinate information of the arrowhead is inputted into the vital sign box through the communication terminal 13 from the doctor's personal computer. Hence, also on the graph of blood glucose level in the vital sign box, an arrowhead is displayed in a location that substantially corresponds to the location that the doctor specifies. In this manner, the above-described arrowhead is utilized as, for example, an arrowhead for informed consent. By the way, since the display 10 stores shape information of an arrowhead to be displayed, it is possible to display the arrowhead by not only being based on the coordinate information of the arrowhead from the doctor's personal computer, but also utilizing the shape information of the arrowhead stored.
[0213] Up to here, for the description of communication between the vital sign box and the doctor's personal computer, an example of communication is explained with using the graphs of blood pressure shown in FIGS. 29 and 30. Nevertheless, the communication between the vital sign box and the doctor's personal computer is not limited to the application of the graph of blood pressure shown in FIG. 29. Thus, other graphs and data shown in FIG. 29 are also used similarly to the graph of blood pressure shown in FIG. 29, and the information of images and/or sound is exchanged between both parties.
[0214] Then, when the user of the vital sign box finishes communication with the communication partner, the user touches an “End” portion displayed in the display 10 at that time when the contents shown in FIG. 29 is displayed in the display 10 , and changes the display of the display 10 to the contents shown in FIG. 9. On the other hand, if the display contents in the display 10 at the time of finishing communication is the contents shown in FIG. 30, the user touches the “Return” portion displayed in the display 10 to let the display 10 display the contents shown in FIG. 29, and touches the “End” portion to change the display in the display 10 to the contents shown in FIG. 9. In any case, if the contents shown in FIG. 9 are displayed in the display 10 , the user next touches the “End” portion shown in FIG. 9. In this manner, when the “End” portion shown in FIG. 9 is touched, the display 10 , as shown in FIG. 31, displays information to instruct the user to finish the use of the vital sign box and turn off the vital sign box, and lets the user to turn off the vital sign box.
[0215] In addition, in the above-described first embodiment, the base 6 is rotatable, and not only can be fixed at a predetermined angle, but also is means of containing the camera 5 , and the camera 5 is detachable from the base 6 . Nevertheless, it can be also performed that, without providing the base 6 in the vital sign box, the camera 5 is rotatable with connecting to the housing 14 and can be fixed at a predetermined angle.
[0216] In addition, in the above-described first embodiment, the lid 15 of the vital sign box, as shown in FIG. 2, is provided through the shank 16 substantially in one edge side of an upper surface of the main body of the housing 14 . In such a structure, there is a possibility of causing such an unstable status that, as shown in FIG. 2, when the lid 15 is let to be vertical to the bottom face of the vital sign box, mainly because of the weight of the display 10 inside the lid 15 , the lid 15 falls down to the side where the shank 16 of the housing 14 is provided, and in connection with it, the main body of the housing 14 rises with one side of the bottom section of the housing 14 , which faces to the shank 16 , as a substantial shaft. Then, in order to solve such structural instability, it can be also performed in regard to the structure of the vital sign box that the shank 16 , as shown in FIG. 32, is located so that the main body of the housing 14 is divided into a front section and a rear section, the lid 15 is provided through the shank 16 , and the display 10 is provided inside the lid 15 with letting the lid 15 be fixed in a status that the lid 15 is vertical to the bottom section of the vital sign box with using the shank 16 at the time of using the vital sign box. In this manner, if the main body of the housing 14 has the front section and rear section to the shank 16 , it is possible to avoid the unstable status that the main body of the housing 14 rises when the lid 15 is let to be vertical to the bottom section of the vital sign box.
[0217] In addition, in order to solve the structural problems that are described above and depends on a mounted location of the lid 15 of the housing 14 as shown in FIG. 2, it can be also performed that the display 10 provided inside the lid 15 is thinned and lightened.
[0218] Furthermore, in order to solve the above-described structural instability depending on a mounted location of the lid 15 of the housing 14 as shown in FIG. 2, instead of providing the display 10 inside the lid 15 , it can be also performed that, as shown in FIG. 33, the display 10 is made to be movable so that the display 10 can be contained in the main body of the housing 14 in a condition that the display 10 lies in a bottom section of the main body of the housing 14 at the time of non-use, and can be fixed in a condition that the display 10 is vertical to the bottom of the main body of the housing 14 at the time of use. Moreover, it can be also performed that, so as to fix the display 10 in a condition that the display 10 is vertical to the bottom section of the housing 14 at the time of using the display 10 , a fixing section of the display 10 is provided in the main body of the housing 14 .
[0219] In addition, although each driving power supply of the respective vital sensors and camera 5 is not explained in the above-described first embodiment, it can be performed that, by mounting each battery in the respective vital sensors and camera 5 , the respective vital sensors and camera 5 are driven by electric power from the batteries respectively. Alternatively, it can be also performed that, by supplying electric power to the respective vital sensors and camera 5 with using the following method, the respective vital sensors and camera 5 are driven by the electric power. Thus, as shown in FIG. 34, for example, it is such a structure that a power supply section 17 is provided in the bottom of the housing 14 of the vital sign box, the power supply section 17 which consists of a predetermined conductive wire that is configured lest the conductive wire should contact to each vital sensor and the camera 5 and further supplies electric power from the outside of the vital sign box to each vital sensor and the camera 5 with using an electromagnetic wave by electromagnetic induction. In addition, the power supply section 17 is provided inside the main body of the housing 14 so that the power supply section 17 becomes substantially in parallel to the bottom face of the main body of the housing 14 . In this case, as shown in FIG. 34, a shape of the power supply section 17 in a position corresponding to each housing location at the time of each vital sensor and the camera 5 being housed in the housing 14 is made to be a winding wire shape. Furthermore, each electric power storage section storing the electromagnetic wave from the power supply section 17 as electric power is provided in each vital sensor and the camera 5 . Moreover, with using an electromagnetic wave by electromagnetic induction from each winding wire section by applying the current to the power supply section 17 from the outside of the vital sign box external when electric power is supplied to each vital sensor and the camera 5 , the electric power is supplied to each vital sensor and the camera 5 . In this way, it becomes not necessary to mount each battery in each vital sensor and the camera 5 . By the way, it can be also performed that, for example, instead of such a structure that each winding wire section is provided only in the specific location as shown in FIG. 34, the power supply section 17 provided in the bottom section of the housing 14 is configured by a predetermined conductive wire whose entire shape is a winding wire shape. In brief, the power supply section 17 is sufficient so long as the power supply section 17 does not contact to each vital sensor and the camera 5 , and supplies electric power from the outside of the vital sign box to each vital sensor and the camera 5 with using an electromagnetic wave by electromagnetic induction. In addition, it is not always necessary to supply electric power with using an electromagnetic wave by above-described electromagnetic induction to all of the vital sensors and camera 5 , but it is also good to supply the electric power to part of the vital sensors and camera 5 .
[0220] Furthermore, in the above-described first embodiment, it is assumed that the display 10 , as shown in FIG. 26, displays inquiry items to a user of the vital sign box just before the vital sign box and the personal computer of the “Matsushita Hospital” or “xx clinic” can communicate with each other. Nevertheless, the display of the inquiry items to a user by the display 10 is not limited to the display performed just before communication. For example, the display of the inquiry items to a user by the display 10 can be performed after the vital sign box and personal computer of the “Matsushita Hospital” or “xx Clinic” can communicate with each other. In brief, the display 10 of the vital sign box according to the first embodiment of the present invention is sufficient so long as the display 10 displays the inquiry items to a user.
[0221] Moreover, in the above-described first embodiment, although it is assumed that inquiry items to a user of the vital sign box are displayed by the display 10 , the inquiry can be also performed with using sound from the speaker 11 . The inquiry to a user of the vital sign box with using sound, similarly to the display by the display 10 , can be also performed in any timing. By the way, if the inquiry items are outputted with using sound, it becomes necessary to provide an inquiry result input section, into which the user inputs answers to the inquiry items, in the vital sign box. It is possible to use, for example, the display 10 as the inquiry result input section. In addition, it is made to provide a communication terminal for transmitting answers to inquiry items, which the inquiry result input section inputs, to a communication partner. As the communication terminal, for example, the communication terminal 13 can be also used. In addition, by also using the communication terminal to be used so as means of inputting information from a communication partner, it can be performed not only to let the display 10 display the information from the communication partner, but also to let the speaker 11 output the information from the communication partner with using sound. Nevertheless, the information from the communication partner can be also outputted with using one out of the display 10 and speaker 11 .
[0222] In addition, in the above-described first embodiment, although it is made that the usage of the vital sign box is outputted by the display performed by the display 10 and by sound from the speaker 11 , the usage of the vital sign box can be also performed by any one of the display by the display 10 and the sound from the speaker 11 . Furthermore, if the usage of the vital sign box is output only by sound from the speaker 11 , a change instruction input section for inputting an instruction from a user can be also provided in the vital sign box so that an output method of the usage is changed to the display by the display 10 .
[0223] Moreover, in the above-described first embodiment, as described at the time of describing the configuration of the vital sign box according to the first embodiment of the present invention, the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , and blood glucose meter 4 are used as an example of vital sensors in the vital sign box of the present invention according to each of claims 1 , 11 , 13 , 15 , 17 , 20 , 21 , 25 and 26 . Nevertheless, the vital sensors that are provided in the vital sign box of the present invention according to each of the above-described claims are not limited to the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , and blood glucose meter 4 . All of the electrocardiograph 1 , blood pressure monitor 2 , earhole clinical thermometer 3 , and blood glucose meter 4 can be provided in the vital sign box of the present invention, or only the part of them can be also provided. In addition, for example, other vital sensors such as a blood oxymeter measuring blood oxygen concentration can be also provided.
[0224] In addition, in the above-described first embodiment, as shown in FIG. 11, it is made that the usage of the vital sign box is displayed in graphic images of measurements measured by respective vital sensors, images taken by the camera 5 , a graphic image of measurements measured by the scale, and letters. Nevertheless, the usage of the vital sign box can be displayed only in graphic images of measurements measured by respective vital sensors, images taken by the camera 5 , and a graphic image of measurements measured by the scale, or can be also displayed only in letters. Furthermore, only the images, only the letters, or images combined with letters can be also used and displayed every screen. Moreover, although each graph in FIG. 11 is made to be a graphic image of measurements measured by each vital sensor, if a user's data has been already stored in the memory 9 at that time, a graph of the data stored can be also used as each graph in FIG. 11. In addition, also as for an image to be taken by the camera 5 , if a user's image has been already stored in the memory 9 at that time, the memory can be also substituted by the image stored.
[0225] Furthermore, in the above-described first embodiment, it is made that a measurement measured by each vital sensor is displayed in the display 10 with using a number of the measurement or in a transition graph of measurements for last 5 days or 30 days including the measurement. In addition, it is made that a measurement is also outputted from the speaker 11 by sound. However, a measurement measured by each vital sensor can be also displayed only in a number in the display 10 , or can be also displayed only in a graph in the display 10 . Moreover, only sound can be also outputted from the speaker 11 . Furthermore, the display of only a number in the display 10 and an output by sound from the speaker 11 can be also performed. Alternatively, the display of only a graph in the display 10 and an output by sound from the speaker 11 can be also performed.
[0226] In addition, in the above-described first embodiment, it is made that, for example, as shown in FIGS. 12, 13, and 14 , a measurement measured by each vital sensor is displayed in the display 10 as a transition graph of measurements for 5 days or 30 days including the measurement. However, in the display 10 , a transition graph of measurements for the last 10 days can be also displayed without displaying the transition graph showing the measurements for 5 days or 30 days. In brief, a graph displayed in the display 10 is sufficient so long as the graph shows the transition of measurements in a predetermined period. Moreover, by providing means of a user inputting, for example, an instruction for specify the period in the vital sign box, it is also possible to let the display 10 change the period according to the instruction each time a graph is displayed.
[0227] In addition, in the above-described first embodiment, for example, as shown in FIGS. 12 and 13, when measurements measured by each vital sensor are displayed on the display 10 as a graph so as to show the transition during the last 5 days or 30 days, a display range is determined with a final measurement as a reference. Nevertheless, the display range can be also determined by letting a mean value of measurements in a period to be displayed be a reference, and defining the period be a range between predetermined higher value and lower value than the value that is the reference.
[0228] Moreover, in the above-described first embodiment, as shown in FIGS. 12 and 14, it is made that the display 10 displays and blinks a final measurement in a 5-day graph of measurements when displaying the graph of measurements measured by each vital sensor. On the other hand, it can be also performed that the display 10 displays and blinks the final measurement when displaying a 30-day graph of measurements, or that the display 10 displays and does not blink the final measurement.
[0229] Furthermore, in the above-described first embodiment, a communication partner of the vital sign box is the “Matsushita Hospital.” Nevertheless, the contents, first displayed in the display 10 when the vital sign box can communicate with another communication partner, is not limited to the contents shown in FIG. 29. It is also good to display some one except inquiry items among contents shown in FIG. 29, or to display only a message that the vital sign box becomes communicable with a communication partner. In brief, this means that, if a communication partner of the vital sign box is not the “Matsushita Hospital,” when the vital sign box becomes communicable, the contents displayed in the display 10 are not limited.
[0230] In addition, in the above-described first embodiment, it is made that, when the vital sign box becomes communicable with a personal computer of the “Matsushita Hospital” that is a communication partner of the vital sign box, a latest image taken by the camera 5 is displayed in FIG. 29 displayed in the display 10 . Nevertheless, so long as the image is an image taken by the camera 5 , it is not necessary to display the latest image in the display 10 displaying the contents shown in FIG. 29. For example, it is also good to display an image to be selected by letting a user select beforehand the image to be displayed. Furthermore, it is also good that, if image data is not stored in the memory 9 , an image taken by the camera 5 is displayed.
[0231] Moreover, in the above-described first embodiment, although it is assumed that a communication partner of the vital sign box is “Matsushita Hospital,” it is also good that the communication partner is, for example, a personal computer of a relative who lives apart from the “Grandfather” who is a user of the vital sign box. In that case, it is also possible to use the camera 5 in the vital sign box as means of taking a realtime picture of the “Grandfather” that is a user, or as a picture phone for performing communication with the relative.
[0232] In addition, in the above-described first embodiment, although a communication partner of the vital sign box is a personal computer of the “Matsushita Hospital.” The communication partner of the vital sign box is not limited to a personal computer so long as the partner can communicate with the vital sign box via a communication line such as a telephone line. For example, by connecting two vital sign boxs with each other via a communication line, both vital sign boxs can communicate with each other, and hence it is also possible to use the partner's vital sign box as an alternative of a personal computer. Furthermore, it is also possible to use both vital sign boxs as alternatives of picture phones.
[0233] Moreover, in the above-described first embodiment, it is made that it may happen that, when the vital sign box becomes communicable with a personal computer of the “Matsushita hospital” that is a communication partner, as shown in FIG. 30, arrowhead information for displaying an arrowhead in a graph is transmitted from the personal computer to the vital sign box. In addition, in that case, it is made that the arrowhead information is coordinate information and the vital sign box displays the arrowhead on the basis of the coordinate information of the arrowhead from the personal computer by utilizing shape information of the arrowhead stored. However, it is also good that arrowhead information transmitted from the personal computer to the vital sign box is coordinate information and shape information, and the arrowhead is displayed in a predetermined position by decoding the arrowhead from the shape information by the vital sign box and further using the coordinate information. However, in this case, an amount of information of the arrowhead information from the personal computer to the vital sign box increases in comparison to a case of only the coordinate information.
[0234] Furthermore, in the above-described first embodiment, although it is described that the vital sign box is operated by a user himself/herself, a user of the vital sign box can be a person, who assists a patient who cannot operate the vital sign box by oneself, such as a family member of a bedridden home health care patient or a visiting nurse.
[0235] Moreover, in the above-described first embodiment, although it is made that the display 10 is a touch panel type liquid crystal display, the display. 10 can be a CRT display. In brief, it is good that the display 10 is a display just displaying each measurement measured by each vital sensor such as the electrocardiograph 1 and the blood pressure monitor 2 , an object taken by the camera 5 , the usage of the vital sign box, and the like. In addition, it is better that the display changes display contents when a predetermined portion is touched.
[0236] In addition, in the above-described first embodiment, it is made that, for example, as described in FIG. 6, when a predetermined portion such as the “Grandfather” in the display 10 is touched by a user, the portion touched is displayed and blinked. Nevertheless, it is also good that, when the predetermined portion in the display 10 is touched by the user, a color of the touched portion changes so that the touched portion is distinguished from other portion. In brief, it is sufficient only that, when a predetermined portion on the display 10 is touched by a user, the portion touched is displayed so that the portion is distinguished from the other portion.
[0237] Furthermore, in the above-described first embodiment, it is made that, if contents displayed in the display 10 are not change in a predetermined period, the measurement result of blood pressure and a pulse rate measured by the blood pressure monitor 2 are displayed with being mutually changed to an opponent measurement. Nevertheless, it is also good that, by providing switching means of changing the measurement result between blood pressure and a pulse rate, which is displayed in the display 10 , in the vital sign box, the display 10 changes display contents when a user instructs the switching means. Moreover, it is also good to substitute the touch panel type display 10 for the switching means.
[0238] In addition, in the above-described first embodiment, it is made that a user presses a switch, which is provided in the camera 5 , for recording an image in the memory 9 when an image taken by the camera 5 is recorded in the memory 9 . Nevertheless, recording means of recording an image in the memory 9 can be provided in the main body of the vital sign box. It is also good to substitute the touch panel type display 10 for the recording means. In brief, it is sufficient only that the recording means of recording an image taken by the camera 5 in the memory 9 is provide in the vital sign box.
[0239] In addition, if the display 10 in the above-described vital sign box is a touch panel type display and a software keyboard function shown in FIG. 7 is provided and displayed in the display 10 , a merit that a user can input characters is created without connecting a keyboard to the vital sign box. The software keyboard function can be utilized for the above-described inquiry result input, and further can be used for inputting questions to a doctor.
[0240] Furthermore, in the above-described first embodiment, although it is made that an image to be recorded in the memory 9 is a static image, an image stored in the memory 9 can be a moving image.
[0241] Moreover, in the above-described first embodiment, it is made that the vital sign box receives data from a scale that is outside the vital sign box and can transmits a measured value to the vital sign box with using an infrared ray having a predetermined wavelength. But, it is also good that it is made that the vital sign box cannot receive data from such a scale. Alternatively, it can be performed that the vital sign box receives data from equipment, which is outside the vital sign box and can transmit a measurement to the vital sign box with using an infrared ray having a predetermined wavelength, besides a scale, and records and manages the measurement with data from each vital sensor.
[0242] In addition, in the above-described first embodiment, it is made that the vital sign box is used by any user among a “Grandfather,” a “grandmother,” “Registration wait 3 ,” and “Registration wait 4 ,” that are shown in FIG. 5, that is, a user having been already registered, or a user who is going to be registered from now on. Nevertheless, it can be performed to provide, for example, a function for making it possible for a house guest to an owner of the vital sign box, a one-time user, and the like, that is, a person, whose name and password are not registered, to use the vital sign box.
[0243] Furthermore, although the camera 5 in the vital sign box according to the above-described first embodiment is used, for example, for taking a picture of an arm injury, it is necessary to adequately adjust a focus at that time. Although fixed focus adjustment and automatic focus adjustment can be listed as the focus adjustment, it can be assumed that the camera 5 in this embodiment is a fixed focus type camera. If so, it is possible to make the camera be smaller, lighter, and cheaper than an automatic focusing type camera.
[0244] In this way, if the camera 5 is a fixed focus type camera like this, it is desirable to provide range-finding means, which is used for measuring the distance between an imaging object such as an arm injury and a predetermined section such as a lens of the camera 5 , in the camera 5 . The reason is because it is necessary to condense rays of light from the camera 5 to the imaging object and to adjust the focus.
[0245] By the way, it is possible to use a string-like body or a rod-like body, which is attached in a predetermined location such as a lens of the camera 5 and has predetermined length, as the above-described range-finding means. The length of the string-like body or rod-like body may be set in such a manner that in taking a picture of the imaging object, when the tip of the string-like body or rod-like body is brought into contact with the imaging object, the focus can be adjusted. For example, it is recommended that the length is 3 cm.
[0246] In addition, instruction receiving means such as a button for receiving an imaging instruction from a user, and imaging means of taking a picture of an imaging object when the imaging instruction is received are provided in the camera 5 . It is made that the user takes a picture of the imaging object by performing the imaging instruction to the camera 5 through contacting an end of the above-described string-like body or rod-like body with the imaging object, and pressing the button at that time when the user is going to take a picture of the imaging object such as an arm injury. By performing this, it becomes possible to take a picture at a correct focus.
[0247] In addition, the range-finding means is not limited to the above-described string-like body or rod-like body, but it is possible to use means, which utilizes an electromagnetic wave such as an ultrasonic wave or an infrared ray, as the range-finding means. Concretely, means of emitting an electromagnetic wave such as an infrared ray and detecting means of detecting the electromagnetic wave such as an infrared ray reflected by an imaging object is provided in the camera 5 . Further, the distance between the imaging object and a predetermined position such as a lens of the camera is measured from the result detected by the detecting means. At that time, if comparison result output means of comparing the measured distance with the predetermined distance that the imaging object can be adequately shot, and outputting the comparison result by a sound and an image is provided in the camera 5 , a user can perform an imaging instruction by pressing a button when the imaging object is located in an appropriate focal position. For example, the result that it becomes possible to adequately take a picture of the imaging object by accessing the imaging object by 2 cm more corresponds to the comparison result. By performing so, it becomes possible to take a picture at a correct focus. In addition, it can be performed that the above-described comparison result output means outputs information as such by a sound or an image when the imaging object is located in an appropriate focal position.
[0248] Furthermore, if the distance between the imaging object and camera is measured with using an electromagnetic wave as described above, it can be performed that the imaging means automatically takes a picture of the imaging object when the detected distance is the distance that the imaging object can be shot adequately.
[0249] Moreover, it can be performed that at least part of the housing 14 of the above-described vital sign box consists of metallic material, and a connecting section that connects a heating section, which generates heat in connection with image display to a display, outputting of sound from a speaker, and information communication at a communication terminal, such as a CPU (central control processing unit) and an HDD (hard disk drive) that are housed in the housing 14 , and a metallic material section of the above-described housing 14 , and that consists of metallic material (for example, a copper wire) is provided in the vital sign box. Then, heat in the heating section can be discharged outside the vital sign box through the connecting section.
[0250] For example, if the body temperature of a human body is measured with a clinical thermometer contained in the vital sign box, it is necessary to keep the temperature of the clinical thermometer itself at about room temperature before measurement. Hence, by discharging heat in this way, the clinical thermometer is kept to be at about room temperature, and hence this has a merit that the clinical thermometer can be used effectively. In addition, even if the clinical thermometer is an actually measuring type clinical thermometer or a forecasting type clinical thermometer, the heat radiation effect is the same so long as the clinical thermometer is a device measuring body temperature electrically.
[0251] Furthermore, if heat radiation is neglected, it is conceivable that the measurement accuracy of a clinical thermometer deteriorates. Nevertheless, as described above, for example, by providing a connecting section consisting of a copper wire or the like, heat can be radiated with using heat transfer in the connecting section, and hence it becomes possible to suppress the temperature rise of the vital sign box. Moreover, in regard to an vital sign box, when sensor installation locations are designed, it is effective to arrange the vital sign box apart from a clinical thermometer.
[0252] Furthermore, a medium that bears a program and/or data for letting a computer execute all or part of functions of the above-described vital sign box, from which the computer can read the above-described program and/or data, and with which the above-described program and/or data that are read execute the above-described functions with collaborating with the above-described computer also belongs to the present invention.
[0253] Moreover, an information aggregation that is a program and/or data for letting a computer execute all or part of functions of the above-described vital sign box, from which the computer can read the above-described program and/or data, and with which the above-described program and/or data that are read execute the above-described functions with collaborating with the above-described computer also belongs to the present invention.
[0254] The data includes data structure, a data format, and a kind of data. The medium includes a recording medium such as ROM, a communication medium such as the Internet, and a transmission medium such as light, a radio wave, and a sound wave. The bearing medium includes, for example, a recording medium recording a program and/or data, a transmission medium transmitting a program and/or data, and the like.
[0255] The processability by a computer includes readability by a computer in case of, for example, a recording medium such as ROM, and processability of a program and/or data, which are objects of transmission and have been actually transmitted, by a computer in case of a transmission medium.
[0256] The information aggregation includes, for example, software such as a program and/or data.
[0257] Apparently from the above description, the present invention can provide an vital sign box that has means of being able to take a picture with flexibly changing an imaging object and/or an imaging angle.
[0258] In addition, the present invention can provide an vital sign box that has a vital sensor that can input a measurement into memory without letting a user perform a manual input.
[0259] Furthermore, the present invention can provide an vital sign box including a display to clearly display the fluctuations of measurements in a predetermined period that are measured and recorded by a vital sensor.
[0260] Moreover, the present invention can provide an vital sign box including a speaker outputting a measurement, which is measured by a vital sensor, with using sound.
[0261] In addition, the present invention can provide an vital sign box that includes imaging means of taking a picture of an object, and can transmit an image of the object that is taken by the imaging means to a communication partner. Furthermore, the present invention can provide an vital sign box that receives information from a communication partner, and can perform bi-directional communication.
[0262] Moreover, the present invention can provide an vital sign box inquiring health conditions of a user of the vital sign box.
|
An vital sign box has a plurality of vital sensors measuring predetermined biological, chemical, or physical conditions of a living body; an camera taking a picture of a predetermined object; and a housing containing the plurality of vital sensors and the camera.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of complementary metal oxide silicon (CMOS) memory arrays and a means for biasing a well in which such memory arrays are formed.
2. Background Art
Memory arrays processed using CMOS technology often include memory cells formed in a well of a P or N conductivity type. It is often desired to bias this well to a voltage level above that of the supply voltage for N-well CMOS memory arrays, or below the power supply ground for P-well CMOS arrays. The well is biased in order to reduce leakage current (both isolation and access transistor) in the memory array cell.
In the past, a ring oscillator coupled to a substrate pump was utilized to provide biasing. A disadvantage of ring oscillators is the strong dependence of the output frequency on the supply voltage. The frequency of the ring oscillator is proportional to the square of the supply voltage. Thus, even small changes in supply voltage can create large shifts in output frequency. A second disadvantage of the previous method results from the use of a substrate pump. The substrate pump must supply, in addition to the injection and avalanche multiplication currents in the substrate, the leakage current of the memory array. These additional currents require large power consumption by the ring oscillator and charge pump.
In order to overcome the disadvantage of varying frequency, the prior art has provided a voltage regulated lower bias supply to the ring oscillator. Although this reduces power consumption of the oscillator and provides a more constant oscillating frequency source, the voltage regulator providing this regulated bias voltage supply dissipates the power drop to the oscillator as well as consuming additional power itself as needed to provide a constant regulated voltage.
Other attempts to reduce power consumption include duty cycling the ring oscillator when the pump node has reached its regulated voltage. In order to determine when to shut off the oscillator, prior art methods have utilized an inverter as a comparator having a trip point as a reference at approximately VCC/2. When the inverter is tripped, the oscillator is shut off, and does not draw power until the substrate node falls below the reference level voltage. This method has a further disadvantage of unacceptable process sensitivity.
Therefore, it is an object of the present invention to provide a means for supplying leakage currents to a memory array, particularly a CMOS memory array having low power consumption, frequency independence, and process insensitivity.
It is a further object of the present invention to provide a means for biasing a well of a memory array in which the frequency output is independent of the supply voltage.
It is a further object of the present invention to provide a means for biasing a well of a CMOS memory array in which the well voltage maintains a constant relationship to the supply voltage.
SUMMARY OF THE PRESENT INVENTION
The present invention provides a well pump which utilizes a multivibrator oscillator coupled to a constant current source to provide a frequency independent of supply voltage. The output of the oscillator is coupled to a charge pump which biases the well of a memory array. A feedback loop compares the well voltage to a reference voltage which represents the desired difference between well and supply voltage. The present invention also compares the well voltage to a second reference voltage to determine when the circuits interfacing with the memory array should be powered up. This second reference is approximately 300 millivolts above the supply voltage. Translation means are used to convert the well voltage from a value representing VCC plus approximately the desired difference volts to a value representing VCC minus approximately the desired difference. A comparator compares this value with the constant reference voltage and the output is used to duty cycle the multivibrator oscillator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the layout of the present invention.
FIG. 2 is an electrical schematic illustrating the constant current source of the present invention.
FIGS. 3A and 3B are an electrical schematic illustrating the preferred embodiment of the present invention.
FIG. 4 is an electrical schematic illustrating the comparing means of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A CMOS well pump is described which has low power consumption and utilizes a current source whose output is independent of the supply voltage. In the following description, numerous specific details are set forth, such as voltage levels, conductivity types, etc., in order to provide a more thorough understanding of the present invention. It will be obvious, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well known circuits have not been shown in detail in order not to unnecessarily obscure the present invention.
The present invention is a well pump which is used to bias the well of a memory array. In particular, the present invention is advantageously used in conjunction with a memory array fabricated using complementary metal oxide silicon (CMOS) technology. The well pump may be used to bias the well of a memory array above the power voltage (for N-well CMOS memory arrays), or below the power supply ground (for P-well CMOS memory arrays) at a constant voltage bias with respect to the supply voltage VCC (or VSS). The present invention supplies this constant voltage difference independently of the supply voltage or process parameters. The present invention provides this well bias with a minimum of power consumption.
FIG. 1 illustrates a block diagram of the layout of the present invention. Current supplies provided by the constant current source 10 supplies current biasing through lines 11 and 12 to oscillator 13. The constant current source 10 has a fixed level of output regardless of the supply voltage. The multivibrator oscillator 13 replaces the ring oscillator used with prior art substrate pumping methods. Prior art ring oscillators have a strong dependence on supply voltage. In the present invention, the multivibrator oscillator 13, coupled to the constant current source 10, has a frequency output independent of the supply voltage.
The output of multivibrator oscillator 13 is a small differential output which is coupled on lines 14 and 15 to level shifting circuit 16. The level shifting circuit 16 amplifies the small differential output and feeds it to the non-overlapping clock generator 18. The output of non overlapping clock generator 18 is coupled to charge pump 19. The output of charge pump 19 is coupled to the well of a memory array at node 20 and the charge pump is used to bias the well to a level above supply voltage or below VSS, depending upon the conductivity type of the well.
The well is coupled through line 21 to a voltage sensing and translation means 22. The translation means is used to convert the well voltage from VCC plus some amount VNW to VCC minus VNW. The translation means shows a large resistance to the well so that a minimum of current is drawn from the well. This output is fed on line 23 to the inverting input of comparator 27. VREF 25 represents the supply voltage minus desired voltage difference. VREF is coupled through line 24 to the non inverting input of comparator 27. The output of comparator 27 is coupled to the oscillator 13. When the voltage difference exceeds the desired reference voltage, the oscillator 13 is powered down, ceasing its output. The oscillator remains powered down until the well voltage falls below the desired bias voltage, at which point the oscillator is powered up.
As an additional feature of the present invention a second comparator 99 is used to determine when there is sufficient well bias to power up the memory array. The well is coupled through line 98 to comparator 99. Comparator 99 is also coupled to supply voltage VCC. Comparator 99 is biased so that when the well is biased a certain amount above the supply voltage, the memory array may be powered up. In the preferred embodiment of the present invention, the array is powered up when the well bias exceeds the supply voltage by 300 millivolts.
The constant current source is shown in detail in FIG. 2. A pair of gate coupled P channel transistors 28 and 29 are source coupled to the supply voltage VCC 33. Gate coupled N transistors 30 and 31 are drain coupled to P transistors 28 and 29 respectively. The source of transistor 31 is coupled through resistor 32 to VSS 34. The source of transistor 30 is also coupled to VSS. The gates of transistors 28 and 29 are coupled to the drains of transistors 29 and 31 at node 106. The gates of transistors 30 and 31 are coupled to the drains of transistors 28 and 30 at node 107. Bias P signal 11 is taken from node 106 and bias N signal 12 is taken from node 107. It can be seen that when VCC increases, the current in N transistors 30 and 31 tries to increase the voltage drop across resistor 32 and reduces gate to source voltage on transistor 31, opposing any current increase (i.e. negative feedback loop operates). In this manner, the bias P signal 11 and bias N signal 12 may be kept constant.
MULTIVIBRATOR OSCILLATOR
The multivibrator oscillator is shown in greater detail in FIG. 3A. The bias N signal 12 is coupled through N transistor 35 to the drain of N transistor 36 and the gates of N transistors 40 and 41. The gate of transistor 35 is coupled to PDX 108 while the gate of transistor 36 is coupled to PDY 109. PDX 108 and PDY 109 are used to enable the oscillator. When the oscillator is off, PDY 109 is at VCC and PDX 108 is at VSS. To enable the oscillator, PDX 108 is taken to VCC and PDY 109 is taken to VSS.
Transistors 40 and 41 are source coupled to VSS 34. Bias P signal 11 is coupled to the gates of P channel transistors 42 and 45 which are source coupled to VCC 33. The drain of transistor 42 is coupled to the gate and drain of P channel transistor 43. The source of transistor 43 is also coupled to VCC. The drain of transistor 45 is coupled to the gate and drain of P channel transistor 44, whose source is coupled to VCC 33.
Transistor 42 is also drain coupled to N channel transistor 46 and transistor 45 is drain coupled to N channel transistor 47. Transistors 46 and 47 are cross coupled with the gate of transistor 47 coupled to the drain of transistor 46 and the gate of transistor 46 coupled to the drain of transistor 47. The source of transistor 46 is coupled to the drain of transistor 40 while the source of transistor 47 is coupled to the drain of transistor 41. The source of transistor 46 is coupled through a capacitor to the source of transistor 47.
The capacitor is comprised of P channel transistors 48 and 49. In the preferred embodiment of the present invention, the capacitors comprise depletion transistors (as shown) however, any suitable capacitors may be utilized in the present invention. The source and drain of transistor 49 are coupled to the gate of transistor 48 and to the source of transistor 47. The source and drain of transistor 48 are coupled to the gate of transistor 49 and to the source of transistor 46.
N channel transistors 40 and 41 and P channel transistors 42 and 45 are current sources for cross coupled transistors 46 and 47 and the associated capacitor. Line 14, coupled to the drain of transistor 47, and line 15, coupled to the drain of transistor 46, carry the output of the multivibrator oscillator. This output is a small differential output whose frequency is determined by the size of the capacitor and the current source values. The signal on line 14 is the complement of the signal on line 15. This output is coupled to the level shifter, also shown in FIG. 3A.
VOLTAGE LEVEL SHIFTER
The output on line 14 is coupled to the gates of P channel transistor 51 and N channel transistor 53. The output on line 15 is coupled to the gates of P channel transistor 50 and N channel transistor 52. Transistors 50 and 51 are source coupled VCC 33. Transistor 50 is drain coupled to transistor 52 while transistor 51 is drain coupled to transistor 53. The source of transistor 52 is coupled to the drain of N transistor 54. The source of transistor 53 is coupled to the drain of N transistor 55. Transistors 54 and 55 are source coupled to VSS 34. The gate of transistor 54 is coupled to the drain of transistor 51 while the gate of transistor 55 is coupled to the drain of transistor 50. Inverters 56 and 57 are coupled to the gate of transistor 54. The outputs of inverters 56 and 57 are coupled through lines 17A and 17B respectively to the clock generator circuit, shown in FIG. 3B.
CLOCK GENERATOR
The non overlapping clock generator is comprised of nand gates A and B and nor gates C and D. In the preferred embodiment of the present invention, nand gate A is comprised of P channel transistors 58A and 59A source coupled to VCC 33 and drain coupled to N channel transistors 60A and 61A, coupled in series to VSS. The gate of transistor 59A is coupled to the gate of transistor 60A. The gate of transistor 58A is coupled to the gate of transistor 61A and to line 17A. The ouput of nand gate A is taken from node 62A, which is the junction of the drains of transistors 58A and 59A and 60A.
Nand gate B is constructed similarly with the output of nand gate B coupled to the gates of transistor 59A and 60A of nand gate A. Correspondingly, the gates of transistors 58B and 60B of nand gate B are coupled to the output of nand gate A.
The outputs of nand gate A and B on line 65 and 66 respectively are non overlapping signals which are coupled to the charge pump of the present invention.
In the preferred embodiment in the present invention, nor gate C is comprised of P channel transistor 67C and 68C coupled in series with the source of transistor 67C coupled to VCC 33 and the drain of transistor 68C coupled to the drains of N channel transistors 69C and 70C. Transistor 69C and 70C are source coupled to VSS 34. The gates of transistor 67C and 69C are coupled to the output of nand gate A. The gates of transistor 68C and 70C are coupled to the output of nor gate D. The output of nor gate C is taken from node 71C which is the junction of the drains of transistor 69C, 70C and 68C and is coupled through line 64 to the charge pump of the present invention.
Nor gate D is configured in a manner similar to nor gate C with the output of nor gate C coupled to the gates of transistor 68D and 70D of nor gate D. The gates of transistors 67D and 69D are coupled to the output on line 17B of the level shifter. The output of nor gate D is coupled to the gates of transistors 58D and 61D of nand gate B as well as to the charge pump through line 63.
The signals on line 63 and 64 are the complements of the signals on line 65 and 66 respectively.
CHARGE PUMP
The charge pump consists of a string of N channel series transistors 79 through 82, coupled in parallel with N transistor 83 to VCC 33 and the N well node 20. The gate of transistor 83 is coupled to its own drain. The gates of transistors 79 through 82 are each coupled to their own drains. These series transistors are controlled by the output of the clock generator. The gate of transistor 79 is coupled to the source of P channel transistors 72 and 73. The gate of transistor 73 is coupled to signal on line 65 and the gate of transistor 72 is coupled to the signal on line 66. The drains of transistor 72 and 73 are coupled to the drains of N channel transistors 77 and 78 respectively at nodes 100 and 101. The sources of transistors 77 and 78 are coupled to ground. The gate of transistor 77 is coupled to the signal on line 64. The signal on line 63 is coupled to the gate of transistor 78. The drain of P channel transistor 72 is coupled to the gate of P channel transistor 75.
The source and drain of transistor 75 are each coupled to the gate of transistor 81. The drain of transistor 73 is coupled to the gates of P channel transistors 74 and 76. The source and drain of transistor 74 are coupled to the gate of transistor 80 and the source and drain of transistor 76 are coupled to the gate of transistor 82. The source and drains of transistors 74 through 76 are also coupled to the N well in which they are formed. These transistors (74 through 76) function as capacitors and in conjunction with transistors 79 through 82 form a three stage charge pump. Transistors 74 through 76 may be depletion transistors, as shown, or may be replaced by any suitable capacitors.
The gate of transistor 75 is coupled to the drains of transistors 72 and 77 at node 100. The gates of transistors 74 and 76 are coupled to the drains of transistors 73 and 78 and node 101. During the operation of the charge pump, nodes 100 and 101 are alternately at 5 volts and ground respectively. When node 101 is at ground, transistor 74, acting as a capacitor, is charged to VCC minus VTN (through transistor 79). Node 101 is then charged to VCC and node 100 is at ground. Transistor 74 discharges through transistor 80 and transistor 75 is charged to approximately 1.6 VCC-VTN.
Next, node 101 returns to ground and node 100 charges to VCC. As a result, transistor 75 discharges through transistor 81 and charges transistor 76 to approximately 2.8 VCC-2 VTN. When node 101 returns to VCC, transistor 76 discharges through transistor 82 to the N well node 20.
During initial power up to VCC, transistor 83 raises the voltage of the N well node 20 to VCC minus VTN. When the charge pump is off, transistor 83 acts as a clamping device to prevent the N well from going below VCC minus VTN.
TRANSLATION CIRCUIT AND COMPARATOR
The voltage translation circuit and comparator are shown in detail in FIG. 4. The voltage translation means consists of P transistors 84 and 86 and N transistors 85 and 87. The gate of P channel transistor 84 is coupled to VCC 33. The source of transistor 84 is coupled to the N well while the drain of transistor 84 is coupled to the drain of transistor 85 and the gates of both transistors 85 and 87. The sources of N transistors 85 and 87 are coupled to VSS 34 and the drain of transistor 87 is coupled to the drain and gate of P channel transistor 86 at node 102. The source of transistor 86 is coupled to VCC 33. Node 102 is the output of this translator and is coupled through line 23 to the gate of P channel transistor 89 comparator circuit. The N well voltage coupled to transistor 84 is some amount VNW above VCC. The well voltage is sensed with current across transistor 84 and turns on transistors 85 and 87, which form a current mirror. Transistor 86 is biased on with the mirrored current from transistor 84 such that gate-source voltages for transistors 84 and 86 are equal. Node 102 thus represents 2 VCC voltage minus the N well voltage. 2 VCC-N well voltage (or VCC-VNW) is inputed to the comparator on line 23.
The other input to the comparator is generated by P transistor 95 and N transistors 96 and 97. The source of P transistor 95 is coupled to VCC 33. The gate and drain of transistor 95 are coupled to the gate and drain of N transistor 96. The source of transistor 96 is coupled to the drain of transistor 97 at node 103. The source of transistor 97 is coupled to VSS 34. The gate of transistor 97 is coupled to the biasN signal 12. VTP of transistor 95 plus VTN of transistor 96 is the voltage reference output of this circuit and is coupled at node 103 to line 24. VTP plus VTN is biased by N transistor 97 through the biasN signal 12. In the preferred embodiment of the present invention, transistors 95 and 96 are such that the output of the circuit on line 24 is approximately 2.5 volts below VCC and is coupled to the comparator on line 24.
The comparator of the present invention comprises P channel transistors 88, 89 and 90 and N channel transistors 91, 92, 93 and 94. The sources of N channel transistors 91 through 94 are coupled to VSS 34. The gates of transistors 91 and 92 are coupled to the drains of transistors 91 and 93 at node 104. The gates of transistors 93 and 94 are coupled to the drains of transistors 92 and 94 at node 105. Node 104 is coupled through P channel transistor 89 to the drain of P channel transistor 88. Node 105 is coupled through P channel transistor 90 (whose gate is coupled to line 24) to the drain of P channel transistor 88. The source of P channel transistor 88 is coupled to VCC 33 and the gate of transistor 88 is coupled to the biasP signal 11. Nodes 104 and 105 are the outputs of the comparator circuit. The comparator shown relates to comparator 27 of FIG. 1. However, a similar configuration can be used for comparator 99 of FIG. 1.
The outputs of the comparator at nodes 104 and 105 are coupled to a level shifter to provide a full swing between VSS and VCC. The outputs of this level shifter (not shown) are PDX 108 and PDY 109. As described above, these signals power down the multivibrator oscillator of the present invention.
Although the present invention has been described with application to a well pump, it can be applied to bias the substrate or any other portion of a semiconductor body.
Thus, a CMOS charge pump has been described which biases the well of a memory array a fixed amount above the supply voltage. The charge pump of the present invention provides constant frequency with low power consumption and process insensitivity.
|
A CMOS charged pump circuit for biasing the N well of a memory array. The present invention utilizes a multivibrator oscillator coupled to a constant current source to provide a frequency output which is independent of the supply voltage. The multivibrator oscillator uses less power than prior art ring oscillators. Feedback through a comparator circuit is used to monitor the N well voltage so that the multivibrator oscillator and ultimately the charge pump may be duty cycled to further reduce power consumption.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to control of an electrophotographic printer having a non-volatile memory inside the printer or in a functional portion capable of transmitting and receiving data to and from the main body of the printer and detachably attachable to the main body.
[0003] 2. Related Art
[0004] [0004]FIG. 9 is a block diagram showing a configuration of a conventional printer control portion.
[0005] Numeral 101 designates a printer controller, which executes communication with a host computer, which receives image data to expand the received image data into information for the printer to be able to print, and which executes exchange and serial communication of signals with a printer engine control portion described hereinafter. Numeral 102 is an engine control portion, which executes control of each unit in a printer engine through the exchange and serial communication of signals with the printer controller.
[0006] Numeral 103 denotes a sheet convey control portion which feeds and conveys a sheet to be printed and which executes sheet conveyance up to discharging of a sheet after printed, based on an instruction from the engine control portion; numeral 104 an optical system control portion which executes control of driving of a scanner motor and ON/OFF of a laser, based on an instruction from the engine control portion; numeral 105 a high voltage control portion which executes output of high voltages necessary for the electrophotographic process including charging, developing, transferring, and so on, based on an instruction from the engine control portion; numeral 106 a fixing temperature control portion which performs control of temperature of a fixing device, based on an instruction from the engine control portion, and which performs detection of abnormality of the fixing device, and the like; numeral 107 a sheet presence/absence sensor input portion which transmits information of sheet presence/absence sensors in a sheet feed portion and in a sheet conveyance path to the engine control portion; numeral 108 a jam detecting portion which detects defective conveyance during sheet conveyance; numeral 109 a breakdown detecting portion which detects a breakdown of functional part in the printer; numeral 110 a toner cartridge detachably attachable to the printer engine.
[0007] A non-volatile memory 111 capable of transmitting and receiving data to and from the engine control portion is mounted in this toner cartridge, thereby constituting a configuration enabling reading of data from the engine control portion or writing of data therein.
[0008] Conventionally, the engine control portion was configured to count up in the non-volatile memory, data concerning consumption of consumable supplies in the process cartridge, e.g., data about operation of the drum (time of rotation of the drum or the like), the residual amount of toner, etc., and to perform, upon arrival at a predetermined threshold, such control as to inform the printer controller of the fact.
[0009] The conventional apparatus was, however, designed without sufficient consideration to timing of carrying out a switch process of primary current values for lengthening the lifetime of the process cartridge and thus had the problem that switching occurred during execution of the electrophotographic process, so as to fail to maintain the uniformity of image quality.
SUMMARY OF THE INVENTION
[0010] The present invention has been accomplished in view of the above-stated problem and an object of the invention is to provide image processing apparatus that can maintain the uniformity of image quality in printing of identical images and that can drastically improve the performance of the printer.
[0011] The other object of the present invention is to provide an image forming apparatus including an image control portion for expanding predetermined information supplied from an external device, into print information, and a printer control portion for performing print control based on the print information, the image forming apparatus being adapted to print the expanded information in a predetermined recording medium under the print control, the image forming apparatus comprising:
[0012] process cartridge means which transmits and receives signals for the print control to and from the printer control portion, which executes an electrophotographic process according to the signals for the print control, and which is detachably attachable to a main body of the image forming apparatus;
[0013] non-volatile memory means which stores operation information including information concerning an operation quantity of the process cartridge means and which is mounted in the process cartridge means;
[0014] means which performs read/write control of the operation information out of or into the non-volatile memory means, according to the print control from the printer control portion;
[0015] switch timing determining means which determines switch timing of a condition for the electrophotographic process, based on the operation information stored in the non-volatile memory means and a state of the printer control portion; and
[0016] switching means which switches the condition for the electrophotographic process at the switch timing.
[0017] The other objects, configurations, and effects of the present invention will become apparent from the detailed description and drawings which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a drawing showing a mechanical configuration of an electrophotographic printer according to the first embodiment of the present invention;
[0019] [0019]FIG. 2 is a block diagram showing the printer control portion according to the first embodiment;
[0020] [0020]FIG. 3 is a flowchart of a sequence in the engine control portion according to the first embodiment;
[0021] [0021]FIG. 4 is a block diagram showing a system for carrying out switching of primary current according to the first embodiment;
[0022] [0022]FIG. 5 is a block diagram showing the printer control portion according to the second embodiment;
[0023] [0023]FIG. 6 is a drawing showing job information to be designated for the engine control portion according to the second embodiment of the present invention;
[0024] [0024]FIG. 7 is a flowchart showing the flow of control of the above engine control portion according to the second embodiment;
[0025] [0025]FIG. 8 is a drawing showing an example using an FeRAM or the like as a non-volatile memory according to the third embodiment of the present invention; and
[0026] [0026]FIG. 9 is a block diagram showing the conventional printer control portion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] First Embodiment
[0028] [0028]FIG. 1 is a drawing showing a mechanical configuration of an electrophotographic printer according to the first embodiment of the present invention.
[0029] Numeral 1 designates a photosensitive drum for forming an electrostatic latent image, 2 a charging roller for uniformly charging the photosensitive drum 1 , 5 an optical unit for scanning the area on the photosensitive drum 1 with a laser beam, 6 the laser beam emitted from the optical unit 5 , 3 a developing device for developing with toner, the electrostatic latent image formed on the photosensitive drum 1 with the laser beam, 4 a transferring roller charging device for transferring a toner image on the photosensitive drum 1 onto a predetermined sheet, 7 a fixing device for fusing the toner on the sheet to fix the toner image on the sheet, 8 a standard cassette for carrying sheets for print, 9 a standard cassette sheet feed roller for picking up a sheet from the standard cassette, 10 discharging rollers for discharging a sheet out of the apparatus, 11 a registration sensor for effecting registration of the leading end for printing of a sheet having been conveyed thereto, 12 a sheet discharge sensor for checking whether a sheet has normally been discharged from the fixing device, and 13 a sensor for detecting presence/absence of a sheet in the standard cassette.
[0030] These functional components operate in accordance with instructions from the printer controller described hereinafter. The printer controller performs control to operate the foregoing functional components to implement print processing, based on instructions from an unrepresented image controller.
[0031] Numeral 19 represents a non-volatile memory mounted in the cartridge, which stores information, e.g., concerning the photosensitive drum in the cartridge and the volume of toner in the developing device. Data, e.g., about consumption of toner is written from the engine control portion into the memory according to the print operation of the engine or the like. In the engine control portion there exists a memory access means 302 described hereinafter and access is made through the memory access means 302 to the non-volatile memory 19 at predetermined timing, or in accordance with a read request or a write request from the printer controller.
[0032] [0032]FIG. 2 is a block diagram showing the printer control portion.
[0033] Numeral 201 designates the printer controller, which performs the communication with the host computer, which receives image data and expands the received image data into information for the printer to be able to print, and which executes exchange and serial communication of signals with the printer engine control portion described hereinafter. Numeral 202 denotes the engine control portion, which executes control of each unit in the printer engine through the exchange and serial communication of signals with the printer controller.
[0034] Numeral 203 represents the sheet convey control portion which sequentially performs the processes of feeding, conveyance, and discharging of sheet, based on an instruction from the engine control portion; 204 the optical system control portion which performs driving/stopping of the scanner motor, control of emission of laser, etc., based on an instruction from the engine control portion; 205 the high voltage control portion which executes control of respective high voltages of charging, developing, and transferring, based on an instruction from the engine control portion, the high voltage control portion carrying out control to switch process conditions in accordance with an instruction from a process condition switching means in the engine control portion, which will be described hereinafter. In the present embodiment, the apparatus is adapted to perform control to lower the electric current value with increase in an operation quantity, based on the operation quantity of the drum (total drum rotation time).
[0035] Numeral 206 indicates the fixing temperature control portion which carries out control of temperature of the fixing device, based on an instruction from the engine control portion; 207 the sheet presence/absence sensor input portion which detects presence/absence of a sheet in the cassette, presence/absence of a sheet in the conveyance path, etc. to transmit the detection result to the engine control portion; 208 the jam detecting portion which detects an abnormality in conveyance of sheet; 209 the breakdown detecting portion which detects an abnormality of each function in the print process, such as an abnormality of the motor for conveyance of sheet, an abnormality of the fixing device, and so on; 300 the toner cartridge which incorporates the photosensitive drum and the charging and developing functions, which is detachably attachable to the printer engine, which carries the non-volatile memory 301 inside, and which has the function of transmitting and receiving data to and from the engine control portion; 302 the memory access means in the engine control portion, which performs reading/writing of data from or in the nonvolatile memory 301 in the toner cartridge.
[0036] Signals between the printer controller and the engine control portion will be described.
[0037] Numeral 210 represents a serial data signal in the serial communication between the print controller and the engine control portion, and this signal handles a command outputted from the printer controller and a signal of status outputted from the engine control portion in two ways. Numeral 211 indicates a synchronous clock in the serial communication, which is outputted from the printer controller to the engine control portion.
[0038] Numeral 212 stands for/TOP signal which is a vertical synchronizing signal to designate a start of sending of an image signal when a sheet has been conveyed up to the image write position after a start of sheet conveyance; 213 for/BD signal which is a horizontal synchronizing signal for image synchronization in the main scanning direction; 214 for an image signal; 215 for/CCRT signal which is a condition change reporting signal for reporting a condition change from the engine control portion to the printer controller upon occurrence of a condition change, e.g., either of various condition changes in the engine (for example, presence/absence of sheet, occurrence of jam, and occurrence of breakdown).
[0039] The serial communication between the engine control portion and the non-volatile memory will be described below.
[0040] Numeral 311 represents CS signal which is a chip select signal outputted from the memory access means to the non-volatile memory; 312 /DOUT signal which is a serial command signal outputted from the memory access means to the non-volatile memory; 313 /DIN signal which is a data signal returned from the non-volatile memory to the memory access means; 314 /CLK signal which is a serial synchronous clock outputted from the memory access means to the non-volatile memory.
[0041] Numeral 303 denotes a switch timing control means in the engine control portion, which monitors the state of the engine control portion and which determines switch timing of the process conditions; 304 a process condition switching means which gives the high voltage control portion an instruction to change the predetermined high voltage outputs to outputs matching with the memory contents, in accordance with an instruction from the switch timing control means 303 .
[0042] In the present embodiment, the switch timing control means judges whether the engine control portion is in the print operation, i.e., whether it is in control of sheet conveyance or in output for charging or developing of the electrophotographic process for printing, and determines the switch timing at the time when the both are negative; not in the sheet conveyance and not in the electrophotographic process.
[0043] With determination of the switch timing, the process condition switching means is informed of a primary charging current value based on the drum operation quantity data in the memory, and the new set value will be outputted upon next application of high voltage.
[0044] [0044]FIG. 3 is the flowchart showing the above sequence of the engine control portion.
[0045] First, the engine control portion checks whether a print request from the controller is present (step S 301 ).
[0046] When the condition for switching of primary current is met, data of the sum of drum driving time is read from the non-volatile memory in the cartridge, which stores the data corresponding to the sum of past drum driving time (step S 302 ).
[0047] It is then determined whether the sum exceeds Td being a threshold of primary current (step S 303 ). When the sum exceeds Td, the primary current is set to I1 (step S 304 ). When it does not exceed Td, the primary current is set to I2 (step S 305 ).
[0048] After that, the engine control portion starts driving the motor for printing, starts the optical system including the scanner motor and others, starts the various high voltages, and starts the temperature control of the fixing device (step S 306 ).
[0049] The engine control portion starts measuring of the drum driving time at the same time as the start of driving of the motor (step S 307 ).
[0050] It is then determined whether the print is finished (step S 308 ). When it is determined that the print is finished, the engine control portion terminates the fixing temperature control, stops the motor, breaks the high voltages, stops the optical system, and terminates the driving of the drum finally (step S 309 ).
[0051] Then the engine control portion stops the measuring of the driving time of the drum (step S 310 ) and it adds the result of the measuring of drum driving time at that time to the sum of drum driving time in the non-volatile memory in the cartridge and again stores the result of the addition in the non-volatile memory (step S 311 ). After that, the engine control portion goes into the first state of waiting for a print request (step S 301 ).
[0052] According to the sequence as described above, the switching of primary current is not effected instantly, but is postponed at least to the end of print.
[0053] [0053]FIG. 4 is a block diagram showing a system for carrying out the switching of primary current.
[0054] Numeral 401 designates a CPU presiding over the center of the engine control portion, only a high voltage control part of which is extracted in the illustration herein. Numeral 402 denotes a high voltage control circuit, which controls output of the respective high voltages for primary charging, developing bias, and transferring charging and which performs the switching of output in accordance with an instruction from the CPU. Numeral 403 represents a primary charging voltage setting circuit which outputs the primary charting voltage in a value designated from the CPU, to the charging roller 2 ; 404 a developing bias setting circuit which outputs a developing bias in accordance with an instruction from the CPU; 405 a transferring voltage setting circuit which outputs the transferring voltage in accordance with an instruction from the CPU.
[0055] The CPU can turn the primary charging on or off by PreON signal. The CPU can also switch the primary charging current value between I1 and I2 by High signal.
[0056] Second Embodiment
[0057] The second embodiment will be described next. Since the mechanical configuration of the electrophotographic printer in the second embodiment is similar to that in FIG. 1 in the first embodiment, the description thereof is omitted herein.
[0058] [0058]FIG. 5 is a block diagram showing the printer control portion according to the second embodiment.
[0059] Numeral 201 designates the printer controller, which performs the communication with the host computer, which receives image data and expands the received image data into information for the printer to be able to print, and which executes the exchange and serial communication of signals with the printer engine control portion described hereinafter. Numeral 202 denotes the engine control portion, which executes the control of each unit in the printer engine through the exchange and serial communication of signals with the printer controller.
[0060] Numeral 203 represents the sheet convey control portion which sequentially performs the processes of feeding, conveyance, and discharging of sheet, based on an instruction from the engine control portion; 204 the optical system control portion which performs driving/stopping of the scanner motor, control of emission of laser, etc., based on an instruction from the engine control portion; 205 the high voltage control portion which executes control of the respective high voltages of charging, developing, and transferring, based on an instruction from the engine control portion, the high voltage control portion carrying out control to switch the process conditions in accordance with an instruction from the process condition switching means in the engine control portion, which will be described hereinafter. In the present embodiment, the apparatus is adapted to perform the control to lower the electric current value with increase in an operation quantity, based on the operation quantity of the drum (total drum rotation time).
[0061] Numeral 206 indicates the fixing temperature control portion which carries out the control of temperature of the fixing device, based on an instruction from the engine control portion; 207 the sheet presence/absence sensor input portion which detects presence/absence of a sheet in the cassette, presence/absence of a sheet in the conveyance path, etc. to transmit the detection result to the engine control portion; 208 the jam detecting portion which detects an abnormality in conveyance of sheet; 209 the breakdown detecting portion which detects an abnormality of each function in the print process, such as an abnormality of the motor for conveyance of sheet, an abnormality of the fixing device, and so on; 300 the toner cartridge which incorporates the photosensitive drum and the charging and developing functions, which is detachably attachable to the printer engine, which carries the non-volatile memory 301 inside, and which has the function of transmitting and receiving data to and from the engine control portion; 302 the memory access means in the engine control portion, which performs reading/writing of data from or in the nonvolatile memory 301 in the toner cartridge.
[0062] Signals between the printer controller and the engine control portion will be described.
[0063] Numeral 210 represents a serial data signal in the serial communication between the print controller and the engine control portion, and this signal handles a command outputted from the printer controller and a signal of status outputted from the engine control portion in two ways. Numeral 211 indicates a synchronous clock in the serial communication, which is outputted from the printer controller to the engine control portion. Numeral 212 stands for/TOP signal which is a vertical synchronizing signal to designate a start of sending of an image signal when a sheet has been conveyed up to the image write position after a start of sheet conveyance; 213 for/BD signal which is a horizontal synchronizing signal for image synchronization in the main scanning direction; 214 for an image signal; 215 for/CCRT signal which is a condition change reporting signal for reporting a condition change from the engine control portion to the printer controller upon occurrence of a condition change, e.g., either of various condition changes in the engine (for example, presence/absence of sheet, occurrence of jam, and occurrence of breakdown). The serial communication between the engine control portion and the non-volatile memory will be described below.
[0064] Numeral 311 represents/CS signal which is a chip select signal outputted from the memory access means to the non-volatile memory; 312 /DOUT signal which is a serial command signal outputted from the memory access means to the non-volatile memory; 313 /DIN signal which is a data signal returned from the non-volatile memory to the memory access means; 314 /CLK signal which is a serial synchronous clock outputted from the memory access means to the non-volatile memory.
[0065] In the first embodiment, the switch timing of primary current was determined based on the information intrinsic to the engine, i.e., based on whether a transition is made into the standby state. In the second embodiment, however, the engine control portion determines the switch timing of primary current value, based on reception of job information from the printer controller, i.e., information about a predetermined heap of print works from the user under print requests from the host computer to the printer controller.
[0066] The job information from the printer controller is transmitted through the serial communication between the foregoing printer controller and the engine control portion.
[0067] Numeral 303 denotes the switch timing control means in the engine control portion, which monitors the state of the engine control portion and which determines the switch timing of the process conditions; 304 the process condition switching means which gives the high voltage control portion an instruction to change the predetermined high voltage outputs to outputs matching with the memory contents, in accordance with an instruction from the switch timing control means 303 .
[0068] In the present embodiment, the switch timing control means performs the switch work at the time when the engine has completed the print of a series of print jobs designated from the printer controller, based on the job information designated from the printer controller, to go into the standby state, and the control means then executes the print at the primary current value thus switched, from a next designated print job.
[0069] [0069]FIG. 6 shows the job information designated for the engine control portion by the print controller in the serial communication. The serial communication is of a 16-bit configuration and the highest four bits thereof indicate a job information designating command. Eleven bits below them except for the parity bit designate the number of prints in a job printed next. In the present embodiment, the figure shows such an illustration that the job information designating command is indicated when the highest four bits are 0001 B.
[0070] This command demonstrates its effect when it is outputted prior to output of a print request from the printer controller. Namely, by issuing the foregoing job designating command prior to the print request, it is recognized how many prints from the next requested print are in one job.
[0071] [0071]FIG. 7 is a flowchart showing the control of the above engine control portion.
[0072] First, the engine control portion determines whether all printing of a print job in the number designated from the printer controller is finished (step S 701 ). When all is finished, the engine control portion starts checking whether a next job is designated (step S 702 ). When there is a designated print job from the printer controller, the number of print is stored (step S 703 ). When there is no designation, the engine control portion sets job designation of one print as a default value (step S 704 ).
[0073] After that, the engine control portion checks whether a print request is present (step S 705 ). When there is a print request, the engine control portion reads the drum driving time used as a threshold for switching of primary current from the data stored in the non-volatile memory in the cartridge (step S 706 ). When there is no print request, the engine control portion returns to step S 701 . After the process at step S 706 , the engine control portion determines whether the drum driving time exceeds the predetermined time (step S 707 ). When it is determined as a result that the drum driving time does not exceed Td being the predetermined threshold, the engine control portion sets the initial primary current value I1 (step S 708 ). When the drum driving time exceeds the threshold Td, it is determined whether the printer is at the first page of the job (step S 709 ). When it is at the first page, the primary current value is set to I2 (step S 710 ).
[0074] After that, the engine control portion starts driving the motor for the print, starts the optical system including the scanner motor and others, starts the various high voltages, and starts the temperature control of the fixing device (step S 711 ). Then the engine control portion executes the actual print operation and the measurement to count the drum driving time (step S 712 ). It is then determined whether the print of one page is finished (step S 713 ). When it is determined that the print is finished, the print number is counted up (step S 714 ); the break processes of the high voltages, the optical system, etc. are carried out (step S 715 ); the measuring of the drum driving time is terminated (step S 716 ); the result of the measuring of the drum driving time at that time is further added to the sum of drum driving time in the non-volatile memory in the cartridge and the result of the addition is again stored in the non-volatile memory (step S 717 ).
[0075] After completion of the above, the engine control unit returns to the first process (step S 701 ).
[0076] According to the above processing, before completion of printing in the print number of the job designated from the printer controller, the engine control portion does not switch the primary current in the middle of the job before finishing the printing operation through the print number of the designated job even if the sum of drum driving time exceeds the predetermined threshold to meet the primary current switch condition. In addition, switching is not effected during the print operation, either, whereby the primary current can be switched at optimal timing.
[0077] Third Embodiment
[0078] In the first and second embodiments, the serial communication is implemented by signals through wires between the non-volatile memory and the engine control portion.
[0079] However, it is also feasible to employ such a configuration that the non-volatile memory such as an FeRAM or the like is mounted in the cartridge and the exchange of data is implemented with the memory by use of electromagnetic coupling through coils, as shown in FIG. 8, and this configuration according to the present invention can also achieve the same effects as in the case of the wire communication.
[0080] Other Embodiments
[0081] The present invention may be applied to systems comprised of a plurality of devices (e.g., a host computer, an interface device, a reader, a printer, etc.) and also to an apparatus consisting of one device (e.g., a copier, a facsimile device, etc.).
[0082] It is also needless to mention that the object of the present invention can also be accomplished by supplying a storage medium (or recording medium) storing the program code of software for realizing the functions of the aforementioned embodiments, to a system or apparatus and making a computer (or CPU or MPU) of the system or apparatus read and execute the program code stored in the storage medium. In this case, the program code itself read out of the storage medium realizes the functions of the foregoing embodiments, so that the storage medium storing the program code constitutes the present invention.
[0083] It is also needless to mention that, in addition to the configuration wherein the computer executes the program code thus read to implement the functions of the foregoing embodiments, the invention also embraces such a configuration that, based on instructions of the program code, an operating system (OS) operating on the computer executes part or the whole of the actual processing and the processing implements the functions of the foregoing embodiments.
[0084] Further, it is also a matter of course that the present invention also embraces such a configuration that the program code read out of the storage medium is written into a memory in a function extension card inserted into a computer or in a function extension unit connected to a computer, then a CPU in the function extension card or in the function extension unit executes part or the whole of the actual processing, based on the instructions of the program code, and the processing implements the functions of the foregoing embodiments.
[0085] When the present invention is applied to the above storage medium, the program code corresponding to the flowcharts described previously (as shown in FIG. 3 and/or FIG. 7) is stored in the storage medium.
[0086] According to the present invention, as described above, the switch instruction to switch the electrophotographic process condition is given when the engine control portion is not in execution of the electrophotographic process, whereby switching of the process condition is not effected for the switching process of the primary current value for extending the lifetime of the drum, which makes it feasible to achieve the effects of maintaining the uniformity of image quality in printing of identical images and drastically improving the performance of the printer.
[0087] The present invention was described above with some preferred embodiments thereof, but it is noted that the present invention is by no means intended to be limited to these embodiments and it is apparent that the present invention can involve various modifications and applications in the scope of claims.
|
Provided is an image processing apparatus that maintains uniformity of image quality in print of identical images and that improves the performance of a printer.
An image forming apparatus includes an image control portion for expanding predetermined information supplied from an external device, into print information, and a printer control portion for performing print control based on the print information, and is adapted to print the expanded information in a predetermined recording medium under the print control. The image forming apparatus is configured to have a process cartridge unit which transmits and receives signals for the print control to and from the printer control portion, which executes an electrophotographic process according to the signals for the print control, and which is detachably attachable to the main body of the image forming apparatus, a non-volatile memory unit which stores operation information including information concerning an operation quantity of the process cartridge unit and which is mounted in the process cartridge unit, a unit which performs read/write control of the operation information out of or into the non-volatile memory unit, according to the print control from the printer control portion, a switch timing determining unit which determines switch timing of a condition for the electrophotographic process, based on the operation information stored in the non-volatile memory unit and a state of the printer control portion, and a switching unit which switches the condition for the electrophotographic process at the switch timing.
| 6
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/311,139, filed on Mar. 5, 2010. The entire content of that application is incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
SEQUENCE LISTING, TABLE OR COMPUTER PROGRAM ON COMPACT DISC
[0003] Not applicable.
FIELD OF INVENTION
[0004] This invention relates generally to snow and ice control systems for motor vehicles. The invention more specifically relates to systems for mounting granular material spreading equipment, liquid storage tanks and liquid delivery equipment onto trucks.
BACKGROUND OF THE INVENTION
[0005] In areas throughout the world subject to snow and ice weather conditions, it is common for municipalities and institutions to own and employ vehicles for snow and ice removal and control (collectively referred to in this application as “snow/ice control”). As opposed to having a dedicated vehicle limitedly adapted for snow/ice control it is more common for those institutions with snow/ice control needs to own adaptable general purpose trucks with dump bodies (“dump trucks”) that can be used year-round. These dump trucks are primarily used to haul materials and perform other utilitarian tasks. During the winter months, snow plows and granular material spreading equipment are mounted to the trucks, thereby allowing the trucks to be used for snow/ice control purposes. In some cases, snow/ice control equipment is mounted onto a truck frame in place of the dump body or bed.
[0006] For purposes of this application, “granular material spreading equipment” is defined as equipment that may be connected to a truck and which is used to: a) convey material from a holding area on the truck (e.g, dump body) to a broadcasting device; or b) broadcast that material from the truck. Granular material spreading equipment may include equipment that can be mounted in or to the bed of a pick up or flat bed truck. A typical prior art material broadcasting device is the rotating disc spreader, which is capable of broadcasting a variety of snow/ice control substances. Known substances include granular ice melting materials, pre-wetted granular materials (e.g., salt) and traction-aiding granular materials such as sand. The substances are broadcasted over road surfaces from behind a moving truck to improve driver safety in winter conditions.
[0007] Granular material spreading equipment intended for mounting to the dump body of a general purpose truck can take many forms. For example, it is known to use an under-tailgate mounted cross conveyor attached to the back end of a dump body. The conveyor moves granular material to the broadcasting device, which in turn spreads the material over the road surface. Another piece of granular material spreading equipment that can be mounted to a dump body for purposes of snow/ice control is the vee-box spreader body. With this device, a “V”-shaped storage body is mounted either inside a dump body or directly onto the truck chassis frame. The vee-box body includes a storage cavity for snow/ice control substances and a conveying system. The conveying system is usually in the bottom of the vee-box body. As suggested by its name, the body of the vee-box usually has sloping side walls in the general shape of a “V.” These side walls aid in the delivery of the snow/ice control substances to the broadcasting system.
[0008] An example of prior art granular material spreading equipment used to convert a general purpose truck to a snow/ice control truck is a combination dump-spreader body. This device includes a body mountable to the described multipurpose truck. The device often includes a hoist system that allows the body to be used as both a snow/ice control substance conveying system and a general purpose dump body. The device also often includes a conveying system mounted into the body.
[0009] There are other versions of granular material spreading equipment but most are some combination of the above-identified styles of equipment. In recent years, the use of liquid materials for snow and ice control (melting) has increased dramatically. Multiple studies have shown that pretreatment (applying snow/ice control materials before a storm arrives) of road surfaces can be a useful tool in improving driving conditions. “Pre-wetting” the granular snow/ice control substances enhances ice melting or improves adhesion of the substances to the road surface. The deployment of liquid storage tanks in conjunction with liquid delivery equipment allows existing snow/ice control trucks to dispense salt slurry or liquefied snow/ice control substances. Thus, in addition, to having granular material storage and conveying mechanisms, the prior art snow/ice control truck may also have, liquid storage tanks and liquid delivery equipment mounted to the truck or outside of the component body cavity. As used herein the term “liquid delivery equipment” includes equipment (including but not limited to tubing, valves, pumps, control systems, filters, sprayers and nozzles) used to deliver liquid from a liquid storage tank to either the roadway surface or to materials intended for application on the roadway surface.
[0010] Materials such as salt brine, calcium chloride, magnesium chloride and other substances are being used at increasing rates in all areas of the country. Liquid delivery of salt via salt brine and other liquids has been a common approach for many years. In recent years it has become common to increase the liquid content over the historical pre-wetted granular levels to create a salt “slurry.” Such a slurry material is sticky and reportedly provides for faster snow and ice melting as well as longer lasting performance due to the high salt content.
[0011] With the advantages of using pre-wetted substances and slurries, the demand for mounting granular material spreading equipment together with storage tanks and liquid delivery equipment has increased. In an attempt to satisfy the need for pre-wetted substances and slurries, special tank-receiving structures have been developed. These tank-receiving structures allow basic dump bodies to carry liquid storage tanks. However, when such tanks are added to the combination dump bodies that have integral conveying systems, the tanks have limited capability for liquid storage.
[0012] The prior art liquid holding tank can have many shapes. A common tank shape is the “wedge” shape, which provides a profile to aid in the easy discharge of granular substances from the body cavity. Typically, the tank is attached to the inside of at least one of the sidewalls of the dump body (or combination body). This results in an open center section of the dump body, permitting the storage of the granular snow/ice control substances. Another method of deploying a′ liquid holding tank involves mounting a rectangular tank to the front of the dump body, allowing for the storage of granular snow/ice control substances to the rear of the tank in the dump body cavity. Another common practice is to mount tanks to the outsides of the combination bodies in shapes especially designed to match the shape of the combination dump/spreader body or specially shaped dump bodies.
[0013] Mounting a general purpose truck with granular material spreading equipment, liquid storage tanks and liquid delivery equipment presents several issues. First, is the time needed to convert a general purpose truck to a snow/ice control truck. When a general duty truck is converted to snow/ice control mode, the conversion time can be as much as 200 man-hours. Secondly, the conversion inhibits the use of the vehicle for non-snow/ice control purposes. Hence, once a vehicle is converted for winter use, it is out of service for all other uses. This fact, in turn, creates pressure to quickly restore the truck to its original general purpose state. The second phase conversion from “snow/ice control truck” to “general purpose truck” also takes time. In many areas of the country, the winters can be harsh for only a few days and during the remainder of the year the general purpose truck must be used for other applications. With the time and manpower requirements of converting and restoring the general purpose truck, along with the fact the converted truck is no longer generally useful, municipalities end up having more trucks in their fleet than needed, resulting in many trucks sitting idle for extended periods. Alternatively, the manpower and budgetary issues attendant to converting and restoring general purposes trucks to snow/ice control trucks may cause a municipality to reduce the number of trucks in their fleet. Fewer resources can, in turn, mean longer times needed to clear ice and snow from roads. Additionally, if a truck goes out of service due to break-down, a greater share of the fleet is unavailable for supporting the general public needs.
[0014] In addition to the institutional issues, there are technical issues involved with the conversion of a general purpose truck to a snow/ice control truck and its subsequent restoration. The liquid delivery equipment that can be added to snow/ice control trucks has many constituent elements. These elements are usually individually mounted to the truck chassis and there frequently is not enough room to mount the equipment in locations where the items are both easy to access and service. Also, some of the elements need to be mounted at lower elevations on the truck in order to properly function. For example, the liquid pump must be mounted below the liquid tanks in order to provide positive head pressure to suction pumps. Hence, current methods for mounting liquid delivery equipment entail significant compromises as to where and whether liquid delivery equipment will be mounted to a truck.
[0015] Another drawback with prior art mounting methods for liquid storage tanks or liquid delivery equipment arises by virtue of the need for attachment points in the dump body beds in order to mount the liquid tanks. In this respect, with prior art mounting methods, the dump beds must be provided with attachment points in order to constrain the tanks at the desired locations. Frequently, these attachment points are in the form of protrusions welded to the sides and floors of dump bodies. These protrusions inhibit the gravity fed clean-out of the dump bodies during normal use and act like catch points to retain material being hauled. In other cases, holes are cut into the dump body surfaces to effect the attachment of the liquid tanks. These holes can reduce the component member strength and also act like catch points for many materials. Both the weld-on and hole-cutting attachment methods create areas where the original finish surface of the truck body is destroyed. Once the finish surface is destroyed, corrosion can set in and reduce the usable life of the truck body.
[0016] Another problem with prior art snow/ice equipment conversion methods arises from the fact that during the non-winter months, the many elements that make up the granular material spreading equipment, liquid storage tanks and liquid delivery equipment are removed and stored for the season. Many of these elements will become misplaced, stolen or damaged. These incidents will often not be known until the following winter season when a truck needs to be converted to snow/ice control purposes. The lack of on-hand parts results in delays in effecting the truck's conversion. There are frames that provide for the unitary mounting and storage of granular material spreading equipment (such as for the vee-box spreader body). There are also frames that provide for the mounting and storage of liquid storage tanks. However, there are no known frames that have the capability to mount and store granular material spreading equipment, liquid storage tanks and liquid delivery equipment.
[0017] There is thus a need in the art for a device that: reduces the time and effort for installing and removing granular material spreading equipment, liquid storage tanks and liquid delivery equipment on general purpose dump trucks, flat beds and pick-up trucks; reduces the mounting damage and obstruction issues resulting from mounting liquid tanks for snow/ice control systems; and helps prevent the loss of equipment components due to storage.
SUMMARY OF THE INVENTION
[0018] The present invention satisfies the needs in the art and provides owners of general purpose dump, flat bed and pick-up trucks with a frame that both stores granular material spreading equipment, liquid storage tanks and liquid delivery equipment and allows the rapid installation of that equipment on trucks. The preferred embodiment frame is adapted to hold granular material spreading equipment, liquid storage tanks and liquid delivery equipment allowing for liquid spraying and slurry applications. In one particular respect, the present invention frame comprises a frame that holds granular material spreading equipment, liquid storage tanks and liquid delivery equipment in a deployed (ready-to-use) position such that the frame with adjoined equipment may be unitarily installed in a general purpose truck.
[0019] A preferred embodiment present invention frame includes structure for mounting a material broadcasting spreader, such as is used to broadcast granular, pre-wetted granular and slurry materials. In accordance with the invention, when such a broadcasting mechanism is attached to the frame, it is simultaneously removed when the frame is “un-installed” from the truck body.
[0020] One embodiment of the present invention frame further includes structure for mounting spreader and conveyor equipment utilizing under-tailgate conveyor spreader mechanisms. In accordance, with the present invention, when such spreader conveyor equipment is attached to the frame, it is simultaneously removed when the frame unit is “un-installed” from the truck body.
[0021] The preferred embodiment present invention frame further includes structure for mounting liquid delivery equipment in an easily accessible and serviceable location. In this regard, without limitation, the frame can allow for the mounting of single-lane liquid dispensers, multi-lane liquid dispensers, spray booms, pre-wetted control systems and plumbing control equipment such as liquid pumps, liquid control valves, filters and flow monitoring devices. The frame holds liquid storage tanks and may include metalwork designed to cap off the rear end of the truck body to aid in transitioning the body from “snow truck” to “work truck.”
[0022] The preferred embodiment present invention frame further includes deflectors necessary to retain the granular materials inside the truck body and aid in directing flow of granular materials to a conveyor or to a material-dispensing spreader.
[0023] The preferred embodiment present invention frame includes mechanisms for safely attaching a unitary structure comprising the frame and adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment to the dump body or truck frame. In the case of a truck with dump body, the attachment mechanisms will preferably utilize the dump body tailgate latch and a dump body tailgate connection as connection points.
[0024] The present invention frame also allows for the unitary removal and storage of the frame with adjoined granular material spreading, liquid storage tanks and liquid delivery equipment. For storage purposes, the preferred embodiment present invention frame includes an integral stand leg kit, which legs are preferably retractable. Preferably, the rear legs retract telescopically and the front legs retract by swinging (pivoting) up. This way, the legs can be positioned out of the way when the frame (along with adjoined equipment in deployed formation) is installed in a truck. However, by virtue of the integral stand leg kit, the frame's legs can be easily deployed when the frame and equipment are removed. In this respect, the legs are simply extended or dropped into a “standing” position when un-installing the unit from the truck body. In the preferred embodiment both pairs of legs are height adjustable. Once the legs are in the standing position, the unit is ready to be stored. Hence, by virtue of mounting the granular material spreading equipment, storage tank(s) and liquid delivery equipment on a frame with the integral legs, when the equipment is removed from a truck body after winter, all of the equipment can be safely and unitarily stored above-ground.
[0025] The present invention is further directed to a snow/ice control apparatus that comprises the described frame bearing granular material spreading equipment, liquid storage tank(s) and liquid delivery equipment in a ready-to-use position such that the frame with the borne equipment may be unitarily installed on a dump, flat-bed or pick-up truck. A preferred embodiment apparatus includes integral legs. The integral legs are connected to the frame such that when the frame is removed from the truck, the frame and adjoined granular material spreading equipment, liquid storage tank or tanks and liquid delivery equipment may be unitarily stored with the borne equipment off the ground. It is preferred that the legs of the apparatus be retractable. Desirable leg arrangements include an apparatus wherein the legs comprise a pair of front legs and a pair of rear legs, with the rear legs retracting telescopically and the front legs retracting by pivoting. In the preferred embodiment, the legs are height adjustable. Those frames lacking integral legs, can include lifting structures such as rings to allow for securing of hooks, ropes or chains to aid in installation.
[0026] In a further refinement to the preferred embodiment, the snow/ice control apparatus includes one or more pieces of liquid delivery equipment selected from the following: a single-lane liquid dispenser, a multi-lane liquid dispenser, a spray boom and a liquid delivery control system. The liquid delivery equipment may also include one or more pieces of equipment selected from the following: a liquid pump, a liquid control valve, a filter and a flow monitoring device.
[0027] The snow/ice control apparatus may comprise metalwork that caps off the rear end of the truck. It may also comprise deflectors adapted to retain granular materials inside the truck body or direct flow of granular materials to a conveyor or material spreader.
[0028] The present invention is further directed to an apparatus comprising a frame with one more adjoined liquid storage tanks. The frame is adapted to receive granular material spreading equipment and liquid delivery equipment in a ready-to-use position such that the frame with the borne equipment in deployed position may be unitarily installed on a dump, flat-bed or pick-up truck.
[0029] By providing for unitary mounting and storage of granular material spreading, liquid storage tanks and liquid delivery equipment, the present invention frame and snow/ice control apparatus increase the time available to use the granular material spreading and liquid delivery equipment, while reducing the time and costs associated with equipment change-out as well as reducing the number of vehicles needed in the fleet.
[0030] Further features and advantages of the present invention frame and snow/ice control apparatus include reduced transformation time to restore a snow/ice control truck to a general purpose truck from days to minutes, improved vehicle utilization and reduced manpower needs for the changeover. Further, the granular material spreading, liquid storage tank(s) and liquid delivery equipment can be easily inspected and serviced while mounted on the frame. In addition, the frame and snow/ice control apparatus allow for the storage of the granular material spreading equipment, one or more liquid storage tanks and liquid delivery equipment on a single assembly, in an area no larger than that required for the liquid storage tank or tanks.
[0031] The present invention frame and snow/ice control apparatus also eliminate the need to alter a dump body's sides and floor via welding and cutting operations that are required for prior art systems. The frame can come in a variety of configurations to allow for the mounting of the several types of granular material spreading equipment including conveying dump bodies, standard dump bodies with under-tailgate conveying systems and vee-box style systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a perspective view of a preferred embodiment of the present invention frame having integral legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment for use in a combination truck body with an integral conveyor system located in the center of the truck body floor. Collectively the depicted frame with adjoined granular material spreading, liquid storage tanks and liquid delivery equipment constitute an embodiment of a present invention snow/ice control apparatus.
[0033] FIG. 2 is a side elevation view of a preferred embodiment of the present invention frame having integral legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment for use in a combination truck body with an integral conveyor system located in the center of the truck body floor. Collectively the depicted frame with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment constitute an embodiment of a present invention snow/ice control apparatus.
[0034] FIG. 3 is an overhead plan view of a preferred embodiment of the present invention frame having integral legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment for use in a combination truck body with an integral conveyor system located in the center of the truck body floor. Collectively the depicted frame with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment constitute an embodiment of a present invention snow/ice control apparatus.
[0035] FIG. 4 is a rear elevation view of a preferred embodiment of the present invention frame having integral legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment for use in a combination truck body with an integral conveyor system located in the center of the truck body floor. Collectively the depicted frame with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment constitute an embodiment of a present invention snow/ice control apparatus.
[0036] FIG. 5 is a perspective view of the frame weldment for a preferred embodiment of the present invention frame with integral legs.
[0037] FIG. 6 is a side elevation view of the frame weldment for a preferred embodiment of the present invention frame with integral legs.
[0038] FIG. 7 is an overhead plan view of the frame weldment for a preferred embodiment of the present invention frame with integral legs.
[0039] FIG. 8 is a rear elevation view of the frame weldment for a preferred embodiment of the present invention frame with integral legs.
[0040] FIG. 9 is a perspective view of a preferred embodiment frame with integral legs.
[0041] FIG. 10 is a side elevation view of a preferred embodiment frame with integral legs.
[0042] FIG. 11 is an overhead plan view of a preferred embodiment frame with integral legs.
[0043] FIG. 12 is a rear elevation view of a preferred embodiment frame with integral legs.
[0044] FIG. 13 is an enlarged perspective view of a preferred embodiment frame with integral legs, adjoined granular material spreading equipment, adjoined liquid delivery equipment, but no liquid storage tanks.
[0045] FIG. 14 is a perspective view of an alternative embodiment of the present invention frame having integral legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment for use in a dump truck body with an integral under-tailgate conveyor system located at the rear of the truck body floor. Collectively the depicted frame with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment constitute an embodiment of a present invention snow/ice control apparatus.
[0046] FIG. 15 is a side elevation view of an alternative embodiment of the present invention frame having integral legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment for use in a dump truck body with an integral under-tailgate conveyor system located at the rear of the truck body floor. Collectively the depicted frame with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment constitute an embodiment of a present invention snow/ice control apparatus.
[0047] FIG. 16 is an overhead plan view of an alternative embodiment of the present invention frame having integral legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment for use in a dump truck body with an integral under-tailgate conveyor system located at the rear of the truck body floor. Collectively the depicted frame with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment constitute an embodiment of a present invention snow/ice control apparatus.
[0048] FIG. 17 is a rear elevation view of an alternative embodiment of the present invention frame having integral legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment for use in a dump truck body with an integral under-tailgate conveyor system located at the rear of the truck body floor. Collectively the depicted frame with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment constitute an embodiment of a present invention snow/ice control apparatus.
[0049] FIG. 18 is a perspective view of a legless embodiment of the present invention frame with lifting mechanisms and adjoined tanks. The frame has structure adapted to receive, in ready-to use position, granular material spreading equipment and equipment used to deliver liquid from the tanks to the roadway or to the materials intended for spreading.
[0050] FIG. 19 is a side elevation view of a legless embodiment of the present invention frame with lifting mechanisms and adjoined tanks. The frame has structure adapted to receive, in ready-to use position, granular material spreading equipment and equipment used to deliver liquid from the tanks to the roadway or to the materials intended for spreading.
[0051] FIG. 20 is an overhead plan view of a legless embodiment of the present invention frame with lifting mechanisms and adjoined tanks. The frame has structure adapted to receive, in ready-to use position, granular material spreading equipment and equipment used to deliver liquid from the tanks to the roadway or to the materials intended for spreading.
[0052] FIG. 21 is a perspective view of a legless embodiment of the present invention frame with lifting mechanisms and adjoined tanks. The frame has structure adapted to receive, in ready-to use position, granular material spreading equipment and equipment used to deliver liquid from the tanks to the roadway or to the materials intended for spreading.
[0053] FIG. 22 is a side elevation view of a legless embodiment of the present invention frame with lifting mechanisms and adjoined tanks. The frame has structure adapted to receive, in ready-to use position, granular material spreading equipment and equipment used to deliver liquid from the tanks to the roadway or to the materials intended for spreading.
[0054] FIG. 23 is an overhead plan view of a legless embodiment of the present invention frame with lifting mechanisms and adjoined tanks. The frame has structure adapted to receive, in ready-to use position, granular material spreading equipment and equipment used to deliver liquid from the tanks to the roadway or to the materials intended for spreading.
[0055] FIG. 24 is a rear elevation view of a legless embodiment of the present invention frame with lifting mechanisms and adjoined tanks. The frame has structure adapted to receive, in ready-to use position, granular material spreading equipment and equipment used to deliver liquid from the tanks to the roadway or to the materials intended for spreading.
DETAILED DESCRIPTION
[0056] Embodiments of the present invention frame 10 with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment are shown in FIGS. 1-4 and in FIGS. 14-17 . Collectively the depicted frame with adjoined granular material spreading, liquid storage tanks and liquid delivery equipment constitute embodiments of a present invention snow/ice control apparatus 5 . A preferred embodiment frame 10 sans adjoined granular material spreading and liquid delivery equipment is shown in FIGS. 9-12 . FIG. 13 depicts frame 10 with adjoined spreading equipment and liquid delivery equipment, but without liquid storage tanks. In practical use, foot 14 of lower leg section 11 of legs 12 , 13 will normally rest upon a surface (such as ground) considered horizontal in reference to the user. Thus, the directional terms “vertical” and “horizontal” and the like are used to describe the frame 10 and its components with respect to the orientation illustrated in the figures and are employed merely for the purposes of clarity and illustration. For example, in the orientation shown in FIG. 1 , liquid dispensing system (spray boom) 50 is lower than (spaced “vertically”) from storage tanks 51 . The directional terms “inner,” “outer” and the like are used herein with respect to the described container to refer to directions along the directional component toward and away from the geometric center of the frame.
[0057] As shown in FIGS. 5-8 , frame 10 comprises frame weldment 15 . Frame weldment 15 provides basic skeletal support for frame 10 . Frame weldment 15 includes main support rails 16 , which in the preferred embodiment are parallel. Main support rails 16 are connected at their front ends via front weldment strut 17 and at their rear ends via rear weldment strut 18 . Side brackets 19 extend outwardly from main support rails 16 and connect to tank support rails 20 . Panel systems 21 are attached to the front ends of main support rails 16 and include structure to which main support rails 16 and tank support rails 20 connect. In the preferred embodiment, panel system 21 includes one or more formed panels or sheets of metal of appropriate thickness to which rails 16 , 20 can be attached via mechanical, welding or other known means.
[0058] Frame weldment 15 further includes main rear support bracket 25 . Rear support bracket 25 comprises rear weldment strut 18 along with other structure adapted to hold preferred embodiment legs 12 of frame 10 and supporting structure for granular material spreading, one or more liquid storage tanks and liquid delivery equipment. Rear support bracket 25 may also be adapted to hold granular material spreading and liquid delivery equipment. In the depicted weldment embodiment shown in FIGS. 5-8 , rear support bracket includes top bracket rail 26 and bottom bracket rail 27 . The preferred embodiment frame 10 includes legs, 12 and 13 . Upper leg section 28 of leg 12 connects top bracket rail 26 and bottom bracket rail 27 such that rear support bracket 25 is generally rectangular. Upper leg section 28 receives lower leg section 11 , such that lower leg section 11 is slidably positionable therein for retraction and height adjustment purposes. In the preferred embodiment, upper leg section 28 comprises a length of metal box section (rectangular tubing) having graduated apertures. Lower leg section 11 is of reduced section gauge and is slidably received by tubing 28 and fixed into height position by a pin. In alternative designs, spray boom mounting bracket 31 may connect to leg section 28 . Rear support bracket 25 includes panels 29 , 30 for added strength and rigidity and to provide attachment points for other structure.
[0059] FIGS. 9-12 depict an embodiment frame 10 comprising weldment 15 , legs 12 , 13 and additional supporting structure adapted to securely receive granular material spreading equipment, one or more liquid storage tanks and liquid delivery equipment. As shown in these drawings, preferred embodiment frame 10 comprises material retention housing 35 and one or more longitudinal tank support panels 36 above each main support rail. Material retention housing 35 is positioned above rear weldment strut 18 . Further, material retention housing 35 connects to one or more of rear weldment strut 18 and rear support bracket 25 . Longitudinal tank support panels 36 extend above each of main support rail 16 and extend between and connect to panel system 21 and material retention housing 35 . Frame 10 includes one or more transverse supports 37 for added support and rigidity.
[0060] The preferred embodiment frame 10 further includes height adjustable front legs 13 which may be of similar box section telescoping construct as rear legs 12 . In the depicted embodiment, front legs 13 are pivotably retractable so as to permit frame 10 to be securely received by a dump body. In the shown preferred embodiment, legs 13 retract by pivoting inward toward the center of frame 10 . Frame 10 further includes frame securing system 40 at the ends of rear weldment strut 18 to aid in the securing of the frame to a dump body.
[0061] FIGS. 1-4 depict a preferred embodiment frame having legs 12 , 13 and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment (collectively a snow/ice control apparatus 5 ) for use in a combination truck body with an integral conveyor system located in the center of the truck body floor. As shown in these drawings, main support rail 16 , tank support rail 20 , longitudinal tank support panels 36 and panel system 21 all serve to connect to and support liquid storage tank 51 and provide structure for attachment mechanisms used to secure tank 51 to the frame. Likewise, rear support bracket 25 serves to connect to and support liquid delivery equipment and provide structure for attachment mechanisms used to secure such equipment to the frame. Example liquid delivery equipment shown in FIGS. 1-4 includes liquid delivery dispenser system 52 , liquid dispensing system (spray boom) 50 and granular material broadcaster 53 .
[0062] FIGS. 14-17 depict a preferred embodiment frame having legs and with adjoined granular material spreading equipment, liquid storage tanks and liquid delivery equipment (collectively a snow/ice control apparatus 5 ) for use in a dump truck body with an under-tailgate conveyor system located at the rear of the truck body floor. As shown in these drawings, main support rail 16 , tank support rail 20 , longitudinal tank support panels 36 and panel system 21 all serve to connect to and support liquid storage tank 51 and provide structure for attachment mechanisms used to secure tank 51 to the frame. Likewise, rear support bracket 25 serves to connect to and support liquid delivery equipment and provide structure for attachment mechanisms used to secure such equipment to the frame. Example equipment shown in FIGS. 14-17 includes liquid delivery dispenser system 52 , liquid dispensing system (spray boom) 50 and granular material broadcaster 53 .
[0063] FIGS. 18-24 show an embodiment of frame 10 with adjoined tanks, but with granular material spreading equipment and liquid delivery equipment removed. The frames of FIGS. 18-24 include lifting mechanisms 59 . This frame mounts inside a standard dump body equipped with a standard (non-integral) under-tailgate conveyor system located at the rear of the truck body floor. The normal tailgate of the dump body is removed and this embodiment invention is installed in place of the standard tailgate. The tanks and frame are pre-assembled and can be installed and removed as a single unit. This embodiment of the invention does not include any legs on the frame and would be stored on level ground when not in use. The frame of FIGS. 18-20 is intended for use in a dump truck body with a replacement dump body tailgate 35 . A standard under-tailgate conveyor system located at the rear of the truck body floor is usually employed with this type of snow truck. As shown in these drawings, tank support panels 36 connect to and support liquid storage tank 51 . Rear support bracket 25 (of different geometric construct than the version of the bracket shown in FIG. 8 ) connects to and supports the tailgate panel and provides structure for attachment mechanisms for securing equipment. Lifting brackets 59 are used to install and remove the entire assembly.
[0064] FIGS. 21-24 depict an alternative embodiment of the present invention frame 10 with adjoined tanks, but with granular material spreading equipment and liquid delivery equipment removed. This embodiment is intended for use in a dump truck body. This version frame mounts inside a standard dump body equipped with a standard (non-integral) under-tailgate conveyor system located at the rear of the truck body floor. The tanks and frame are pre-assembled and can be installed and removed as a single unit. This embodiment of the invention frame does not include any legs and would be stored on level ground when not in use. As shown in these drawings, longitudinal tank support panels 36 connect to and support liquid storage tank 51 . Panels 36 also provide structure for mechanisms that can be used to secure tank 51 to the frame and the frame to the dump body. Lifting brackets 59 are used to install and remove the entire assembly.
[0065] As used herein the words “connect,” “connected” or “connection” include direct or indirect connection by any known means including but not limited to welding, adhesive, mechanical fastening or otherwise. Having described the invention in detail, those skilled in the art will appreciate that modifications may be made of the invention without departing from its spirit. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described.
|
A frame for mounting granular material spreading equipment, liquid storage tanks and liquid delivery equipment in a dump body or to a truck body is adapted to hold such equipment and allow for unitary removal of the frame with adjoined equipment from the truck body. The frame provides structure for mounting of granular material spreading equipment, liquid storage tanks and liquid delivery equipment, including liquid dispensing and metering components, granular dispensing and metering components, hydraulic equipment and electrical components. The frame may include integral legs, which in the preferred embodiment are self storing. The frame with adjoined equipment in a deployed position may be stored as a unit. A frame bearing granular material spreading, liquid storage tanks and liquid delivery equipment constitutes a snow/ice control apparatus that may be unitarily deployed on trucks and removed for storage purposes.
| 4
|
[0001] The present application claims the benefit of Korean Patent Application No. P2003-99336 filed in Korea on Dec. 29, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a display device, and, more particularly, to an in-plane-switching mode liquid crystal display device using a ferroelectric liquid crystal material and a method of fabricating the same.
[0004] 2. Discussion of the Related Art
[0005] In general, a liquid crystal display (LCD) device controls an electric field applied to a liquid crystal cell. The controlling of the electric field modulates light incident to the liquid crystal cell, thereby displaying a picture. The liquid crystal display devices may employ a vertical electric field method and a horizontal electric field method to drive the liquid crystal cell.
[0006] In the vertical electric field method, a pixel electrode and a common electrode are formed on an upper substrate and a lower substrate, respectively. Thus, the pixel and common electrodes are vertically opposite to each other, and an electric field is generated vertically across a liquid crystal cell by a voltage difference applied between the pixel and common electrodes. For example, a twisted nematic (TN) mode LCD device generally uses the vertical electric field method. The twisted nematic mode LCD device has a relatively wide aperture ratio. However, since the liquid crystal molecules have different refractive indices, a display picture varies for an observer depending on a viewing angle. Thus, there is a disadvantage that the realization of wide viewing angle is difficult.
[0007] Further, in-plane-switching (IPS) mode LCD devices generally use the horizontal electric field method. In the horizontal electric field method, an electric field is generated between the electrodes formed on the same substrate to drive the liquid crystal cell.
[0008] FIG. 1 is a schematic cross-sectional view of an in-plane-switching mode liquid crystal display device according to the related art. In FIG. 1 , a liquid crystal display device includes an upper glass substrate 12 and a lower glass substrate 18 with a liquid crystal layer having liquid crystal molecules 14 formed therebetween. A polarizer 11 and an alignment layer 13 are respectively formed on an upper surface and a lower surface of the upper substrate 12 . In addition, an alignment film 17 and a polarizer 19 are respectively formed on an upper surface and a lower surface of the lower substrate 18 . In particular, the axes of the polarizers 11 and 19 cross each other.
[0009] Further, a common electrode 15 and a pixel electrode 16 are formed on the alignment film 17 on the lower substrate 18 . In particular, an electric field 20 is generated along a horizontal direction by a voltage difference applied between the common electrode 15 and the pixel electrode 16 . As a result, the liquid crystal molecules 14 are rotated by the electric field 20 , thereby modulating a polarization component of light transmitting through the liquid crystal layer. For instance, if the polarization component of light transmitting through the liquid crystal layer is changed by 90 degrees, then light passes through the upper polarizer 11 . On the other hand, if the polarization component of light does not change, then light cannot pass thorough the upper polarizer 11 .
[0010] The IPS mode liquid crystal display device according to the related art has a wide viewing angle since a refractive index change of the liquid crystal molecules 14 is not large. However, the electric field applied to the liquid crystal molecules 14 is done with the opaque common and pixel electrodes 15 and 16 on the lower substrate 18 . In particular, because a light switching is not made on the common and pixel electrodes 15 and 16 , the electric field applied to the liquid crystal molecules 14 is bent. Thus, the IPS mode liquid crystal display device according to the related art has a disadvantage of having a low aperture ratio.
SUMMARY OF THE INVENTION
[0011] Accordingly, the present invention is directed to an in-plane-switching mode liquid crystal display device and a method of fabricating the same that substantially obviate one or more of the problems due to limitations and disadvantages of the related art.
[0012] An object of the present invention is to provide a liquid crystal display device of in-plane-switching mode, where it is possible to realize a wide viewing angle without a deterioration of the aperture ratio, and a fabricating method thereof.
[0013] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0014] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, an in-plane-switching mode liquid crystal display device includes a first ferroelectric liquid crystal layer on a first substrate, a second ferroelectric liquid crystal layer on a second substrate, the first and second substrates being bonded to each other with a space therebetween, and a nematic liquid crystal layer at the space between the first and second ferroelectric liquid crystal layers, the first and second ferroelectric liquid crystal layers including a photo-polymerizational monomer.
[0015] In another aspect, a method of fabricating an in-plane-switching mode liquid crystal display device includes forming a first ferroelectric liquid crystal layer on a first substrate, forming a second ferroelectric liquid crystal layer on a second substrate, the first and second ferroelectric liquid crystal layers including a photo-polymerizational monomer, attaching the first and second substrates to each other with a space therebetween, and forming a nematic liquid crystal layer at the space between the first and second ferroelectric liquid crystal layers.
[0016] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] 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 embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
[0018] FIG. 1 is a schematic cross-sectional view of an in-plane switching mode liquid crystal display device according to the related art;
[0019] FIGS. 2A to 2 D are schematic cross-sectional views illustrating a method of fabricating a liquid crystal display according to an embodiment of the present invention; and
[0020] FIG. 3 is a schematic perspective view illustrating the movement of a ferroelectric liquid crystal and a nematic liquid crystal in the liquid crystal display according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings. FIGS. 2A to 2 D are schematic cross-sectional views illustrating a method of fabricating a liquid crystal display according to an embodiment of the present invention. In FIG. 2A , an upper electrode 22 and an upper alignment film 23 are formed on an upper substrate 21 . In addition, a lower electrode 32 and a lower alignment film 33 are formed on a lower substrate 31 . The upper and lower substrates 21 and 31 may be formed of a transparent glass material. The upper and lower electrodes 22 and 32 may be formed of a transparent conductive material, such as indium-tin-oxide (ITO).
[0022] Further, the upper and lower alignment films 23 and 33 may be formed of an organic material, such as polyimide. The upper and lower alignment films 23 and 33 also may be rubbed to set a pre-tilt angle of ferroelectric liquid crystal molecules 24 and 34 (shown in FIG. 2B ) that are subsequently formed therebetween. The polarizer (not shown) crossing a light transmission axis is formed onto the light incident plane of the lower substrate 31 and the light out-coming plane of the upper substrate 21 .
[0023] As shown in FIG. 2B , a slight amount of photo-polymerizational monomers 25 and 35 are added into ferroelectric liquid crystal molecules 24 and 34 during a chiral smectic C* phase of forming the ferroelectric liquid crystal molecules 24 and 34 . For instance, the ferroelectric liquid crystal molecules 24 and 34 and the photo-polymerizational monomers 25 and 35 may have a composition ratio as shown in Table 1 below.
TABLE 1 Ferroelectric liquid crystal 95 wt %˜99 wt % Photo-polymerizational monomer 1 wt %˜5 wt %
[0024] In addition, the ferroelectric liquid crystal molecules 24 and 34 may include any known ferroelectric liquid crystal material, and the photo-polymerizational monomers 25 and 35 may include any known nematic photo-polymerizational monomer. In particular, the photo-polymerizational monomers 25 and 35 may be uniformly mixed with the ferroelectric liquid crystal molecules 24 and 34 , respectively, and then the mixture may be evenly spread on the alignment films 23 and 33 , respectively. The ferroelectric liquid crystal molecules 24 and 34 may be formed in a nematic system.
[0025] Further, the mixture of the ferroelectric liquid crystal molecules 24 and 34 and the photo-polymerizational monomers 25 and 35 may be exposed to a medium of which the electrical negativity is high. Alternatively, an electric field or a magnetic field may be applied to the mixture of the ferroelectric liquid crystal molecules 24 and 34 and the photo-polymerizational monomers 25 and 35 . Thus, the ferroelectric liquid crystal molecules 24 and 34 may be aligned along the spontaneous polarization direction, shown as the arrows in FIG. 2B . For instance, the mixture may be exposed to an atmosphere of water (H 2 O) or oxygen (O 2 ) as a medium with a high polarity.
[0026] When exposing to the medium with a high polarity, the ferroelectric liquid crystal molecules 24 and 34 change from an isotropic phase to a smectic A phase, a chiral smectic C* phase and a chiral nematic N* phase due to the transition temperature. In addition, the spontaneous polarization of the ferroelectric liquid crystal molecules 24 and 34 faces toward the medium. On the contrary, when exposing to a medium with a low polarity, such as nitrogen (N 2 ) or air, the spontaneous polarization of the ferroelectric liquid crystal molecules 24 and 34 faces toward the opposite of the medium. Thus, a temperature treatment is carried out to make phase transition from the smectic A phase or the chiral nematic N* phase to the chiral smectic C* phase.
[0027] Further, when applying an electric field or a magnetic field to the ferroelectric liquid crystal molecules 24 and 34 under the transition temperature, the ferroelectric liquid crystal molecules 24 and 34 change from the isotropic phase to the smectic A phase, the chiral smectic C* phase and the chiral nematic N* phase. The spontaneous polarization of the ferroelectric liquid crystal molecules 24 and 34 is aligned in parallel to the electric field or the magnetic field.
[0028] As a result, by exposing the mixture to the medium with an electrical polarity or by applying an electric field or a magnetic field to the mixture, the ferroelectric liquid crystal molecules 24 formed on the upper substrate 21 may have the spontaneous polarization direction facing the opposite direction of the upper substrate 21 and the ferroelectric liquid crystal molecules 34 formed on the lower substrate 31 may have the spontaneous polarization direction facing toward the lower substrate 31 .
[0029] As shown in FIG. 2C , a photo-polymerization of the photo-polymerizational monomers 25 and 35 may be induced by illuminating ultraviolet ray (not shown) on the mixture. In particular, the photo-polymerizational monomers 25 and 35 may have a bridge bond generated by the photo-polymerization to form a polymer network. As a result, the ferroelectric liquid crystal molecules 24 and 34 have the spontaneous polarization direction sustained uniformly and their initial alignments stabilized.
[0030] In particular, a polymer stabilized FLC(PSFLC) alignment film may be formed on the substrates 21 and 31 , thereby enabling the alignment state to be stabilized. Further, since a small amount of the photo-polymerizational monomers 25 and 35 is added, the extent of the bridge bond of the ferroelectric liquid crystal molecules 24 and 34 allows the ferroelectric liquid crystal molecules 24 and 34 to be rotated.
[0031] As shown in FIG. 2D , the upper and lower substrates 21 and 31 are bonded facing each other with a predetermined cell gap therebetween by a sealant (not shown) at a periphery of the substrates 21 and 31 . Further, a nematic liquid crystal material 30 is formed at the cell gap between the upper and lower substrates 21 and 31 . In particular, the ferroelectric liquid crystal layers containing the ferroelectric liquid crystal molecules 24 and 34 are not mixed with the nematic liquid crystal material 30 . Thus, a phase separation is formed at an interface between the nematic liquid crystal material 30 and the ferroelectric liquid crystal layers. The nematic liquid crystal material 30 may be of a positive type or a negative type liquid crystal material.
[0032] FIG. 3 is a schematic perspective view illustrating the movement of a ferroelectric liquid crystal and a nematic liquid crystal in the liquid crystal display according to an embodiment of the present invention. As shown in FIG. 3 , when a voltage difference is applied to the upper and lower electrodes 22 and 32 (shown in FIG. 2D ), a nematic liquid crystal molecule 30 is driven in plane, thereby modulating light transmitted therethrough.
[0033] In addition, a ferroelectric liquid crystal molecule 34 rotates along a virtual cone, is driven in plane, and induces the in-plane-drive of the nematic liquid crystal molecule 30 adjacent thereto. In particular, when an electric field is applied to the ferroelectric liquid crystal molecule 34 , the ferroelectric liquid crystal molecule 34 has a permanent polarization, i.e., spontaneous polarization. Thus, the interaction of the electric field and the spontaneous polarization like an interaction of magnets causes the ferroelectric liquid crystal molecule 34 to rapidly rotate.
[0034] As a result, the liquid crystal display device minimizes the deterioration of an aperture ratio by applying the electric field using the vertical electric field method, and realizes a wide viewing angle by the in-plane-driving of the nematic liquid crystal molecule 30 . Further, the ferroelectric liquid crystal molecule 34 causes the nematic liquid crystal molecule 30 to rotate rapidly. Thus, the response speed of the nematic liquid crystal molecule 30 is improved.
[0035] As described above, the liquid crystal display device of the in-plane switching mode and the fabricating method thereof according to an embodiment of the present invention forms a ferroelectric liquid crystal layer on an alignment film in each of the upper and lower substrates and forms a nematic liquid crystal layer between the ferroelectric liquid crystal layers. The liquid crystal display device applies an electric field to the ferroelectric liquid crystal layers and the nematic liquid crystal layer using the vertical electric field method. As a result, the liquid crystal display device of the in-plane switching mode and the fabricating method thereof according to an embodiment of the present invention drives the liquid crystal molecules of the nematic liquid crystal layer in plane by an induction of the ferroelectric liquid crystal layers. Thus, an aperture ratio is increased and a wide viewing angle is achieved.
[0036] Further, the liquid crystal display device of the in-plane switching mode and the fabricating method thereof according to an embodiment of the present invention include inducing a photo-polymerization in the ferroelectric liquid crystal layers. Thus, the ferroelectric liquid crystal layers have the spontaneous polarization direction sustained uniformly and their initial alignments stabilized.
[0037] It will be apparent to those skilled in the art that various modifications and variations can be made in the in-plane-switching mode liquid crystal display device and the method of fabricating the same of the present invention without departing from the sprit or scope of the invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
|
An in-plane-switching mode liquid crystal display device includes a first ferroelectric liquid crystal layer on a first substrate, a second ferroelectric liquid crystal layer on a second substrate, the first and second substrates being bonded to each other with a space therebetween, and a nematic liquid crystal layer at the space between the first and second ferroelectric liquid crystal layers, the first and second ferroelectric liquid crystal layers including a photo-polymerizational monomer.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Continuation of U.S. patent application Ser. No. 13/076,948, filed Mar. 31, 2012, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
A multiple output and effect grenade is provided, in which an exothermic delay column is utilized to initiate a series of primers via the application of heat to the strike faces thereof. In particular, a multiple output and effect grenade comprised of an exothermic delay column operable to initiate a series of primers disposed in primer cavities within the main body of the grenade, so as to produce a desired firing signature, as well as initiate effect charges disposed within the primer cavities.
2. Description of the Related Art
The prior art is replete with numerous examples of various explosive non-lethal devices such as hand grenades, stun grenades, and the like, which have been utilized to train law enforcement and military personnel over the years, and utilized to control personnel with non-lethal/less than lethal force. For example, in U.S. Pat. No. 3,194,161 discloses a practice grenade and which is characterized by at least two shell segments which are articulated on a cap and are held in an assembled fashion so as to form a shell by a safety pin. The shell segments are urged to an opened or spreaded condition by spring means which upon removal of the pin become operative to spread the shell segments.
The practice grenade carries an ignitable material and all parts with the exception of the cap adjusting spring and certain parts of the igniter can be made out of plastic. In U.S. Pat. No. 3,369,486, a training hand grenade is described and which has a body which is made out of a soft spongy material so as to be harmless to a person hit by the device, and further has a combustible cartridge to provide an indicating flash when the cartridge is detonated within the soft spongy pliable body material.
U.S. Pat. No. 3,492,945 relates to a practice hand grenade and more specifically to a practice grenade which produces an amount of noise, flash and smoke and which also projects droplets of marker dye in a predetermined pattern so as to permit scoring during training exercises. In this invention, this training device further has a character by which it may be reloaded with dye and pyrotechnic and propellant charges for repeated usage.
U.S. Pat. No. 4,932,328 relates to a reloadable stun grenade, and more specifically to a stun grenade that minimizes the possibility of accidental injury by directing the force of the explosion which is detonated within the grenade out through the ends of the grenade rather than through the sides.
U.S. Pat. No. 5,654,523 describes an invention invented by the present inventor, which relates to a stun grenade including a plurality of vents which are defined in the housing and wherein each of the vents is angularly offset from the longitudinal axes of the cavity for discharging explosive energy radially outwardly from the grenade. The stun grenade also includes a bore for receiving a replaceable explosive charge.
U.S. Pat. No. 6,065,404 relates to a training grenade for a multiple integrated laser engagement system (MILES).
U.S. Pat. No. 7,387,073 relates to an explosive training device, capable of producing sound and visibly discernable light, and reloaded and reused.
While these devices noted above, and others, have operated with various degrees of success, they are unable to provide/employ varying signatures and effects in a single device in a controllable manner. Further, such conventional devices require a firing mechanism to initiate each effect, which makes production thereof expensive, and the device reliable only to the extent of the reliability of the firing mechanism. Further, scalability of effects is limited, and shipping and storage thereof are difficult and hazardous due to the firing mechanisms.
Accordingly, it is an object of the present invention to provide a grenade requiring no firing mechanism for each individual effect, thereby increasing the reliability and decreasing the expense of manufacture. In addition, it is an object of the present invention to provide a grenade which allows scalability of effects through the placement, quantity and type of effects therein. In particular, it is object of the present invention to provide a multiple output and effect grenade operable to be configured to deploy a plurality of outputs and effects in a controllable manner.
SUMMARY OF THE INVENTION
In order to achieve the objects of the present invention as mentioned above, the present inventor earnestly endeavored to develop a multiple output and effect grenade operable to be configured to deploy a plurality of outputs and effects in a controllable manner. Accordingly, in a first embodiment of the present invention, a multiple output and effect grenade is provided, comprising:
(a) a main body having a first end, a second end opposite the first end, an outer circumference therebetween, and a main cavity disposed within the main body between the first end and the second end;
(b) an exothermic delay column disposed within the main cavity, said delay column having a first end, a second end opposite the first end, and a middle portion therebetween;
(c) a plurality of primer cavities disposed within the main body, extending from the outer circumference to the main cavity so as to define an internal orifice in communication with the main cavity, and an output orifice within the outer circumference; and
(d) at least one primer disposed within at least one of the primer cavities, a strike face of the primer being in communication with and/or adjacent to the delay column adjacent the internal orifice of the primer cavity,
wherein the exothermic delay column is operable to initiate the primers in a controlled manner via the application of heat thereto.
In a second embodiment of the present invention, the multiple output and effect grenade of the first embodiment above is provided, wherein the delay column is preferably comprised of one or more fuze cords. In an alternative preferred embodiment, the delay column is comprised of one or more combustible compositions operable to burn from about the first end to about the second end of the delay column.
In a third embodiment of the present invention, the multiple output and effect grenade of the first embodiment is provided, further comprising one or more effect agents selected from illuminant compositions, chemical irritant agents, report (sound) agents, smoke agents and/or marking agents, disposed within one or more of the primer cavities, wherein the delay column is operable to initiate the one or more effect agents via initiation of the one or more primers.
In a fourth embodiment of the present invention, the multiple output and effect grenade of the first embodiment above is provided, further comprising an ignition charge disposed within the main cavity, adjacent the first end of the delay column, said ignition charge operable to ensure ignition of the delay column at or adjacent the first end thereof.
In a fifth embodiment of the present invention, the multiple output and effect grenade of the first embodiment above is provided, further comprising a booster charge disposed within one or more of the primer cavities, adjacent the strike face of the primers, wherein the booster charge is operable to ensure ignition of the delay column adjacent the first end thereof.
In a sixth embodiment of the present invention, the multiple output and effect grenade of the first embodiment above is provided, further comprising a transfer cavity disposed between the main cavity and one or more of the primer cavities.
In a seventh embodiment of the present invention, the multiple output and effect grenade of the first embodiment above is provided, further comprising one or more covering materials disposed on the outer circumference of the main body, adjacent the output orifice of one or more of the primer cavities, the one or more covering materials operable to secure the primer cavities from the environment. In addition to the covering materials, or as an alternative therefor, a U-formed closure means may be provided within the primer cavities to secure the primer cavities from the environment.
Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
FIG. 1 is a cross sectional view of the multiple output and effect grenade of the present invention.
FIG. 2 is a horizontal cross sectional view of the multiple output and effect grenade of the present invention, illustrating the disposition of the primer and effects charge within the primer cavity, the covering material disposed thereover, and the U-formed closure disposed therein.
FIG. 3 is a perspective view of the multiple output and effect grenade of the present invention shown in FIGS. 1 and 2 .
FIG. 4 is a longitudinal cross sectional view of the multiple output and effect grenade of the present invention, illustrating the preferred embodiment wherein the delay column is a fuze cord, and wherein an booster charge is disposed adjacent the primers.
FIG. 5 is horizontal cross sectional view of the multiple output and effect grenade of the present invention shown in FIG. 4 .
FIG. 6 is a perspective view of the multiple output and effect grenade of the present invention, wherein the main body has a hexagonal shaped outer surface.
FIG. 7 is a longitudinal cross sectional view of the multiple output and effect grenade of the present invention, as illustrated in FIG. 6 .
FIG. 8 is a horizontal cross sectional view of the multiple output and effect grenade shown in FIGS. 6 and 7 , illustrating the disposition of the combustible composition comprising the delay column, as well as disposition of the transfer cavity relative to the primer.
FIG. 9 is a side view of the multiple output and effect grenade of the present invention shown in FIGS. 6-8 , illustrating one preferred configuration of the primer cavities, wherein the primer cavities are disposed in a radial, equally spaced pattern relative to the delay column (i.e., the longitudinal axis).
FIG. 10 is a longitudinal cross sectional view of the multiple output and effect grenade of the present invention, wherein the primer cavities are disposed in an asymmetrical helical pattern relative to the delay column.
FIG. 11 is a horizontal cross sectional view of the multiple output and effect grenade of the present invention as illustrated in FIG. 10 , illustrating the disposition of primer cavities across a level plane when the primer cavities are disposed in an asymmetrical helical pattern relative to the delay column.
FIG. 12 is a side view of the multiple output and effect grenade of the present invention, illustrating an embodiment wherein the primer cavities are disposed in an asymmetrical helical pattern relative to the longitudinal axis.
DETAILED DESCRIPTION OF THE INVENTION
Commercial primers have evolved over the years to provide inexpensive, extremely reliable and safe functionality over a wide range of operational environments. The present inventor, realizing the advantages in safety and stability with regards to shipping and storing such primers, unexpectedly discovered that by utilizing the application of heat instead of percussion to the strike face of the primer, a safe, effective multiple output and effect grenade could be provided. Importantly, the grenade of the present invention requires no firing mechanism for each individual primer, making the grenade herein reliable and inexpensive to manufacture while allowing scalability of effects through the placement, quantity and type of primers used, and by changing the delay characteristics of the column. Specifically, the primer type, quantity and placement affect the output intensity, while the placement and delay time affect the rate of fire.
In particular, as illustrated in FIGS. 1-12 , the present invention provides a multiple output and effect grenade 1 , comprised of a main body 2 having a first end 14 , a second end 16 opposite the first end 14 , and an outer circumference therebetween. The main body 2 may have a circular outer circumference, as illustrated in FIGS. 2 and 3 . Alternatively, the main body 2 may have a multi-surfaced outer circumference, as illustrated in FIGS. 6 , 8 and 9 . Such a multi-surfaced outer circumference, such as the hexagonal configuration shown in FIG. 6 , enables the grenade to maintain a stable disposition on a resting surface when laid on its side. During use, such a characteristic may be preferred, so as to prevent unintended rolling of the grenade.
As illustrated in FIG. 1 , a main cavity 18 is disposed within the main body 2 between the first end 14 and the second end 16 , the main cavity 18 defining a longitudinal axis. As illustrated in FIGS. 1 and 10 , an exothermic delay column 4 is disposed within the main cavity 18 , the delay column 4 having a first end, a second end opposite the first end, and a middle portion therebetween. A fuze 3 , which may be any conventional type of fuze assembly/mechanism, may also be disposed on or adjacent to the first end of the main body 2 so as to be in communication with the delay column 4 , thereby being operable to initiate same. In addition, as illustrated in FIG. 4 , an ignition charge 10 may be optionally provided, so as to ensure initiation of the delay column 4 at the first end thereof by the fuze 3 , by providing an initiation bridge therebetween.
As illustrated in FIGS. 1 , 2 , 7 , 8 , 10 and 11 , the delay column 4 may be comprised of one or more combustible compositions operable to burn from about the first end to about the second end of the delay column. Such combustible compositions may be any convention combustible composition operable to burn in a controlled manner. Preferably, the combustible composition(s) making up the delay column is one or more of zirconium-nickel alloy based composition, tungsten based composition, manganese based composition, chromium base composition, boron based composition, barium chromate based composition and/or black powder based composition.
Upon initiation of the delay column 4 , the combustible material controllably burns from the first end to the second end of the delay column 4 , creating a highly exothermic reaction at the burning surface of the column 4 . As the burning surface travels adjacent to the strike face of each of the primers 9 , the heat of such exothermic reaction initiates each primer 9 sequentially as the delay column 4 burns to the second end. By varying the composition, density, etc. of the delay column 4 , the rate of initiation of the primers 9 can be varied as desired.
Alternatively, in a preferred embodiment as illustrated in FIGS. 4 and 5 , the delay column may be comprised of one or more fuze cords. Like the combustible materials described above, the fuze cord functions to create an exothermic reaction operable to initiate the primers 9 . However, when using one or more fuze cords as to the delay column 4 , it is also preferred to employ a booster charge 11 adjacent to the strike face of the primer 9 , so as to ensure that there is sufficient heat produced to initiate the primer 9 . Accordingly, the booster charge 11 is comprised of any combustible material operable to produce sufficient heat, such as black powder or A1A gasless ignition composition. In addition, a transfer cavity 12 is preferably disposed between the fuze cord (acting as the delay column 4 ) and the booster charge 11 , so as to provide a means of ensuring that the booster charge does not predetonate, i.e., detonate prior to the initiation thereof by the fuze cord.
As shown in FIGS. 1 , 2 , 4 , 5 , 7 , 8 , 10 and 11 , a plurality of primer cavities 5 is disposed within the main body 2 , extending from the outer circumference to the main cavity 18 so as to define an internal orifice in communication with the main cavity 18 , and an output orifice within the outer circumference of the main body 2 . As illustrated in FIGS. 1-9 , in a preferred embodiment, the primer cavities 5 are disposed in a symmetrical helical arrangement with relation to the outer circumference of the main body 2 . By being arranged in this configuration, during use when the primers (and optionally effects charges) are initiated, a simulated automatic gunfire effect is produced.
Alternatively, in a preferred embodiment as illustrated in FIGS. 10-12 , the primer cavities 5 may be disposed in an asymmetrical helical arrangement with relation to the outer circumference of the main body 2 . In such an arrangement, during use, a simulated random gunfire effect is produced. Further, different types of effects charges 8 may be disposed in one or more primer cavities 5 , so as to produce varying effects at different stages during the combustion/burning of the delay column 4 .
As mentioned above, and as illustrated in FIGS. 1 , 2 , 4 , 5 , 7 , 8 , 10 and 11 , one or more effect agents 8 are preferably disposed within the primer cavities 5 , adjacent the primer 9 , such that the effect agents 8 are deployed/initiated via initiation of the primer 9 disposed adjacent thereto. Although these effect agents 8 are not limited to a particular type, such effect agents 8 are preferably selected from illuminant compositions, chemical irritant agents, report (sound) agents, smoke agents and/or marking agents. In a preferred embodiment, the one or more illuminant compositions are selected from the group consisting of magnesium; magnesium powder, sodium nitrate and a binder; magnesium powder, aluminum powder, barium nitrate, strontium nitrate and a binder; aluminum powder, potassium perchlorate and barium nitrate; aluminum powder, barium nitrate and sulfur; magnesium powder, potassium perchlorate, barium nitrate, barium oxalate, calcium oxalate and graphite; magnesium powder, antimony sulfide and potassium perchlorate; black powder, and/or smokeless powder.
In another preferred embodiment, the one or more report (sound) agents are selected from the group consisting of magnesium powder, aluminum powder and potassium perchlorate; aluminum powder and potassium perchlorate; titanium powder and potassium perchlorate (TPP), zirconium powder and potassium perchlorate (ZPP); black powder, and smokeless powder.
In another preferred embodiment, the one or more smoke agents are selected from the group consisting of potassium chlorate, sugar, magnesium carbonate and anthraquinone; potassium chlorate, sugar, green dye (MIL-D-3277), potassium bicarbonate and polyvinyl acetate (PVA); potassium chlorate, sugar, red dye (MIL-D-3284), sodium bicarbonate and PVA; and/or aluminum, hexachloroethane and zinc oxide.
Preferably, the one or more marking agents are selected from the group consisting of direct dyes, azoic dyes, acid dyes, cationic dyes, disperse dyes, vat dyes, reactive dyes, fluorescent dyes, sulfur dyes, infrared dyes, and/or ultraviolet dyes.
Preferably, the one or more chemical irritant agents are selected from the group consisting of CS (o-chlorobenzylidene malononitrile) and OC (oleoresin capsicum).
In a preferred embodiment, as illustrated in FIGS. 1-2 , one or more of the primer cavities 5 is sealed by one or more covering materials 6 and/or a U-formed closure 19 , which are disposed on the outer circumference of the main body 2 and/or within the primer cavity(s) 5 , respectively. These covering materials 6 and/or U-formed closures 19 are operable to secure the primer cavities 5 from the exterior environment, thereby protecting the primers 9 and effect charges 8 during shipping and storage.
The covering materials 6 may be comprised of any suitable material functional to cover the primer cavities 5 , and prevent the introduction therein of moisture, particles, etc. In a preferred embodiment, the covering materials are one or more of a polymeric material or rubber material adhesively disposed on/to the outer circumference of the main body 2 . Alternatively, the covering material 6 may be a loose plug frictionally engaged with the primer cavity 9 , which may be dispelled therefrom by the pressure of the primer initiation/effect charge initiation. The U-formed closure 19 may be a simple disk made of cardboard, plastic or foam, such as styrofoam or similar material, or may be comprised of a thin metal. Additionally, sealing or adhesive compounds may be used to affix the U-formed closure 19 in place and enhance sealing of the primer cavity 5 .
The grenade 1 can be configured to provide varying “signatures” by changing the pattern of primer placement, the quantity and type of primers used and the delay characteristics of the delay column. As mentioned above, FIGS. 1-9 illustrate a basic design where 9 (nine) groups of primers 9 are equally spaced apart from each other along the delay column 4 . The resulting “signature” would be approximately 9 distinct and equally timed reports, as each group of primers 9 is initiated by the delay column 4 . The intensity of the output can be adjusted by increasing or decreasing the amount, as well as type of, primers per group.
A symmetrical helical arrangement of primer cavities 5 , as illustrated in FIGS. 1-9 , produces a signature simulating automatic gunfire. Alternatively, as illustrated in FIGS. 10-12 , an asymmetrical helical arrangement of primer cavities 5 simulates random single shots, and effects if effect charges 8 are disposed in the primer cavities 5 . It should be noted that there is no limitation (albeit greater than 2) to the number of primer cavities 5 , primers 9 and/or effect charges 8 . Rather, these elements are tailored to create the desired effect. For example, the grenade 1 can contain primers, as well as one or more of illuminant compositions, smoke generating compositions, crowd control (chemical irritant agents), etc., depending upon the situation. Further, advantageously, such effect agents 8 can be added into existing grenades 1 in the field, enabling user to tailor the grenade “on the fly”.
Although specific embodiments of the present invention have been disclosed herein, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiments. Furthermore, it is intended that the appended claims cover any and all such applications, modifications, and embodiments within the scope of the present invention.
List of Drawing Elements:
1 : multiple output and effect grenade
2 : main body
3 : fuze
4 : delay column
5 : primer cavity
6 : covering material
8 : effects charge
9 : primer
10 : ignition charge
11 : booster charge
12 : transfer cavity
14 : first end of delay column 4
16 : second end of delay column 4
18 : main cavity
19 : U-formed closure means
|
A multiple output and effect grenade is provided, in which an exothermic delay column is utilized to initiate a series of primers via the application of heat to the strike faces thereof, thereby providing a reliable and relatively safe grenade to ship and store. In particular, a multiple output and effect grenade comprised of an exothermic delay column disposed within a central cavity, operable to initiate a series of primers disposed in primer cavities located within the main body of the grenade. The primer cavities may be arranged in a symmetrical or asymmetrical configuration, so as to produce a firing signature resembling an automatic weapon or random gunfire, respectively. In addition, effect charges, such as illuminants, sound agents, chemical irritants, etc., may be disposed within the primer cavities, as desired by the user.
| 5
|
BACKGROUND OF THE INVENTION
An important consideration in the design of high technology equipment is the ease of service and maintenance of the equipment once it is placed in its operational environment. Therefore, almost without exception all equipment involving complex electronic circuitry utilize modular construction techniques wherein much of the circuitry whether purely electronic or various hybrids thereof comprise printed circuit boards mounted in card cages. The card cages which may be integral parts of the equipment to be controlled contain a plurality of printed circuit boards. The printed circuit boards are easily removed from the card cages for servicing. In most cases the serviceman may simply replace the defective circuit board with a new one and return the defective one for repair at a service center. Thus, the equipment is serviceable with a minimum of down time.
A disadvantage of such construction is that each printed circuit board contains completely different circuitry from the other cards in the cage and must be replaced with one that is identical.
BRIEF SUMMARY OF THE INVENTION
The present invention overcomes the above disadvantage by providing a structure wherein each of the printed circuit boards in a card cage is identical. Thus, the printed circuit boards are interchangeable. This greatly increases the efficiency and economy of servicing inasmuch as a serviceman is only required to carry identical printed circuit boards and not one of each of a variety of different printed circuit boards. In addition, cost to the manufacturer is greatly reduced inasmuch as he is required only to build and maintain an inventory of the same printed circuit board.
In particular, the present invention relates to a pneumatic control system wherein certain functions within a system, e.g., a plasma etching system, are pneumatically controlled. Such a system employs one or more card cages which are permanent parts of the machine under control. Each card cage has disposed therein a plurality of identical control valve printed circuit board pneumatic connectors. Each of these control valve printed circuit board pneumatic connectors pneumatically interfaces with individual control logic manifolds fixed to the back of the card cage. Each of the control logic manifolds are programmed to provide the required pneumatic functions to the machine in response to the state of energization of valves mounted on the control valve printed circuit board pneumatic connector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a frontal view of the card cage of the present invention with the control valve printed circuit boards pneumatic connectors in place,
FIG. 2 is a pictorial representation of a control valve printed circuit board pneumatic connector and its associated control logic manifold,
FIG. 3 is a detailed sectional view of one of the valves mounted on the control valve printed circuit board pneumatic connector shown in FIG. 2,
FIG. 4 is a pictorial representation of a control logic manifold; and
FIGS. 5a-5f show various programming configurations for the control logic manifold.
DESCRIPTION
FIG. 1 shows a typical card cage assembly 10 used in the present invention. It comprises a frame 11 forming a plurality of slots 12 into which control valve printed circuit board pneumatic connectors 13 are inserted. Each of the control valve printed circuit board pneumatic connectors 13 comprises a printed circuit board 18. The printed circuit boards 18 are guided, e.g., via grooves 14 fixed to the frame 11 and are fixed in place by means of a shaft 15 fixed to the circuit board and screwed into the back board of the frame by turning knobs 16. The backboard of the card cage 11 contains the electrical and pneumatic structure which interfaces with the apparatus which is to be controlled. The card cage 10 is shown having six slots for receiving circuit boards but it should be noted that it could contain more or less depending on the particular functions required. The card cage assembly thus far described is of a conventional type but has been described as an aid in understanding the present invention.
FIG. 2 is a pictorial illustration of a control valve printed circuit board pneumatic connector 13 shown in association with a control logic manifold 17. Each slot 12 in the card cage 10 would contain such a control valve printed circuit board pneumatic connector with a control logic manifold 17. There is a control logic manifold 17 for each of the control valve printed circuit board pneumatic connectors 13. Each of the control manifolds 17 is appropriately fixed to the back plate 40 of the card cage.
As aforesaid, each control valve printed circuit board pneumatic connector 13 comprises a printed circuit board 18. Mounted on the printed circuit board 18 is a pneumatic connector 19. The pneumatic connector 19 is made of any convenient material, e.g., aluminum alloy. Also mounted on the circuit board 18 and secured to pneumatic connector 19 are four solenoid operated valves 20, 21, 22 and 23. Each of the valves 20, 21, 22 and 23 has three ports, a normally open port NO, a normally closed port NC and a common port C.
All of the valves, 20, 21, 22 and 23 are identically structured and each communicates through the pneumatic connector 19, i.e., each normally open port NO, normally closed port NC, and common port C extend through the pneumatic connector 19 and terminates at the face 19a of pneumatic connector 19.
The printed circuit board 18 carries the circuitry for activating each of the valves 20, 21, 22 and 23. The valves 20, 21, 22 and 23 may be energized by a computer programmed in accordance with the sequence of pneumatic control functions required to operate the associated apparatus. Neither the computer, the apparatus controlled nor the electronics on each circuit board for operating each of the valves 20, 21, 22 and 23 form part of the present invention and, therefore, are not shown. The essential feature of the present invention is the interchangeability of the control valve printed circuit board pneumatic connectors 13 made possible by incorporating all the pneumatic logic in their associated control logic manifolds.
As best seen in FIG. 3, each solenoid operated valve, e.g., valve 20 comprises a spool 24 forming a chamber 25. An energizing coil 26 is disposed about the spool 24. In its unenergized state solenoid poppet valve 27 is spring biased to maintain normally closed port NC closed with normally open port NO communicating via chamber 25 with common port C. When the valve is energized by applying current to coil 26 this situation is reversed causing normally open port NO to close and normally closed port NC to open connecting it with the common port C via chamber 25. The valve 20 maintains this state as long as it is energized.
The valve 20 is fixed to pneumatic connector 19 which in turn is fixed to printed circuit board 18. As can be seen the normally closed port NC, the common port C and the normally open port extend through pneumatic connector 19 terminating at its face 19a.
Referring to FIGS. 2 and 4 it is seen that control logic manifold 17 has on its face 17a ports which are complimentary to each of the ports on the face 19a of pneumatic connector 19 for each of the four solenoid operated valves 20, 21, 22 and 23.
Thus, it can be seen that when control valve printed circuit board pneumatic connector 13 is inserted in a slot 12 of the card cage 10 and secured by screwing the threaded end of shaft 15 into internally threaded opening 28 each normally open port NO, normally closed port NC and common port of pneumatic connector 19 communicates only with their respective ports on the control logic manifold 17. These connections are made air tight by use of O-rings 29 inserted in grooves on the face 17a of control logic manifold 17.
Fixed to the back plate 40 of the card cage 10 is a printed circuit board connector 29 which forms a slot 30 into which tab 18a is inserted. The tab 18a contains the busses (not shown) which make the electrical connection with printed circuit board connector 29 supplying each printed circuit board 18 with the appropriate signals for energizing the solenoid operated valves 20, 21, 22, and 23. There is a printed circuit board connector 29 fixed to back plate 40 along with an associated control manifold 17 which together form slots 30 for receiving each of the tabs 18a of each printed circuit board 18.
As aforesaid the control logic manifold 17 associated with each control valve printed circuit board pneumatic connector 13 contains the logic, i.e., is programmed to provide the pneumatic control function called for in the apparatus desired to be controlled. This permits each control valve printed circuit board pneumatic connector 13 to be identical which greatly increases efficiency of servicing and lowers manufacturing and inventory expense.
The control logic manifold 17 may be programmed to perform different functions within its associated apparatus. For each solenoid 20, 21, 22 and 23, e.g., the control logic manifold 17 may be programmed differently or the same depending on the control function called for by the apparatus to be controlled.
This is accomplished by three channels 31, 36 and 37 drilled or otherwise formed in the length of the control logic manifold 17. These are then caused to be connected to the normally open port NO, or the normally closed port NC in the control logic module 17 in the manner required for particular pneumatic control function. The common port is always connected to the apparatus to be controlled.
FIGS. 5a-5f show six possible variations in the way one of 4 sections of the control logic manifold 17 may be programmed. Each control logic manifold 17 may have four different program arrangements or some or all four may be the same.
Two of the channels 31, and 36 are connected to sources of air pressure and vacuum. The remaining channel 37 is connected to vent or exhaust.
FIG. 5c which is a view taken through section 5c--5c of the control logic manifold 17 illustrated in FIG. 4 shows a typical program arrangement of a portion of the control logic manifold 17 associated with one of the solenoid operated valves. As seen, the normally open port NO is connected to channel 36 which, for example, may be connected to a source of vacuum. Normally closed port NC is connected to channel 31 which may, for example, be connected to the source of air pressure. Therefore, common port C is normally connected to the source of vacuum. However, when the associated solenoid operated valve 20, 21, 22, or 23 is actuated the common port C is disconnected from the source of vacuum and connected to the source of air pressure while the associated valve remains energized.
FIGS. 5a, 5b, 5d, 5e and 5f show different program arrangements which are similar in concept to the arrangement described with reference to FIG. 5c.
The common port C is the one connected into the associated apparatus which is to be pneumatically controlled. These are shown as extensions of ports C on face 17b of control logic manifold 17. Face 17b interfaces, with the apparatus to be pneumatically controlled, with the common ports C of the solenoid valve.
Thus, it is seen that card cage 10 which has six slots can support 6 control logic manifolds each of which has four sections with each one of those four sections controlled by a single three way solenoid operated valve. By incorporating all control logic in the control logic manifolds 17, it is possible to use identical control valve printed circuit board pneumatic connectors 13 to provide an almost unlimited number of control functions for the associated apparatus.
Other modifications of the present invention are possible in light of the above description which should not be interpreted as placing limitations on the invention other than those limitations set forth in the claims which follow:
|
A pneumatic control assembly comprising a plurality of control valve printed circuit board pneumatic connectors disposed in a card cage in communication with a like number of control logic manifolds fixed to the card cage. The control logic manifolds are programmed to provide the actual control functions to the associated apparatus thereby permitting the conrol valve printed circuit board pneumatic connectors to be identical.
| 5
|
This application is a continuation of application Ser. No. 07/311,023, filed Feb. 16, 1990, now U.S. Pat. No. 5,000,242.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to window assemblies, and, more particularly, to double pane window assemblies which include an adjustable blind positioned between the exterior and interior window panes.
Multiple or double pane window assemblies are being utilized instead of single pane windows in many pre-existing and new buildings to minimize heat transfer through the windows. The dead air space held between the external and interior window panes acts to minimize heat loss through the window during winter months while minimizing the amount of external thermal energy entering through the window into the interior during the summer months.
Many pre existing buildings were originally built with single pane windows. It is often desirable to retrofit or convert these single pane windows to double pane windows in order to reduce air conditioning and heating costs for the building. However, it is often prohibitably expensive and time consuming to remove existing single pane windows and replace them with double pane windows. Therefore, some prior devices have been designed to allow conversion of a single pane window having a conventional frame into a double pane window assembly. A typical prior device of this type is disclosed in U.S. Pat. No. 4,369,828 to Tatro.
It has also been desirable to use venetian or adjustable blinds and other window coverings in conjunction with windows. Such blinds can be closed to reflect direct sun rays which would otherwise enter into a room during a sunny summer day. Alternatively, the blinds can be opened to allow sunlight to enter into a room during cold winter days. Blinds have been used in conjunction with single pane windows and when so used, the blinds are normally located on the interior side of the window. However, use of blinds in this manner can have several drawbacks. The slats are exposed to circulating room air and, thus, dust particles tend to settle on the slats. Because the blind slats are in close proximity to each other, cleaning dusty slats can be a difficult task. Another drawback of previous blind arrangements is the fact that the blinds are left exposed and can be damaged by children, vandals or other individuals.
To overcome these drawbacks, it has been found desirable to place the blind between two window panes in a window assembly. Such an arrangement allows the horizontal slats of the blind to be isolated from the circulation of air in a room, thus minimizing the accumulation of dust and dirt thereon. Also, the slats are separated from direct contact with building occupants by a window pane, thus precluding potential damage to the blinds. Such arrangements are shown in U.S Pat. Nos. 4,611,648 and 4,685,502. In some previous prior devices of this type, the two window panes are hermetically sealed as a unit with the blind between them, thus isolated from dirt and moisture. Such an arrangement can readily be utilized in new building construction, but it can be very difficult and/or expensive to retrofit and hermetically seal an existing single pane window. In other devices, the seal between the two window panes is not as tight and, indeed, the interior pane is mounted so as to be removable or hinged to the window casing or building frame. In either arrangement, the blind or window covering between the two window panes is typically secured to the window casing or building frame exposed between the two window panes by screws, nails, or other suitable penetrating fasteners. Such arrangements usually require headrails, bottom rails and static slats in the blind construction. It has been suggested to hook the window covering directly to the window pane frame, but such arrangements can interfere with blind operation and result in scratches to the window pane surface.
In double pane windows with a blind positioned between the window panes, it is often desirable to provide a means of adjusting the angular orientation of the slats of the blind without opening up the window panes. Prior devices have included various adjustment or control mechanisms to allow this, including rotary mechanisms such as that disclosed in U.S. Pat. No. 4,459,778 to Ball and linear mechanisms such as that disclosed in U.S. Pat. No. 4,588,012 to Anderson. However, use of these arrangements can increase the difficulty of installing and cleaning the window panes and window covering because the controls require mounting connection through the window pane itself. Mounting a blind on the window casing, for example, would then require disassembly of the controls when cleaning the blind, especially where the blind is secured at its top and bottom. On the other hand, hooking the blind to the window pane itself to permit removing the blind and window Pane as a unit for cleaning could interfere with operation of these controls during normal use.
Accordingly, an object of the present invention is the provision of a double pane window assembly including a blind or window covering positioned between adjacent window panes which is readily adapted to be retrofit into existing single pane windows.
Another object is the provision of a double pane window assembly including an adjustable blind positioned between the two adjacent panes where the adjustable blind can be readily adjusted by an adjustment mechanism outside of the window assembly, and access to the interior adjustable blind is restricted.
A further object is to provide a simplified and economical insulating window assembly with a window covering mounted therein.
Still another object is to provide a double pane window assembly with simplified installation, repair, maintenance and replacement requirements.
Still another object is the provision of a double pane window assembly including an adjustable blind positioned between the two panes, which allows one window pane along with the adjustable blind assembly to be removed as a single unit.
Still another object is the provision of a double pane window assembly including an adjustable blind positioned between the two panes in accordance with the preceding objects and which will conform to conventional forms of manufacture, be of simple construction and easy to assemble so as to provide an assembly which will be economically feasible, long lasting and relatively trouble-free during assembly, disassembly and use.
These and other objects of the present invention are attained by the provision of an apparatus for securing a window covering to a window by attachment to the frame of a window pane in a manner which retains the window covering in spaced apart relation relative to the window pane. This apparatus can be snap-fit onto the window pane without use of penetrating fasteners. This apparatus also permits utilization in retrofit double pane arrangements and facilitates removal of individual window panes with the window covering as a single unit to avoid disconnection of through-window adjustment controls.
The present invention includes an interior window pane which is secured to an existing window opening at a location interior of the existing window pane by a simplified support structure. This support structure includes top and bottom U-channels and side rails which prevent the newly installed window pane from moving relative to the existing window pane after installation. Various seal arrangements, including magnetic, adhesive and VELCRO strips between the window pane frame and the support structure are contemplated by this invention.
The window covering is mounted between the existing and additional window panes by use of wing-shaped clips that are snap-fit to the top and bottom of the window pane frame. These clips position the window covering at a spaced apart relation from both window panes such that adjustment and operation of the window covering does not normally result in contact with either of the window panes. At the same time, since these clips permit the window covering to be secured directly to the window pane frame, the window pane frame and the window covering can be removed from the double pane window assembly as a unit for cleaning, repair or adjustment, without disassembly of the window covering controls where through-window controls are utilized.
Other objects, advantages and novel features of the present invention will readily become apparent to those of ordinary skill in the art from the following detailed description of the preferred embodiments considered in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the window assembly including adjustable blind with portions broken away.
FIG. 2 is a horizontal cross-sectional view taken across lines A--A of FIG. 1.
FIG. 3 is a vertical cross-sectional view taken across lines B--B of FIG. 1.
FIG. 4 is an enlarged cross-sectional view of the area indicated by Circle C--C in FIG. 3.
FIG. 5 is an enlarged cross-sectinoal view of the area indicated by Circle D--D in FIG. 3.
FIG. 6 is an enlarged front view of the top wing-shaped clip mechanism including wire attachment means in accordance with a preferred embodiment of the present invention.
FIG. 7 is an enlarged side view of the top wing-shaped clip mechanism (without wire attachment means) in accordance with a preferred embodiment of the present invention.
FIG. 8 is an enlarged front view of the bottom wing-shaped clip mechanism including wire attachment means in accordance with a preferred embodiment of the present invention.
FIG. 9 is an enlarged side view of the bottom wing-shaped clip mechanism (without wire attachment means) in accordance with a preferred embodiment of the present invention.
FIG. 10 is an enlarged cross-sectional view of the area indicated by Circle E--E in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, in which like referenced characters indicate corresponding elements throughout the several views, attention is first directed to FIGS. 1-3 which illustrate a preferred embodiment of a double pane window assembly including adjustable blind using the present invention. This double pane window assembly is shown generally rectangular, corresponding to typical window openings in buildings, and consists of outer frame or window casing 10, exterior window pane 50, interior window pane 60 and adjustable blind 90 mounted therebetween. Outer frame 10 includes, for example, top portion 12, bottom portion 14 and two side portions, 16 and 18.
When applying the present invention to retrofit an existing window structure for improved thermal efficiency, exterior window pane 50 would represent the existing window and frame 10 would represent the existing window casing. The new or additional window pane would then be represented by interior window pane 60 and the support structure for mounting interior window pane 60 would be attached to outer frame 10. This support structure includes elements 22, 32, 34 and 40, as described below. Blind 90 is secured to pane 60, rather than outer frame 10, also as described below.
The lower surface 20 of top portion 12 preferably has a U-shaped channel 22 attached by means of one or more fasteners or screws 24. U-shaped channel 22 preferably extends horizontally from interior surface 26 of side portion 16 to interior surface 28 of side portion 18.
Upper surface 30 of bottom portion 14 preferably has U-shaped channel 32 attached thereto by means of one or more fasteners or screws 24. U-shaped channel 32 preferably extends horizontally from interior surface 26 of side portion 16 to interior surface 28 of side portion 18. In preferred embodiments, U-shaped channels 22 and 32 are fabricated from plastic, aluminum or other suitable material. Channel 32 is generally smaller in vertical dimension than channel 22 and is vertically spaced apart from channel 22 at their respective open end extremus 200 preferably by a distance just less than the vertical dimension of pane 60.
Interior surface 26 of side portion 16 preferably has right angle member 34 attached by means of at least one fastener or screw 24. Right angle member 34 is preferably orientated such that first leg 36 is attached flush against interior surface 26 of side portion 16 and extends towards exterior window pane 50. Second leg 38 extends, for example, perpendicularly away from interior surface 26 of side portion 16. Right angle member 34 preferably extends vertically from U-shaped channel 22 on top portion 12 to U-shaped channel 32 on bottom portion 14. Right angle member 34 is preferably aligned with channels 22 and 32 to simultaneously support the frame of pane 60.
Similarly, interior surface 28 of side portion 18 preferably has right angle member 40 attached by means of at least one fastener or screw 24. Right angle member 40 is preferably orientated such that first leg 42 is attached flush against interior surface 28 of side portion 16 and extends towards exterior window pane 50. Second leg 44 extends perpendicularly away from interior surface 28 of side portion 18. Right angle member 40 preferably extends vertically from U-shaped channel 22 on top portion 12 to U-shaped channel 32 on bottom portion 14 and supports the frame of pane 60 similarly to right angle member 34.
Preferably, second leg 38 of right angle member 32 and second leg 44 of right angle member 40 are positioned flush with vertical portion 21 of U-shaped channel 22 and with vertical portion 31 of U-shaped channel 32 to provide this support of the frame of pane 60.
Exterior window pane 50 is configured and supported within outer frame 10 according to conventional teachings. For example, pane 50 is dimensioned slightly smaller than the opening of outer frame 10. Exterior window pane 50 can be held in place by retention members 52 positioned flush with exterior surface 54 and interior surface 56 of exterior window pane 50. Retention members 52 are, for example secured to outer frame 10 by suitable fasteners or nails 58. Alternatively, pane 50 can be secured to the window casing by a conventional sash arrangement. Window panes 50 and/or 60 can be fabricated from glass, plastic or other transparent material.
Interior window pan 60 is typically configured and dimensioned to correspond generally with pane 50 and frame 10. As shown, pane 60 includes top portion 62, bottom portion 64 and two side portions 66 and 68, along with interior surface 70 and exterior surface 72. A frame is provided about the periphery of pane 60 as follows: bottom frame member 74 slides over bottom portion 64 and extends from side portion 66 to side portion 68; top frame member 76 slides over top portion 62 and extends from side portion 66 to side portion 68; two vertical frame members 78 and 80 slide over side portion 66 and side portion 68, respectively, and extend from top portion 62 to bottom portion 64. In preferred embodiments, the intersections between bottom horizontal support member 74, vertical side support members 78 and 80 and top horizontal support member 76 meet in 45 degree angles and the frame members are secured together by means of screws or other suitable fasteners (not shown).
An adjustable blind 90 is disposed between pane 50 and pane 60. Blind 90 is, for example, of conventional construction. As shown, blind 90 resembles that blind described in U.S. Pat. No. 4,702,296. That description is incorporated herein by reference. Thus, in general, blind 90 includes a preselected number of individual slats 92 which are preferably aligned horizontally and extend from vertical side support member 78 to vertical side support member 80. Individual slats 92 each preferably include four cutout notches 94. Individual slats 92 are held by means of a string chain 96 which includes exterior cord member 98 and interior cord member 100 and a series of cross-cords 102. Each individual slat is held in cutout notches 94 by exterior cord member 98, interior cord member 100 and two cross-cords 102.
Adjustment mechanism 104 is also provided in preferred embodiments of the present invention and includes rotary knob 106 and a means for converting rotary motion in rotary knob 106 into vertical longitudinal motion of string chain 96. Up and down movement of interior cord member 100 results in angular movement of individual slats 92. This mechanism is mounted to blind 90 through 60. Specifically, mechanism 104 is supported on surface 70 and extends through pane 60 to engage blind 90 adjacent surface 72.
Blind 90, or any other selected window covering, is secured to the frame members of pane 60 by wing-shaped clip members 110. Where blind 90 is preferably secured at the top and bottom of pane 60 (where, for example, vehicular vibration would otherwise cause the blind to bump against the pane when the window structure of this invention is used in a vehicle) two or four such clips 110 are used. In general, clips 110 snap onto the frame of pane 60 and elements 35 of the '296 patent mentioned above.
Wing-shaped clips 110 which attach to the bottom of pane 60 (on that portion of the frame of pane 60 if a frame is provided) include wing members 114. Elements 35 of the '296 patent (shown in the present figures as element 112) are preferably attached to first wing member 114 by means of a wire 122 having a depressed portion 124 and two ear members 126 and 128. Ear members 126 and 128 engage with cutouts 130 and 132 in wing member 114 to secure wire 122 to wing member 114. Top wing-shaped clips 116 include wing members 120. Elements 35 of the '296 patent (shown in the present figures as element 118) are attached to wing members 120 by means of a U-shaped wire 113 which engages with opening 111 in wing member 120.
The lengths L of wing members 114 and 120 are preferably at least as great as one-half the width of blind 90 such that when suspended between wires 113 and 124 blind 90 is not in contact with exterior surface 72 of pane 60. At the same time, pane 60 is preferably spaced interiorly of pane 50 by a distance sufficient to prevent blind 90 from coming into contact with the interior surface of pane 50 during normal installation and usage.
Wing member 115 of bottom wing-shaped clip 110 is preferably removably snapped over bottom frame member 74 of pane 60 to secure blind 90 to pane 60. Wing member 115 includes at its end hook 215 which is received within groove 216 of frame member 74. Slot 109 is located between wing member 114 and wing member 115. Vertical portion 31 of U-shaped channel 32 slides into slot 109 when pane 60 is installed in channel 32. Similarly, wing member 121 is preferably removably snapped over top frame member 76 of pane 60. Wing member 121 includes hook 221 which is received in groove 222 of frame member 76. Similarly, slot 119 is located between wing member 120 and wing member 122 and vertical portion 21 of U-shaped channel 22 slides into slot 119 when pane 60 is installed in channel 22. Grooves 216 and 222 can be specially supplied on the frame of pane 60 or, and preferably, can be formed co-extensive with grooves utilized for sealing and cushioning of pane 60 against support elements 22, 32, 34 and 40.
Various sealing and cushioning materials can be used between the frame of pane 60 and support elements 22, 32, 34 and 40. For example, magnetic strip 130 is shown in FIG. 10. This magnetic strip can function both to seal out air flow and to assist in retaining pane 60 to those support elements.
To assemble pane 60 and blind 90 into outer frame 10 top frame member 76 is first placed in U-shaped channel 22 and vertical portion 21 slides into slot 119 in top wing-shaped clip members 110. Pane 60 is then slid downwardly into U-shaped channel 32 until bottom frame member 74 enters U-shaped channel 32. As this occurs, top frame member 76 is moved toward exterior window pane 50 until side frame members 78 and 80 are flush with second leg 38 of right angle member 34 and second leg 44 of right angle member 40. In this position, magnetic backing strips 130 assist in retaining pane 60 in outer frame 10. The final step is to slide interior window pane 60 downward so bottom frame member 74 is secured in U-shaped channel 32 and vertical portion 31 slides into slot 109 in bottom wing-shaped clip members 110.
To disassemble this arrangement, a conventional glass mechanical suction cup device (not shown) is placed on interior surface 70 of pane 60 and then pane 60 is slid upwardly so that bottom frame member 74 clears U-shaped channel 32. When this occurs, the bottom portion 62 of pane 60 can be pulled away from outer frame 10 to clear U-shaped channel 32. In this position, pane 60 can be slid downward allowing top frame member 76 to clear U-shaped channel 22. At this time, pane 60 and blind 90 are independent from outer frame 10 and pane 50.
From the preceding description of the preferred embodiments, it is evident that the objects of the invention are attained and although the invention has been described and illustrated in great detail, it is to be 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 this invention are to be limited only the terms of the appended claims.
For example, wing-shaped clips 110 of this invention are shown with use in a double pane assembly, but those of ordinary skill in the art will now recognize their usefulness in single pane arrangements to permit mounting of window coverings and the like without using penetrating feasteners. Also, wire 111 can be formed as looped in the '296 patent to provide greater spring tension in mounting blind 90.
|
An apparatus is provided for securing a window covering to a window by attachment to the frame of a window pane in a manner which retains the window covering in spaced apart relation relative to the window pane. This apparatus can be snap-fit onto the window pane without use of penetrating fasteners. This apparatus also permits utilization in retrofit double pane arrangements and facilitates removal of individual window panes with the window covering as a single unit to avoid disconnection of through-window adjustment controls.
| 8
|
FIELD OF APPLICATION OF THE INVENTION
The present invention relates to producing superhard materials and more particularly to a method of preparing polycrystalline cubic boron nitride which can be used in various branches of engineering as a cutting tool for high-efficient treating hardened steels and alloys.
BACKGROUND OF THE INVENTION
Known in the art are methods of preparing polycrystalline cubic boron nitride from hexagonal boton nitride at high pressures and temperatures in the presence of catalysts such as alkaline, alkaline-earth metals, tin, lead, antimony, as well as nitrides of the above-cited metals (K. Svenson, "High-Pressure Physics", Moscow, 1963, in Russian). In additiona, as catalysts use can be made of water of compounds liberating water in the process of synthesis.
According to the known methods, the catalysts are introduced into the charge either in the form of separate chemical compounds or as compounds which can decompose to said catalysts under the action of high pressures and temperatures. Known methods make it possible to prepare polycrystalline cubic boron nitride containing the products of interaction of the catalyst with boron nitride, which causes gradual weakening of the boron nitride crystalline structure.
Also known in the art is a method of preparing boron nitride of cubic structure residing in that hexagonal boron nitride is subjected to the action of pressure of 40-90 kbar and temperature of 1200°-2400° C. in the presence of a catalyst. As a catalyst use is made of alkaline, alkaline-earth metals, nitrides thereof, as well as antimony, tin, or lead.
In the process use can also be made of a mixture of two and more catalysts and of alloys containing catalysts and non-catalyst metals. The prepared boron nitride contains the products of interaction thereof with a catalyst, for instance, Li 3 BN 2 , Mg 3 BN 3 .
The method is disadvantageous in that the prepared boron nitride contains the products of interaction thereof with a catalyst. These compounds have a low melting point, high reactivity, and decompose rapidly in humid air.
Being in the bulk of polycrystalline formations of boron nitride, the above-cited compounds in the process of treating hardened steels and alloys at high temperatures favour destruction of cutting edges of the tools manufactured from boron nitride.
BRIEF DESCRIPTION OF THE INVENTION
It is an object of the invention to increase wear resistance of polycrystalline cubic boron nitride used in tools for working hardened steels and alloys.
Said object is accomplished by that in a method of preparing polycrystalline cubic boron nitride hexagonal boron nitride is subjected to the action of pressure 40-90 kbar and temperature 1200°-2400° C. in the presence of a catalyst which is a zinc compound.
The proposed catalyst diffuses easily into the bulk of hexagonal boron nitride at high temperatures and pressures, ensuring a complete transformation of said boron nitride into a cubic modification. The catalyst, remaining in the bulk of polycrystalline cubic boron nitride, affects to a lesser degree the weakening of polycrystals than the catalysts used heretofore. This ensures high wear resistance of polycrystalline cubic boron nitride employed in cutting tools.
It is expedient to use as a zinc compound zinc oxide, hydroxide, nitride or amide, or mixtures thereof in amounts of 0.1-12 wt.%.
The use of the proposed compound in amounts less than 0.1 wt.% is undesirable, since transformation of hexagonal boron nitride into cubic one is incomplete.
The use of the proposed compound in amounts over 12 wt.% is inexpedient, since the strength properties of polycrystalline cubic boron nitride decrease considerably.
DETAILED DESCRIPTION OF THE INVENTION
The herein-proposed method is accomplished in the following way.
Powders of hexagonal boron nitride and of a catalyst are mixed until a homogeneous mixture is obtained. The mixture is pressed into briquettes and placed into a high-pressure chamber where it is subjected to high pressure (40-90 kbar) and temperature (1600°-2400° C.). The final product is polycrystalline cubic boron nitride.
The catalyst is a zinc compound, preferably oxide, hydroxide, nitride, amide, or a mixture thereof in amounts of 0.1-12 wt.%. To attain a more uniform distribution of the catalyst in hexagonal boron nitride, the catalyst is used in the form of solution with subsequent evaporation or precipitation. Preparation of polycrystalline cubic boron nitride with prescribed properties does not depend on the ratio of ingredients in the initial reaction mixture or on the duration of pressure and temperature action period.
The agreement between the actual properties of the resultant polycrystalline cubic boron nitride and the prescribed properties is evaluated by wear resistance in a cutting tool. By wear resistance here implies wearing (in mm) of a cutting edge upon turning treatment of hardened steel for 5 minutes. The cutting parameters are: speed V=100 m/min, feed S=0.07 mm/rev., cutting depth δ=0.2 mm.
The herein-proposed method makes it possible to increase considerably, as compared with the known methods, the wear resistance of polycrystalline cubic boron nitride used in tools for working hardened steels and alloys.
Specific examples of realizing the proposed method are given hereinbelow by way of illustration.
EXAMPLE 1
Powders of hexagonal boron nitride (98 wt.%) and zinc oxide (2 wt.%) are mixed. The mixture obtained is pressed into briquettes and placed into a high-pressure chamber where it is subjected to the action of 65 kbar and 1600° C.
The final product is polycrystalline cubic boron nitride with wear resistance of 0.12 mm.
EXAMPLE 2
A powder of hexagonal boron nitride is introduced into a catalyst which is an aqueous solution of zinc chloride. The obtained mixture is treated with an aqueous solution of ammonia, then evaporated and roasted at 420° C. The prepared mixture containing 98 wt.% of hexagonal boron nitride and 2 wt.% of zinc oxide is treated by following the procedure described in Example 1.
The final product is polycrystalline cubic boron nitride with wear resistance of 0.08 mm.
EXAMPLE 3
Powders of hexagonal boron nitride (98 wt.%) and zinc oxide (2 wt.%) are mixed. The obtained mixture is pressed into briquettes and placed into a high-pressure chamber where it is subjected to the action of 90 kbar and 2400° C.
The final polycrystalline cubic boron nitride has a wear resistance of 0.07 mm.
EXAMPLE 4
Powders of hexagonal boron nitride (99.9 wt.%) and zinc oxide (0.1 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. The final polycrystalline cubic boron nitride has a wear resistance of 0.10 mm.
EXAMPLE 5
Powders of hexagonal boron nitride (88 wt.%) and zinc oxide (12 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. Wear resistance of the polycrystalline boron nitride is 0.14 mm.
EXAMPLE 6
Powders of hexagonal boron nitride (99.9 wt.%) and zinc hydroxide (0.1 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. Polycrystalline cubic boron nitride has a wear resistance of 0.10 mm.
EXAMPLE 7
Powders of hexagonal boron nitride (88 wt.%) and zinc oxide (12 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. Wear resistance of the final polycrystalline cubic boron nitride is 0.15 mm.
EXAMPLE 8
Powders of hexagonal boron nitride (99.9 wt.%) and zinc nitride (0.1 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. Wear resistance of the prepared polycrystalline cubic boron nitride is 0.10 mm.
EXAMPLE 9
Powders of hexagonal boron nitride (88 wt.%) and zinc nitride (12 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. Polycrystalline cubic boron nitride prepared has a wear resistance of 0.14 mm.
EXAMPLE 10
Powders of hexagonal boron nitride (99.9 wt.%) and zinc amide (0.1 wt. %) are mixed. The obtained mixture is treated by following the procedure described in Example 3. The prepared polycrystalline cubic boron nitride has a wear resistance of 0.11 mm.
EXAMPLE 11
Powders of hexagonal boron nitride (88 wt.%) and zinc amide (12 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. Wear resistance of the prepared polycrystalline cubic boron nitride is 0.15 mm.
EXAMPLE 12
The powders of hexagonal boron nitride (88 wt.%), zinc amide (6 wt.%) and zinc nitride (6 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. The prepared polycrystalline cubic boron nitride has a wear resistance of 0.13 mm.
EXAMPLE 13
The powders of hexagonal boron nitride (90 wt.%), zinc oxide (8 wt.%), zinc amide (1 wt.%), and zinc hydroxide (1 wt.%) are mixed. The obtained mixture is treated by following the procedure described in Example 3. The prepared polycrystalline cubic boron nitride has a wear resistance of 0.09 mm.
|
According to the invention, a method of preparing polycrystalline cubic bn nitride resides in that hexagonal boron nitride is subjected to the action of pressure of 40-90 kbar and temperature of 1200°-2400° C. in the presence of a catalyst, namely, a zinc compound.
The proposed method makes it possible to increase considerably wear resistance of polycrystalline cubic boron nitride used in tools for working hardened steels and alloys.
| 2
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of U.S. Ser. No. 12/618,031 “PIVOT PIN FOR FURNACE SIDE REMOVAL” by Briggs et al., filed Nov. 13, 2009 and claims priority from this application.
BACKGROUND
[0002] 1. Field of the Invention
[0003] This disclosure relates to burners of solid fuel fired furnaces and more specifically to a burner nozzle tip design that allows for easier removal and maintenance.
[0004] 2. Discussion of Related Art
[0005] Solid fuel furnaces have many common uses, such as for firing boilers to produce steam and electricity. The solid fuel typically is pulverized coal. Coal particles of the pulverized coal is entrained in a flowing air stream and blown into a combustion chamber of a furnace where it is burned.
[0006] FIG. 1 is a schematic depiction of a fuel firing compartment 100 of a typical solid fuel fired furnace. FIG. 2 is a side elevational view showing a cross section of the nozzle, nozzle tip, and pivot pin shown in FIG. 1 .
[0007] The invention will be described with reference to both FIGS. 1 and 2 . It can be seen here that stationary nozzle 110 receives sold fuel particles entrained in a stream of flowing air. The air/fuel flows through the stationary nozzle 110 and out of the nozzle tip 200 . The air/fuel is then burned in the combustion chamber of a solid fuel furnace. The direction following the flow is referred to as “downstream” and the opposite direction is referred to as “upstream”.
[0008] In order to adjust the operation of the nozzle tip 200 , one or more control arms, shown here as a tilt pivot 120 and a tilt drive 130 , adjust the orientation and operation of the nozzle tip 200 . The nozzle tip 200 may be tilted with respect to the stationary nozzle 110 on a pivot pin 310 to cause the nozzle tip 200 to be directed in a different direction to optimize the firing of the furnace.
[0009] Since the air flow with entrained solid particles passes through the fuel-firing compartment 100 subject to erosion effects similar to sand blasting. Anything within the path of the air/fuel flow is eroded.
[0010] Since the nozzle tips 200 are located in the combustion chamber, they are also exposed to excessive heat and heat cycling. This can overheat and warp the nozzle tips, and have effects on the moving parts, such as pivot pin 310 .
[0011] Combustion occurring near the nozzle tips 200 creates constant expansion, contraction and vibration. If the pivot pin is held in place with standard bolts or nuts, it is possible that they will loosen and vibrate out. This would cause the nozzle tip 200 to fall into the furnace. The furnace has a grinder for grinding up the ashes at the bottom of the furnace. Not only will there be uneven and uncontrolled burning, but the nozzle tip, bolt and nut will become caught in the grinder causing damage and the boiler to become non-operational. This would require time and expense to correct the problem.
[0012] For this reason, one end of the pivot pin is typically welded into place. The pins must be ground off to replace them. The inside of the furnace is covered with water tubes that pass close to each of the nozzle tips 200 . Therefore, the only way to replace the nozzle tips is to grind or burn off the pivot pins from inside of the nozzle tips 200 . There is little access to the nozzle tip 200 openings, making replacement difficult.
[0013] The entire fuel firing compartment, except for the nozzle tip 200 is located within a closed windbox compartment (not shown for clarity in FIG. 1 ). The common method of changing the nozzle tips 200 is to remove the entire fuel firing compartment 100 from the windbox and grind off the pivot pins from the outside of the nozzle tips 200 . This is very time-consuming causing the power plant to be ‘down’ for quite a while.
[0014] Typically these solid fuel furnaces are used as steam generators to create electricity in power plants. When one of these power plants is ‘down’, the owner is required to buy and supply equivalent power from the power grid to provide an uninterrupted supply of electricity to its customers.
[0015] Buying this replacement electricity is much more expensive that generating it. This may amount to significant losses by being out of operation. Therefore, a significant part of the costs are ‘down time’ costs.
[0016] Since nozzle tip operate at very high temperatures and in an erosive environment, the nozzle tips 200 tend to have a short life relative to the other parts of the system and have to be replaced often.
[0017] Since the nozzle tips 200 typically require more maintenance then the remainder of the fuel firing compartment parts, it would be beneficial to be able to quickly and easily replace only the nozzle tip 200 . This then results in a furnace that is less costly to operate and service.
SUMMARY
[0018] The present invention may be embodied as a replaceable nozzle tip assembly 250 within a solid fuel furnace having a stationary nozzle 110 . The nozzle tip assembly 250 includes a nozzle tip 200 having with shroud walls 210 , 220 and a central opening 230 .
[0019] A bearing 510 , 520 , 530 is fixed to the shroud walls 210 , 220 . The bearing 510 , 520 , 530 has a central orifice 511 , 521 , 531 .
[0020] A pivot pin assembly 410 , 420 , 430 passes through the bearing orifice 511 , 521 , 531 and the sidewall of the stationary nozzle 110 , to pivotally and removeably attach the nozzle tip 200 to the stationary nozzle 110 . The pivot pin assembly 410 , 420 , 430 acts as a fastener that is accessible from the central opening 230 . This allows easy replacement of the nozzle tip.
[0021] The present invention may also be embodied as a nozzle tip assembly 250 removeably attached to a stationary nozzle of a solid fuel furnace.
[0022] The nozzle tip assembly 250 includes a nozzle tip 200 having at least one outer shroud wall 210 , 220 and at least one central opening 230 .
[0023] A bearing 510 , 520 , 530 with a bearing orifice 511 , 521 , 531 is attached to the shroud wall 210 , 220 of the nozzle tip 200 .
[0024] A fastener base 413 , 423 , 433 is fitted into the bearing orifice 511 , 521 , 531 and extends at least partially through a sidewall of the stationary nozzle 110 allowing the stationary nozzle 110 to pivot relative to the fastener base 413 , 423 , 433 and nozzle tip 200 .
[0025] A set screw 411 , 421 , 431 is used to secure the fastener base 413 , 423 , 433 to the bearing 510 , 520 , 530 , the set screw 411 , 421 , 431 being accessible from the central opening 230 of the nozzle tip 200 .
[0026] The invention may also be embodied as an aerodynamic pivot pin assembly 600 passing through a surface of a shroud 210 of a nozzle tip 200 for pivotally securing a nozzle tip 200 to a nozzle, having a head 610 inside of the nozzle tip 200 , wherein the head 610 has decreasing thickness “t” from a top 619 to a leading edge 613 to minimize resistance to flow and erosion of head 610 .
[0027] The head 610 may also be designed to decrease in width in a lateral dimension as it extends upstream to further minimize resistance to flow and erosion of head 610 .
BRIEF DESCRIPTION OF FIGURES
[0028] With reference now to the figures where all like parts are numbered alike;
[0029] FIG. 1 is a perspective view of a fuel firing compartment showing a nozzle tip and a pivot pin.
[0030] FIG. 2 is a side elevational view showing a cross section of the nozzle, nozzle tip, and pivot pin of FIG. 1 .
[0031] FIG. 3 is a perspective view showing the inside of the nozzle tip of FIGS. 1 , 2 with an exploded diagram of a pivot pin assembly according to the present invention.
[0032] FIG. 4 is an enlarged view of a portion of the nozzle tip and pivot pin assembly of FIG. 3 .
[0033] FIGS. 5-7 are exploded perspective views of three different embodiments of a pivot pin assembly according to the present invention.
[0034] FIG. 8 is a partial view of a nozzle tip 200 from the furnace side showing another embodiment of a pivot pin assembly, as it would appear installed.
[0035] FIG. 9 is a perspective view showing the curvature of the outside surface of the head of the pivot pin according to one embodiment of the present invention.
[0036] FIG. 10 is a perspective view showing the inner side of the head of the pivot pin of FIG. 9 .
[0037] FIG. 11 shows a top plan view of the pivot pin shown in FIGS. 9 and 10 .
[0038] FIG. 12 is a side elevational view of the pivot pin of FIGS. 9-11 .
[0039] FIG. 13 is a front elevational view of the pivot pin of FIGS. 9-12 .
[0040] FIG. 14 is a bottom plan view of the pivot pin of FIGS. 9-13 .
[0041] FIG. 15 is a partially cut-away view of the nozzle tip assembly of FIG. 8 .
DETAILED DESCRIPTION
[0042] The use of the terms “a” and “an” and “the” and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity). All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.
[0043] The most direct way of replacing a nozzle tip 200 would be from the furnace side, if the pivot pin were not welded.
[0044] The inside of the furnace is covered with water pipes for collecting the heat and for creating steam. These burners may be many feet from the bottom of the furnace. Therefore, temporary scaffolding must be erected to allow access to the nozzle tips 200 . This may be acceptable for light work, but any more involved work may cause accidents that would damage the water pipes and other equipment inside of the furnace. For this reason, it was common to work on the other side of the windbox and remove the entire fuel-firing compartment 100 for maintenance.
[0045] The present invention allows for easier and more economical replacement of the nozzle tips 200 . A new pivot pin assembly design is used instead of the welded pivot pin design for holding the nozzle tip 200 in place. This new design allows for the pivot pin removal and installation from inside the furnace without grinding or cutting.
[0046] FIG. 3 is a perspective view showing the inside of the nozzle tip 200 of FIGS. 1 , 2 with an exploded diagram of a pivot pin assembly 410 according to the present invention. Nozzle tip 200 has an outer shroud 220 that encloses an inner shroud 210 . Pivot pin assembly 410 passes through the stationary nozzle (not shown here for clarity), the inner shroud 210 and the outer shroud 220 . This allows nozzle tip 200 to pivot with respect to the stationary nozzle ( 110 of FIGS. 1 , 2 ).
[0047] The pivot pin assembly 410 remains the same size as the pivot pin 310 currently being used. The pivot pin assembly 410 , however, is manufactured to allow it to be removeably held in place using a fastener that is protected from the hazardous conditions.
[0048] FIG. 4 is an enlarged view of a portion of the nozzle tip and pivot pin assembly 410 of FIG. 3 . In addition to the inner shroud 210 , the outer shroud 220 and the pivot pin assembly 410 , a portion of a bearing 510 is visible.
[0049] FIGS. 5-7 are perspective views of three different embodiments of a pivot pin assembly 410 , 420 , 430 according to the present invention that attach to bearings 510 , 520 , 530 in the nozzle tip. FIG. 5 shows a bearing 510 having an inner extension 515 that fits within the inner shroud ( 210 of FIG. 4 ), and a bearing body 517 that is sandwiched between the inner and outer shrouds ( 210 , 220 of FIG. 4 ). Bearing 510 has a bearing orifice 511 that passes through the bearing 510 .
[0050] A fastener base 413 has a cylindrical portion 415 and an expansion portion 417 . The expansion portion 417 in its normal resting position is slightly larger diameter than bearing orifice 511 . Expansion portion 417 has slits allowing it to be squeezed to make it thinner or released to expand back to make it thicker. The expansion portion 417 also has a snap ridge 419 that protrudes outward from the expansion portion 417 . Bearing 510 also has a snap groove 513 that is designed to receive and removeably hold snap ridge 419 . Cylindrical portion 415 extends outward enough to pass through a sidewall of stationary nozzle ( 110 of FIGS. 1 , 2 ). Cylindrical portion 415 will be flush with respect to the inner surface of the sidewall of the stationary nozzle. (In an alternative embodiment, it may extend only partially through the stationary nozzle and be slightly recessed.) This insures that it will not be abrased away by the flowing air/fuel.
[0051] For assembly, fastener base 413 is pushed into bearing orifice 511 . The leading edge of the extension portion 417 is preferably tapered to the center so as to squeeze expansion portion 417 together making it thinner until snap ridge 419 snaps into snap groove 513 , holding fastener base 413 in place.
[0052] A set screw 411 has a threaded head section 412 and a body section. It is inserted into the fastener base 413 after the fastener base 413 has been inserted into bearing orifice 511 . The body section restricts the expansion section 417 from reducing its thickness and prevents the snap ridge 409 from being removed from the snap groove 513 . The head section 412 is threaded to thread into the outer end of the fastener base 413 .
[0053] FIG. 6 is a second embodiment of the pivot pin assembly according to the present invention. Bearing 520 has a bearing body 527 sandwiched between the inner and outer shrouds ( 210 , 220 of FIG. 4 ) of the nozzle tip when installed. A fastener base 423 has a cylindrical portion 425 and an insertion portion 427 . The insertion portion 427 is inserted into the bearing orifice 521 . Insertion portion 427 is shown here with a square cross sectional shape in this embodiment, however, any geometrical or irregular shaped cross section shape would be acceptable which matches the shape of the bearing orifice 521 .
[0054] A set screw 421 passes through the fastener base 423 and screws into a threaded section fixed within bearing 520 . This may be a threaded nut (not shown) welded within bearing orifice 521 . The shape of insertion section 427 fitting snugly within bearing orifice 521 stops rotation of fastener base 423 restricting loosening of set screw 421 .
[0055] A screw cap 429 threads into fastener base 423 thereby providing a corrosion-tight barrier protecting set screw 431 and fastener base 423 . This screw cap 429 acts as a plug on the stationary coal nozzle side to seal the inner area from coal intrusion and wear. This also acts to jam against set screw 421 and acts as a lock nut in case set screw 421 begins to loosen.
[0056] In an alternative embodiment, cylindrical section 425 of fastener base 423 has internal threads. A screw cap similar to screw cap 429 may be employed and screwed into this cylindrical section 425 to protect fastener base 423 and prevent set screw 421 from loosening.
[0057] Cylindrical portion 425 extends outward enough to pass through a wall of the stationary nozzle ( 110 of FIGS. 1 , 2 ), but it and screw cap 429 will be flush with respect to the inner surface of the stationary nozzle. In an alternative embodiment, they may extend only partially through the sidewall of the stationary nozzle and be slightly recessed. This insures that it will not be abrased away by the flowing air/fuel.
[0058] FIG. 7 shows a bearing 530 having a bearing body 537 that is sandwiched between the inner and outer shrouds ( 210 , 220 of FIG. 4 ) of the nozzle tip when installed. Bearing 530 has an inner extension 535 that fits within the inner shroud ( 210 of FIG. 4 ), an outer extension 539 that fits within outer shroud ( 220 of FIG. 4 ) and a bearing body 537 that is sandwiched between the inner and outer shrouds ( 210 , 220 of FIG. 4 ). Bearing 530 has a bearing orifice 531 that passes through the bearing 530 .
[0059] A fastener base 433 has a cylindrical portion 435 and an expansion portion 437 . The expansion portion 437 in its normal resting position has a diameter slightly smaller than bearing orifice 531 . Expansion portion 437 has slits allowing it to be expanded to make it thicker.
[0060] Cylindrical portion 435 extends outward enough to pass through a wall of the stationary nozzle ( 110 of FIGS. 1 , 2 ), but will be flush with respect to the inner surface of the stationary nozzle sidewall. In an alternative embodiment, it may extend only partially through the stationary nozzle and be slightly recessed. This insures that it will not be abrased away by the flowing air/fuel.
[0061] A set screw 431 has threads at one end. It is inserted through the fastener base 413 and loosely screwed into the narrower end of a truncated cone shaped expander 438 .
[0062] The set screw 431 , fastener base 433 , and expander 438 are inserted into bearing orifice 531 . Set screw 431 is then tightened causing expander 438 to be pulled toward set screw 431 thereby expanding expansion portion 437 . Expansion portion 437 then becomes tightly held within bearing orifice 531 .
[0063] A screw cap 439 is screwed into this cylindrical section 435 to protect fastener base 433 and prevent set screw 431 from loosening.
[0064] Even though a set screw is described in this embodiment, it is appreciated that the invention covers all types of removable fasteners that will allow the nozzle tip to pivot about the stationary nozzle, and be accessed from the furnace side of the nozzle tip.
[0065] As opposed to the prior art designed, with the present invention, a worker will not have to cut out material to replace the nozzle tip. No welding is required to install the present invention.
[0066] The present invention is designed to use existing holes in the stationary nozzle and nozzle tips 200 . The embodiment of FIG. 7 also allows use of the existing bearing block sizing. In this embodiment, no new design sizing is required.
[0067] The present invention may be used to retrofit any existing ‘T fired’ nozzle types. The pivot pin assembly is sealed from wear. Since it attached with fasteners, it may be replaced with hand tools. No special rigging is required.
[0068] Even though this invention has its preferred use for solid fuel burner nozzle tips, and more specifically coal-fired burner nozzle tips, it is equally applicable to other nozzle tips that are intended to pivot and are located inside of a furnace. These may be oil burner nozzle tips, natural gas burner nozzle tips, other fuel gas nozzle tips and air inlet tips.
[0069] FIG. 8 is a partial view of a nozzle tip 200 from the furnace side showing a head 610 of a second embodiment of a pivot pin assembly 600 , as it would appear installed.
[0070] A curved head 610 of the pivot pin assembly 600 is visible fitting flush against the surface of the inner shroud 210 of nozzle tip 200 .
[0071] FIG. 9 is a perspective view showing the curved head of a pivot pin 601 of the pivot pin assembly according to one embodiment of the present invention.
[0072] FIG. 10 is a perspective view showing the inner side of the head of the pivot pin of FIG. 9 .
[0073] FIG. 11 shows a top plan view of the pivot pin shown in FIGS. 9 and 10 .
[0074] FIG. 12 is a side elevational view of the pivot pin of FIGS. 9-11 .
[0075] FIG. 13 is a front elevational view of the pivot pin of FIGS. 9-12 .
[0076] FIG. 14 is a bottom plan view of the pivot pin of FIGS. 9-13 .
[0077] The pivot pin 601 is now described in connection with FIGS. 9-14 .
[0078] FIGS. 9 and 12 show a pin axis 603 passing through the length of the shaft 650 . Also, the indications of the upstream and downstream directions are shown, as well as the lateral direction.
[0079] In this embodiment, the pivot pin 601 includes a shaft 650 . The shaft 650 fits through an orifice of a bearing held by the at least one of the shrouds similar to the embodiment shown in FIG. 4 or the other previously described embodiments. In this embodiment, the shaft 650 has a hole 652 that receives a clip, pin or other fastener on the other side of the shrouds, holding the pivot pin 601 in place.
[0080] Pivot pin 601 has a flat inner surface 620 on head 610 that fits flush against the inner shroud ( 210 of FIG. 8 ). The inner surface 620 also has an alignment peg 622 that fits into a corresponding hole in the inner shroud such that the pivot pin head is oriented to have a portion of the head 610 point upstream, a leading edge 613 , and a portion face downstream, a trailing edge 615 .
[0081] FIG. 9 shows the surface of the head 610 . It is shaped to be aerodynamic with the head 610 being narrow at the leading edge 613 , and increasing to a head thickness “t” at the top 619 . It is curved, or angled to divert flow outward away from the inner shroud surface and around head 610 as shown by arrow “A” in FIG. 12 .
[0082] It may also be designed to divert flow laterally around head 610 as show by arrows “B” in FIGS. 11 and 14 .
[0083] Similarly, to reduce turbulence and abrasive swirling effects, the trailing edge 615 is designed to continue the smooth flow around the head 610 and downstream. In FIG. 12 , the thickness of head 610 decreases from a maximum at the top 619 to a smaller thickness at the trailing edge 615 . This causes the flow to follow arrow “C”.
[0084] The trailing edge 615 may also be aerodynamic in the other dimension. As shown in FIG. 14 , the trailing edge 615 is rounded causing the flow to follow arrows “D”. It is to be understood that other aerodynamic shapes may also be advantageously used for the pivot pin head 610 .
[0085] The gradual redirection of the flow around the head 610 minimized abrasion and erosion of the head. This allows these to function longer before replacement.
[0086] FIG. 15 is a partially cut-away view of the nozzle tip assembly of FIG. 8 . Here, a clip 653 which fits through the hole of the pin shaft ( 652 , 650 of FIGS. 9 , 10 , 12 , 13 , respectively).
[0087] Since these are design for quick replacement from inside the furnace, they are easily replaced when required.
[0088] While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention.
|
Disclosed herein is a novel pivot pin assembly 410, 420 430, 600 for pivotally attaching nozzle tips 200 to stationary nozzles in a solid fuel furnace. The pivot pin assemblies allow rapid replacement of the nozzle tips 200. The pivot pin assembly 410, 420 430, 600 employs fasteners that or recessed or have an aerodynamically shaped head 610. The head 610 includes a leading edge 613 and optionally a trailing edge 615 that are aerodynamically shaped to reduce corrosion and erosion. The pivot pin assembly pivotally attaches the nozzle tip 200 to the stationary nozzle 110. It employs fasteners that are accessible from a furnace side through a central opening of the nozzle tip 200. This allows removal of the nozzle tip 200 from inside the furnace greatly simplifying nozzle tip 200 replacement.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to compounds which are useful additives for lubricating oils. In particular, this invention is directed toward overbased derivatives of ortho-carboxy phenylphenone. The overbased derivatives of ortho-carboxy phenylphenones are useful lubricating oil additives which provide detergency while additionally providing an alkaline reserve for the lubricating oil. An alkalinity reserve is necessary in the lubricating oil in order that acids generated during engine operation may be neutralized. Without this alkalinity reserve, the acids generated result in unwanted corrosion in the engine.
2. Background of the Invention
U.S. Pat. No. 3,526,661 discloses that alkaryl keto acids amidated by reaction with aliphatic polyamines are useful sludge dispersancy and detergency additives for lubricating oils.
U.S. Pat. No. 4,379,092 discloses a process for the preparation of ortho-carboxy phenylphenones. These compounds are taught as intermediates in the synthesis of anthraquinones, which themselves are taught as being used for dyestuffs, paper pulp industries and for the manufacture of hydrogen peroxide.
Great Britian Application No. 1,450,733 discloses ortho-carboxy phenylphenones as useful starting materials for dyes and insecticides.
Other alkyl-substituted ortho-carboxy phenylphenones are disclosed in CA No. 80:47709(e); CA No. 83:146931(q); CA No. 84:179413(w); CA No. 94:15446(q); and U.S. Pat. Nos. 3,880,892 and 3,816,124. Salts of lower alkyl-substituted ortho-carboxy phenylphenones are disclosed in CA No. 82:172012(q). However, there is no teaching in these references, or apparently elsewhere, to prepare overbased derivatives of ortho-carboxy phenylphenones or that these overbased derivatives of ortho-carboxy phenylphenones would be useful additives for lubricating oils.
SUMMARY OF THE INVENTION
It has now been found that overbased derivatives of ortho-carboxy phenylphenones are useful additives for use in lubricating oils. These additives possess detergency properties which supply the lubricating oil with an alkalinity reserve.
Accordingly, the present invention relates to a product prepared by the process which comprises reacting a compound of formula I or a ortho-carboxy phenylphenone of formula II: ##STR1## wherein R is alkyl of from 1 to 30 carbon atoms;
X, Y and Z are independently selected from hydrogen or hydroxy;
M is a metal selected from the group consisting of strontium, barium, calcium, magnesium, sodium and potassium;
m is an integer equal to the valence of M;
n is an integer from 1 to 3;
with the proviso that the total sum of carbon atoms in all R be at least 10 carbon atoms;
with from about 1 to about 50 equivalents of a basically reacting metal compound selected from the group consisting of
calcium oxide, hydroxide, or alkoxide of 1 to 3 carbon atoms;
magnesium oxide, hydroxide or alkoxide of 1 to 3 carbon atoms;
barium oxide, hydroxide or alkoxide of 1 to 3 carbon atoms;
sodium hydroxide or alkoxide of 1 to 3 carbon atoms;
potassium hydroxide or alkoxide of 1 to 3 carbon atoms; and
with from 1 to about 50 equivalents of carbon dioxide.
Preferred overbased ortho-carboxy phenylphenones for use in this invention are those having the following preferred substituents.
X and Z are preferably hydrogen. Most preferably X, Y and Z are hydrogen.
Preferably, n is an integer from 1 to 2.
For values of n greater than one, each alkyl group may be the same or different from other R alkyl group(s).
R alkyl groups may be a single alkyl group or a mixture of alkyl groups. For instance, a C 15 to C 20 alkyl R may be prepared by employing a C 15 to C 20 olefin mixture and alkylating the substituted benzene, IV.
The alkyl groups impart oil solubility to the resulting product. Accordingly, the number of carbon atoms in the alkyl groups must be sufficient to impart oil solubility to the compound. In general, at least 10 carbon atoms are required although fewer would be acceptable if the product was oil soluble. Thus in a preferred embodiment, R is one or more alkyl groups of from 10 to 30 carbon atoms. Most preferably, at least one R is an alkyl group of from 15 to 20 carbon atoms.
M is preferably calcium and magnesium. Most preferably M is calcium.
DETAILED DESCRIPTION OF THE INVENTION
The neutral ortho-carboxy phenylphenones used in this invention are conveniently prepared from the corresponding ortho-carboxy phenylphenones of formula II above. For example, the acid may be reacted by methods known per se in the art with a basically reacting metal compound such as calcium oxide, hydroxide or alkoxide; magnesium oxide, hydroxide or alkyoxide; barium oxide or hydroxide; sodium hydroxide or alkoxide; and potassium hydroxide or alkoxide, and the like, to form the corresponding metal salts useful in this invention.
The overbased ortho-carboxy phenylphenones used in this invention may be conveniently prepared from either the corresponding ortho-carboxy phenylphenone of formula II or the salt of formula I. In either case, the resulting product is an overbased ortho-carboxy phenylphenone having utility as a lubricating oil additive.
In general, the acid or neutral salt may be reacted with a basically reacting metal compound and carbon dioxide to form the overbased products useful in this invention. The reaction is generally conducted in an inert diluent such as oil, carbon thinner, and the like. In order to facilitate efficient mixing of the reagents, a cosolvent may be added. Suitable cosolvents are tridecyl alcohol ethylene glycol or mixtures thereof. In a preferred embodiment, in addition to the cosolvent a dispersant such as an alkyl or alkenyl mono- or bis-succinimide may be added to the system. In order to facilitate reaction completion a nonionic surfactant such as an alkylbenzene hydroxypolyether is added. A particularly suitable catalyst in Triton X-35®, a polyethylene glycol p-isooctylphenyl ether available from Rohm and Haas, Philadelphia, Pa. The reaction is generally conducted at from 50° C. to 200° C., with temperatures of 150° C. to 160° C. being preferred, and is generally complete from within 2 to 60 hours.
Suitable basically reacting metals include calcium oxide, hydroxide or alkoxide, magnesium oxide, hydroxide or alkoxide, barium oxide or hydroxide, sodium hydroxide or alkoxide and potassium hydroxide or alkoxide. Suitable alkoxides include methoxide, ethoxide, n-propoxide, and iso-propoxide. Usually, 1 to 50 equivalents to the compound of either formula I or II of the basically reacting metal is employed in the reaction. Although preferably 1:20 equivalents and most preferably 1:9 equivalents. Carbon dioxide may be employed at the same or different molar amount as the basically reacting compound. Accordingly, 1 to 50 equivalents of the carbon dioxide to the compound of either formula I or II are generally employed while 1:20 equivalents of carbon dioxide are preferred and 1:9 equivalents being most preferred. The resulting overbased ortho-carboxy phenylphenones may contain an alkalinity value (AV- refers to the amount of base as milligrams of KOH in 1 gram of sample) of from 250 to 400. Accordingly, these additives supply an ample alkalinity reserve for the lubricating oil when added to the oil at a concentration of from 0.5 to 20 percent by weight.
Alkyl-substituted ortho-carboxy phenylphenones of formula II are readily prepared by reacting an appropriately substituted phthalic anhydride with an appropriately substituted benzene compound in the presence of a Friedel-Crafts reagent, for example, as shown in reaction (1) below: ##STR2## wherein R, X, Y, Z, and n are as defined above.
The reaction is conducted by contacting essentially equimolar amounts of III, IV and the Friedel-Crafts reagent at a temperature sufficient to cause reaction. In general, temperature of from 110° C. to 115° C. are employed.
Suitable Friedel-Crafts reagent include aluminum trichloride, aluminum tribromide, and the like.
The reaction is generally conducted in an inert anhydrous organic solvent such as chlorobenzene, nitrobenzene, hydrocarbons such as 250 thinner, which is a mixture of aromatics, paraffins and naphthene, and the like.
The reaction is generally complete in from about 1 to about 5 hours. The product may be separated and purified by conventional technique such as by first solvent extraction then water washing followed by filtration and stripping.
Alternatively, the ortho-carboxy phenylphenones of formula II may be prepared as described in U.S. Pat. No. 4,379,092. This reference employs a catalytic amount of boron trifluoride in lieu of the Friedel-Crafts reagent in the synthesis of ortho-carboxy phenylphenones. This reference is incorporated herein by reference for its disclosure of the synthesis of ortho-carboxy phenylphenones.
Compounds of formula IV wherein R is alkyl of C 1 -C 2 are either known in the art, e.g., toluene, xylene, mesetylene, cresol, xylenol, orcinol, etc., or may be prepared by methods known per se. C 3 -C 30 monoalkyl R groups may be prepared by reacting a C 3 -C 30 olefin or a mixture of C 3 -C 30 olefins with a compound of formula V, in the presence of an alkylating catalyst as shown in reaction (2) below: ##STR3## wherein X and Y are as defined above. The reaction is conducted at a temperature of from about 60° C. to 200° C., and preferably 125° C. to 180° C. in an essentially inert solvent at atmospheric pressure. A preferred alkylating catalyst is a sulfonic acid catalyst such as Amberlyst 15® available from Rohm and Haas, Philadelphia, Pa. The reaction is generally complete in about 1 to 10 hours.
Di- and tri-alkyl substituted compounds of formula V above may be prepared by employing 2 or 3 equivalents of olefin VI. In such cases, each alkyl R substituent will be equivalent.
Monoalkylation results in the generation of some di- and tri-alkylated products. Accordingly, the term "monoalkylation" means the reaction of essentially stiochiometric amount (0.9 to 1.2 equivalents) of olefin to V with preferably 1 to 1.1 equivalents of olefin being employed. Likewise, di- and tri-alkylation means essentially two or three equivalents of olefin is employed, respectively.
Alkyl R substituents which are not equivalent in formula V may be prepared by either employing in reaction (2) a known C 1 -C 2 alkyl substituted aromatic or hydroxy aromatic for V above, e.g., cresol, p-ethyltoluene, etc., or by alkylating product VII with a different olefin via reaction (2).
The lubricating oils to which the overbased ortho-carboxy phenylphenones are added may contain an alkenyl or alkylsuccinimide; and a Group II metal salt dihydrocarbyl dithiophosphate.
The alkenyl succinimide is present to, among other things, act as a dispersant and prevent formation of deposits formed during operation of the engine. The alkenyl succinimides are well known in the art. The alkenyl succinimides are the reaction product of a polyolefin polymer-substituted succinic anhydride with an amine, preferably a polyalkylene polyamine. The polyolefin polymer-substituted succinic anhydrides are obtained by reaction of a polyolefin polymer or a derivative thereof with maleic anhydride. The succinic anhydride thus obtained is reacted with the amine compound. The preparation of the alkenyl succinimides has been described many times in the art. See, for example, U.S. Pat. Nos. 3,390,082, 3,219,666 and 3,172,892, the disclosures of which are incorporated by reference. Reduction of the alkenyl-substituted succinic anhydride yields the corresponding alkyl derivative. The alkyl succinimides are intended to be included within the scope of the term "alkenyl succinimide". A product comprising predominantly mono- or bis-succinimide can be prepared by controlling the molar ratios of the reactants. Thus, for example, if one mole of amine is reacted with one mole of the alkenyl or alkyl-substituted succinic anhydride, a predominantly mono-succinimide product will be prepared. If two moles of the succinic anhydride are reacted per mole of polyamine, a bis-succinimide will be prepared.
Particularly good results are obtained with the lubricating oil compositions of this invention when the alkenyl succinimide is a polyisobutene-substituted succinic anhydride of a polyalkylene polyamine.
The polyisobutene from which the polyisobutene-substituted succinic anhydride is obtained by polymerizing isobutene and can vary widely in its compositions. The average number of carbon atoms can range from 30 or less to 250 or more, with a resulting number average molecular weight of about 400 or less to 3,000 or more. Preferably, the average number of carbon atoms per polyisobutene molecule will range from about 50 to about 100 with the polyisobutenes having a number average molecular weight of about 600 to about 1,500. More preferably, the average number of carbon atoms per polyisobutene molecule ranges from about 60 to about 90, and the number average molecular weight ranges from about 800 to 1,300. The polyisobutene is reacted with maleic anhydride according to well-known procedures to yield the polyisobutene-substituted succinic anhydride.
In preparing the alkenyl succinimide, the substituted succinic anhydride is reacted with a polyalkylene polyamine to yield the corresponding succinimide. Each alkylene radical of the polyalkylene polyamine usually has up to about 8 carbon atoms. The number of alkylene radicals can range up to about 8. The alkylene radical is exemplified by ethylene, propylene, butylene, trimethylene, tetramethylene, pentamethylene, hexamethylene, octamethylene, etc. The number of amino groups generally, but not necessarily, is one greater than the number of alkylene radicals present in the amine, i.e., if a polyalkylene polyamine contains 3 alkylene radicals, it will usually contain 4 amino radicals. The number of amino radicals can range up to about 9. Preferably, the alkylene radical contains from about 2 to about 4 carbon atoms and all amine groups are primary or secondary. In this case, the number of amine groups exceeds the number of alkylene groups by 1. Preferably the polyalkylene polyamine contains from 3 to 5 amine groups. Specific examples of the polyalkylene polyamines include ethylenediamine, diethylenetriamine, triethylenetetramine, propylenediamine, tripropylenetetramine, tetraethylenepentamine, trimethylenediamine, pentaethylenehexamine, di(trimethylene)triamine, tri(hexamethylene)tetramine, etc.
Other amines suitable for preparing the alkenyl succinimide useful in this invention include the cyclic amines such as piperazine, morpholine and dipiperazines.
Preferably the alkenyl succinimides used in the compositions of this invention have the following formula: ##STR4## wherein:
a. R 1 represents an alkenyl group, preferably a substantially saturated hydrocarbon prepared by polymerizing aliphatic monoolefins. Preferably R 1 is prepared from isobutene and has an average number of carbon atoms and a number average molecular weight as described above;
b. the "Alkylene" radical represents a substantially hydrocarbyl group containing up to about 8 carbon atoms and preferably containing from about 2 to 4 carbon atoms as described hereinabove;
c. A represents a hydrocarbyl group, an amine-substituted hydrocarbyl group, or hydrogen. The hydrocarbyl group and the amine-substituted hydrocarbyl groups are generally the alkyl and amino-substituted alkyl analogs of the alkylene radicals described above. Preferably A represents hydrogen;
d. n represents an integer of from about 1 to 10, and preferably from about 3 to 5.
The amount of alkenyl succinimide can range from about 1% to about 20% by weight of the total lubricating oil composition. Preferably the amount of alkenyl succinimide present in the lubricating oil composition of the invention ranges from about 1% to about 10% by weight of the total composition.
The group II metal salts of dihydrocarbyl dithiophosphoric acids exhibit wear, antioxidant and thermal stability properties. Group II metal salts of phosphorodithioic acids have been described previously. See, for example, U.S. Pat. No. 3,390,080, columns 6 and 7, wherein these compounds and their preparation are described generally. Suitably, the Group II metal salts of the dihydrocarbyl dithiophosphoric acids useful in the lubricating oil composition of this invention contain from about 4 to about 12 carbon atoms in each of the hydrocarbyl radicals and may be the same or different and may be aromatic, alkyl or cycloalkyl. Preferred hydrocarbyl groups are alkyl groups containing from 4 to 8 carbon atoms and are represented by butyl, isobutyl, sec.-butyl, hexyl, isohexyl, octyl, 2-ethylhexyl and the like. The metals suitable for forming these salts include barium, calcium, strontium, zinc and cadmium, of which zinc is preferred.
Preferably, the Group II metal salt of a dihydrocarbyl dithiophosphoric acid has the following formula: ##STR5## wherein:
e. R 2 and R 3 each independently represent hydrocarbyl radicals as described above, and
f. M 1 represents a Group II metal cation as described above.
The dithiophosphoric salt is present in the lubricating oil compositions of this invention in an amount effective to inhibit wear and oxidation of the lubricating oil. The amount ranges from about 0.1% to about 4% by weight of the total composition, preferably the salt is present in an amount ranging from about 0.2% to about 2.5% by weight of the total lubricating oil composition. The final lubricating oil composition will ordinarily contain 0.025% to 0.25% by weight phosphorus and preferably 0.05% to 0.15% by weight.
The finished lubricating oil may be single or multigrade. Multigrade lubricating oils are prepared by adding viscosity index (VI) improvers. Typical viscosity index improvers are polyalkyl methacrylates, ethylene propylene copolymers, styrene diene copolymers and the like. So-called decorated VI improvers having both viscosity index and dispersant properties are also suitable for use in the formulations of this invention.
The lubricating oil used in the compositions of this invention may be mineral oil or in synthetic oils of viscosity suitable for use in the crankcase of an internal combustion engine. Crankcase lubricating oils ordinarily have a viscosity of about 1300 cst 0° F. to 22.7 cst at 210° F. (99° C.). The lubricating oils may be derived from synthetic or natural sources. Mineral oil for use as the base oil in this invention includes paraffinic, naphthenic and other oils that are ordinarily used in lubricating oil compositions. Synthetic oils include both hydrocarbon synthetic oils and synthetic esters. Useful synthetic hydrocarbon oils include liquid polymers of alpha olefins having the proper viscosity. Especially useful are the hydrogenated liquid oligomers of C 6-12 alpha olefins such as 1-decene trimer. Likewise, alkyl benzenes of proper viscosity such as didodecyl benzene, can be used. Useful synthetic esters include the esters of both monocarboxylic acid and polycarboxylic acids as well as monohydroxy alkanols and polyols. Typical examples are didodecyl adipate, pentaerythritol tetracaproate, di-2-ethylhexyl adipate, dilaurylsebacate and the like. Complex esters prepared from mixtures of mono and dicarboxylic acid and mono and dihydroxy alkanols can also be used.
Blends of hydrocarbon oils with synthetic oils are also useful. For example, blends of 10% to 25% by weight hydrogenated 1-decene trimer with 75% to 90% by weight 150 SUS (100° F.) mineral oil gives an excellent lubricating oil base.
Additive concentrates are also included within the scope of this invention. The concentrates of this invention usually include from about 80% to 10% by weight of an oil of lubricating viscosity and from about 20% to 90% by weight of the overbased additive of this invention. Typically, the concentrates contain sufficient diluent to make them easy to handle during shipping and storage. Suitable diluents for the concentrates include any inert diluent, preferably an oil of lubricating viscosity, so that the concentrate may be readily mixed with lubricating oils to prepare lubricating oil compositions. Suitable lubricating oils which can be used as diluents, typically have viscosities in the range from about 35 to about 500 Saybolt Universal Seconds (SUS) at 100° F. (38° C.), although an oil of lubricating viscosity may be used.
Other additives which may be present in the formulation include rust inhibitors, foam inhibitors, corrosion inhibitors, metal deactivators, pour point depressants, antioxidants, and a variety of other well-known additives.
The following examples are offered to specifically illustrate the invention. These examples and illustrations are not to be construed in any way as limiting the scope of the invention.
EXAMPLES
Example I
Preparation of Ortho-Carboxy Dialkylphenylphenone ##STR6##
(i) A mixture of di and tripropylene benzene, as prepared in U.S. Pat. No. 3,470,097 which is incorporated herein by reference, is alkylated with approximately 1 equivalent of a C 15 to C 20 cracked wax alpha-olefin mixture substantially as described in Example II(i) to give a dialkylbenzene having an average molecular weight of 390.
(ii) To a 3-liter 4-neck flask equipped with a stirrer, condensor, KOH trap, thermistor, and addition funnel, add 460 g of the dialkylbenzene of Example I(i) above, 170 g of phthalic anhydride and 710 ml of chlorobenzene. Slowly add anhydrous aluminum trichloride (400 g) to the system. After addition, heat the system to approximately 115° C. for 5 hours. Stop the reaction by adding cracked ice to the reaction system. Remove the aqueous layer and then strip the organic layer at 125° C. under reduced pressure. Dissolve the solid product in hot chlorobenzene and wash the solution with water. Filter the hot organic solution through a celite pad to give the title product.
Example II
Preparation of Ortho-Carboxy C 15 -C 18 Alkylcatecholphenone ##STR7##
(i) To a 3-liter flask, equipped with stirrer, Dean Stark trap, condensor and nitrogen inlet and outlet add 759 g of a mixture of C 15 to C 18 alpha-olefin, 330 g of pyrocatechol, 165 g of a sulfonic acid cation exchange resin (polystyrene cross-linked with divinyl-benzene) catalyst (Amberlyst 15® available from Rohm and Haas, Philadelphia, Pa.) and 240 ml toluene. Heat the reaction mixture to 150° C. to 160° C. for about 7 hours with stirring under a nitrogen atmosphere. Strip the reaction mixture by heating to 160° C. under vacuum (0.4 mm Hg). Filter the product hot over diatomaceous earth to afford a liquid C 15 to C 18 alkyl-substituted pyrocatechol.
(ii) To a 3-liter 4-neck flask equipped with a stirrer, condensor, KOH trap, thermistor, and addition funnel, add 392 g of a C 15 -C 18 alkylcatechol, 170 g of phthalic anhydride and 710 ml of chlorobenzene. Slowly add anhydrous aluminum trichloride (400 g) to the system. After addition, heat the system to approximately 115° C. for 5 hours. Stop the reaction by adding cracked ice to the reaction system. Remove the aqueous layer and then strip the organic layer at 125° C. under reduced pressure. Dissolve the solid product in hot chlorobenzene and wash the solution with water. Filter the hot organic solution through a celite pad to give the title compound.
Similarly, the following compounds may be substituted at the appropriate stiochiometric amount for the dialkylbenzene in Example I or the C 15 -C 18 alkylcatechol in Example II to yield suitable ortho-carboxy phenylphenones for this invention:
TABLE I
C 15 -C 20 alkylbenzene; C 15 -C 20 alkyltoluene; C 15 -C 20 alkylphenol; p-stearylcatechol; decylbenzene; C 15 -C 18 alkylresorcinol; C 15 -C 18 alkylhydroquinone; C 24 -C 28 alkylcatehol; C 16 alkylcatechol; C 24 -C 28 alkylphenol; C 15 -C 18 alkylxylenol; p-dodecylphenol; p-dodecyltoluene; di-C 15 -C 18 alkylbenzene; tri-C 15 -C 18 alkylbenzene; and C 15 -C 18 alkylbenzene.
Likewise, hydroxy substituted phthalic anhydride may be substituted for phthalic anhydride in Examples I and II above to yield suitable ortho-carboxy phenylphenones for use in this invention.
Example III
Preparation of Calcium Ortho-Carboxy Dialkylphenylphenone
(a) By metathesis
(i) Add 274 g of ortho-carboxy dialkylphenylphenone of Example I above to 300 ml of 250 thinner. Add dropwise, with cooling if necessary, 200 ml of a 25% by weight sodium hydroxide aqueous solution. Stir the system for one hour. Strip the system of solvent at elevated temperature and reduced pressure to recover sodium ortho-carboxy dialkylphenylphenone.
(ii) Add 240 ml of a 20% weight calcium chloride aqueous solution to the sodium ortho-carboxy dialkylphenylphenone of Example III(i) above. Shake the mixture. After allowing the system to settle, remove the aqueous layer. Repeat this process addition of calcium chloride, twice more. Afterwards, strip the remaining solvent from the calcium ortho-carboxy dialkylphenylphenone at 180° C. and reduced pressure to yield the title compound.
(b) By direct neutralization
Prepare a solution of calcium hydride by 12.6 g calcium hydride to 200 ml of tetrahydrofuran. Over 1 hour, add 115 g (0.25 mole) of ortho-carboxy C 15 -C 18 alkylcatecholphenone of Example II in 200 ml of tetrahydrofuran to the calcium hydride solution while venting byproduct gases. Filter the mixture over celite. Strip the solvent to yield the title compound.
By following the process of Example III(a)(i), similarly prepare the potassium salt. By following the procedure of either Example III(a)(ii) or III(b), similarly prepare the magnesium or barium salt of C--C of ortho-carboxy phenylphenone and of ortho-carboxy C 15 -C 18 alkylcatechol and the compounds listed in Table I of ortho-carboxy phenylphenone.
Example IV
Preparation of an Overbased Product of Example I by Treatment With CO 2 and Calcium Hydroxide
Preparation (a)
To a 2-liter 5-neck flask equipped with a thermistor, a gas inlet with a flow meter, dropping funnel, and condensor, add 200 g of the dialkylphenylphenone of Example I, 36 g of tridecyl alcohol, 18 g of an alkenyl succinimide (prepared by reacting polyisobutenyl succinic anhydride of average MW=950 with 0.87 equivalents of tetraethylenepentaamine), 27 g of Triton X-3®--a polyethylene glycol p-isooctylphenyl ether available from Rhom and Haas, Philadelphia, Pa., and 300 g of Cit-Con 100N oil. Heat the system to 90° C. and then slowly add 240 g of calcium hydroxide to the system. After addition of the calcium hydroxide, heat the system to 150° C. and then add 150 g ethylene glycol over a 45-minute period.
Heat the system at 160° C. for 90 minutes while distilling off any volatile components. Over a period of approximately 40 hours, add 300 g of carbon dioxide. Afterwards, cool the system to room temperature and filter, if necessary. Remove only volatiles by stripping at 150° C. and reduced pressure to yield the title compound having an AV of 376 mg KOH per gram.
Preparation (b)
To a 1-liter 4-neck flask equipped with a thermistor, a gas inlet with a flow meter, dropping funnel, and condensor, add 150 g of the dialkylphenylphenone of Example I, 27 g of decyl alcohol, 13.5 g of an alkenyl succinimide (prepared by reacting polyisobutenyl succinic anhydride of average MW=950 with 0.87 equivalents of tetraethylenepentaamine), 20.4 g of Triton X-35®--a polyethylene glycol p-isooctylphenol ether available from Rohm and Haas, Philadelphia, Pa., and 30 g of Cit-Con 100N oil. Heat the system to 90° C. and then slowly add 70 g calcium hydroxide to the system. After addition of the calcium hydroxide, heat the system to 150° C. and then add 45 g ethylene glycol over a 45-minute period. Heat the system at 160° C. for one hour, then for one hour at 170° C. while distilling off any volatile components. Over a period of 5 hours, add 101 g of carbon dioxide. Afterwards, cool the system to room temperature. Remove any volatiles by stripping at 150° C. and reduced pressure to yield the title compound having an AV of 264 mg KOH per gram.
Example V
Preparation of an Overbased Product of Example III
To a 1-liter 4-neck flask equipped with a thermistor, a gas inlet with a flow meter, dropping funnel, and condensor, add 163 g of the calcium dialkylphenylphenone of Example III, 27 g of decyl alcohol, 13.5 g of an alkenyl succinimide (prepared by reacting polyisobutenyl succinic anhydride of average MW=950 with 0.87 equivalents of tetraethylenepentaamine), 20.4 g of Triton X-35®--a polyethylene glycol p-isooctylphenol ether available from Rohm and Haas, Philadelphia, Pa., and 30 g of Cit-Con 100N oil. Heat the system to 90° C. and then slowly add 70 g calcium hydroxide to the system. After addition of the calcium hydroxide, heat the system to 150° C. and then add 45 g ethylene glycol over a 45-minute period. Heat the system at 160° C. for one hour, then for one hour at 170° C. while distilling off any volatile components. Over a period of 5 hours, add 101 g of carbon dioxide. Afterwards, cool the system to room temperature. Remove any volatiles by stripping at 150° C. and reduced pressure to yield the title compound.
Similarly, by following the process of Examples IV and V, the following ortho-carboxy phenylphenones may be substituted for either the dialkylphenylphenone or calcium dialkylphenylphenone:
TABLE II
ortho-carboxy C 15 -C 18 alkylphenylphenones;
calcium ortho-carboxy C 15 -C 18 alkylphenones;
barium ortho-carboxy C 15 -C 18 alkylphenone;
magnesium ortho-carboxy C 15 -C 18 alkylphenone;
sodium ortho-carboxy C 15 -C 18 alkylphenone;
potassium ortho-carboxy C 15 -C 18 alkylphenone;
ortho-carboxy C 15 -C 18 alkylcatechol phenone;
calcium ortho-carboxy C 15 -C 18 alkylcatechol phenone;
ortho-carboxy C 24 -C 28 alkylcatechol phenone;
calcium ortho-carboxy C 24 -C 28 alkylcatechol phenone;
ortho-carboxy di-C 15 -C 18 alkylphenyl phenone;
ortho-carboxy tri-C 15 -C 18 alkylphenylphenone; and
magnesium ortho-carboxy decylphenylphenone;
Likewise, the following basically reacting metals may be employed in place of calcium hydroxide for the purpose of overbasing the ortho-carboxy phenylphenones employed in Examples IV and V above or those listed in Table II: calcium oxide, methoxide, ethoxide, n-propoxide, or iso-propoxide; magnesium oxide, hydroxide, methoxide, ethoxide, n-propoxide, or iso-propoxide; and barium oxide, or hydroxide; sodium hydroxide, methoxide, ethoxide, n-propoxide, or isopropoxide; potassium hydroxide, methoxide, ethoxide, n-propoxide, or iso-propoxide.
Example VI
An overbased product similar to that of Example IV was tested in a Caterpillar 1-G2 test in which a single-cylinder diesel engine having a 5-1/8" bore by 6-1/2" stroke is operated under the following conditions: timing, degrees BTDC, 8; brake mean effective pressure, psi 141; brake horsepower 42; Btu's per minute 5850: speed, 1800 RPM; air boost, 53" HG absolute, air temperature in, 255° C.; water temperature out, 190° F.; and sulfur in fuel, 0.4%w. At the end of each 12 hours of operation, sufficient oil is drained from the crackcase to allow addition of 1 quart of new oil. In the test on the lubricating oil compositions of this invention, the 1-G2 test is run for 60 hours. At the end of the noted time period, the engine is dismantled and rated for cleanliness. The Institute of Petroleum Test Number 247/69 merit rating system for engine wear and cleanliness, accepted by ASTM, API, and SAE, is the rating system used to evaluate the engine. The overall cleanliness is noted as WTD, which is the summation of the above numbers. Lower values represent cleaner engines.
The results of this test were compared against a reference oil without the overbased ortho-carboxy phenylphenone additives. The results indicated that the additives of this invention are useful lubricating oil additives.
|
Disclosed are overbased ortho-carboxy phenylphenones. The overbased ortho-carboxy phenylphenones provide detergency for the lubricating oil additionally providing an alkaline reserve.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION(S)
This application is a division of U.S. patent application Ser. No. 09/821,240, filed on Mar. 29, 2001 now U.S. Pat. No. 6,357,107, which is a division of U.S. patent application Ser. No. 09/350,601, filed on Jul. 9, 1999, now issued as U.S. Pat. No. 6,240,622, the specifications of which are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to inductors, and more particularly, it relates to inductors used with integrated circuits.
BACKGROUND OF THE INVENTION
Inductors are used in a wide range of signal processing systems and circuits. For example, inductors are used in communication systems, radar systems, television systems, highpass filters, tank circuits, and butterworth filters.
As electronic signal processing systems have become more highly integrated and miniaturized, effectively signal processing systems on a chip, system engineers have sought to eliminate the use of large, auxiliary components, such as inductors. When unable to eliminate inductors in their designs, engineers have sought ways to reduce the size of the inductors that they do use.
Simulating inductors using active circuits, which are easily miniaturized, is one approach to eliminating the use of actual inductors in signal processing systems. Unfortunately, simulated inductor circuits tend to exhibit high parasitic effects, and often generate more noise than circuits constructed using actual inductors.
Inductors are miniaturized for use in compact communication systems, such as cell phones and modems, by fabricating spiral inductors on the same substrate as the integrated circuit to which they are coupled using integrated circuit manufacturing techniques. Unfortunately, spiral inductors take up a disproportionately large share of the available surface area on an integrated circuit substrate.
For these and other reasons there is a need for the present invention.
SUMMARY OF THE INVENTION
The above mentioned problems and other problems are addressed by the present invention and will be understood by one skilled in the art upon reading and studying the following specification. An integrated circuit inductor compatible with integrated circuit manufacturing techniques is disclosed.
In one embodiment, an inductor capable of being fabricated from a plurality of conductive segments and interwoven with a substrate is disclosed. In an alternate embodiment, a sense coil capable of measuring the magnetic field or flux produced by an inductor comprised of a plurality of conductive segments and fabricated on the same substrate as the inductor is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cutaway view of some embodiments of an inductor of the present invention.
FIG. 1B is a top view of some embodiments of the inductor of FIG. 1 A.
FIG. 1C is a side view of some embodiments of the inductor of FIG. 1 A.
FIG. 2 is a cross-sectional side view of some embodiments of a highly conductive path including encapsulated magnetic material layers.
FIG. 3A is a perspective view of some embodiments of an inductor and a spiral sense inductor of the present invention.
FIG. 3B is a perspective view of some embodiments of an inductor and a non-spiral sense inductor of the present invention.
FIG. 4 is a cutaway perspective view of some embodiments of a triangular coil inductor of the present invention.
FIG. 5 is a top view of some embodiments of an inductor coupled circuit of the present invention.
FIG. 6 is diagram of a drill and a laser for perforating a substrate.
FIG. 7 is a block diagram of a computer system in which embodiments of the present invention can be practiced.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
FIG. 1A is a cutaway view of some embodiments of inductor 100 of the present invention. Inductor 100 includes substrate 103 , a plurality of conductive segments 106 , a plurality of conductive segments 109 , and magnetic film layers 112 and 113 . The plurality of conductive segments 109 interconnect the plurality of conductive segments 106 to form highly conductive path 114 interwoven with substrate 103 . Magnetic film layers 112 and 113 are formed on substrate 103 in core area 115 of highly conductive path 114 .
Substrate 103 provides the structure in which highly conductive path 114 that constitutes an inductive coil is interwoven. Substrate 103 , in one embodiment, is fabricated from a crystalline material. In another embodiment, substrate 103 is fabricated from a single element doped or undoped semiconductor material, such as silicon or germanium. Alternatively, substrate 103 is fabricated from gallium arsenide, silicon carbide, or a partially magnetic material having a crystalline or amorphous structure. Substrate 103 is not limited to a single layer substrate. Multiple layer substrates, coated or partially coated substrates, and substrates having a plurality of coated surfaces are all suitable for use in connection with the present invention. The coatings include insulators, ferromagnetic materials, and magnetic oxides. Insulators protect the inductive coil and separate the electrically conductive inductive coil from other conductors, such as signal carrying circuit lines. Coatings and films of ferromagnetic materials, such as magnetic metals, alloys, and oxides, increase the inductance of the inductive coil.
Substrate 103 has a plurality of surfaces 118 . The plurality of surfaces 118 is not limited to oblique surfaces. In one embodiment, at least two of the plurality of surfaces 118 are parallel. In an alternate embodiment, a first pair of parallel surfaces are substantially perpendicular to a second pair of surfaces. In still another embodiment, the surfaces are planarized. Since most integrated circuit manufacturing processes are designed to work with substrates having a pair of relatively flat or planarized parallel surfaces, the use of parallel surfaces simplifies the manufacturing process for forming highly conductive path 114 of inductor 100 .
Substrate 103 has a plurality of holes, perforations, or other substrate subtending paths 121 that can be filled, plugged, partially filed, partially plugged, or lined with a conducting material. In FIG. 1A, substrate subtending paths 121 are filled by the plurality of conducting segments 106 . The shape of the perforations, holes, or other substrate subtending paths 121 is not limited to a particular shape. Circular, square, rectangular, and triangular shapes are all suitable for use in connection with the present invention. The plurality of holes, perforations, or other substrate subtending paths 121 , in one embodiment, are substantially parallel to each other and substantially perpendicular to substantially parallel surfaces of the substrate.
Highly conductive path 114 is interwoven with a single layer substrate or a multilayer substrate, such as substrate 103 in combination with magnetic film layers 112 and 113 , to form an inductive element that is at least partially embedded in the substrate. If the surface of the substrate is coated, for example with magnetic film 112 , then conductive path 114 is located at least partially above the coating, pierces the coated substrate, and is interlaced with the coated substrate.
Highly conductive path 114 has an inductance value and is in the shape of a coil. The shape of each loop of the coil interlaced with the substrate is not limited to a particular geometric shape. For example, circular, square, rectangular, and triangular loops are suitable for use in connection with the present invention.
Highly conductive path 114 , in one embodiment, intersects a plurality of substantially parallel surfaces and fills a plurality of substantially parallel holes. Highly conductive path 114 is formed from a plurality of interconnected conductive segments. The conductive segments, in one embodiment, are a pair of substantially parallel rows of conductive columns interconnected by a plurality of conductive segments to form a plurality of loops.
Highly conductive path 114 , in one embodiment, is fabricated from a metal conductor, such as aluminum, copper, or gold or an alloy of a such a metal conductor. Aluminum, copper, or gold, or an alloy is used to fill or partially fill the holes, perforations, or other paths subtending the substrate to form a plurality of conductive segments. Alternatively, a conductive material may be used to plug the holes, perforations, or other paths subtending the substrate to form a plurality of conductive segments. In general, higher conductivity materials are preferred to lower conductivity materials. In one embodiment, conductive path 114 is partially diffused into the substrate or partially diffused into the crystalline structure.
For a conductive path comprised of segments, each segment, in one embodiment, is fabricated from a different conductive material. An advantage of interconnecting segments fabricated from different conductive materials to form a conductive path is that the properties of the conductive path are easily tuned through the choice of the conductive materials. For example, the internal resistance of a conductive path is increased by selecting a material having a higher resistance for a segment than the average resistance in the rest of the path. In an alternate embodiment, two different conductive materials are selected for fabricating a conductive path. In this embodiment, materials are selected based on their compatibility with the available integrated circuit manufacturing processes. For example, if it is difficult to create a barrier layer where the conductive path pierces the substrate, then the conductive segments that pierce the substrate are fabricated from aluminum. Similarly, if it is relatively easy to create a barrier layer for conductive segments that interconnect the segments that pierce the substrate, then copper is used for these segments.
Highly conductive path 114 is comprised of two types of conductive segments. The first type includes segments subtending the substrate, such as conductive segments 106 . The second type includes segments formed on a surface of the substrate, such as conductive segments 109 . The second type of segment interconnects segments of the first type to form highly conductive path 114 . The mid-segment cross-sectional profile 124 of the first type of segment is not limited to a particular shape. Circular, square, rectangular, and triangular are all shapes suitable for use in connection with the present invention. The mid-segment cross-sectional profile 127 of the second type of segment is not limited to a particular shape. In one embodiment, the mid-segment cross-sectional profile is rectangular. The coil that results from forming the highly conductive path from the conductive segments and interweaving the highly conductive path with the substrate is capable of producing a reinforcing magnetic field or flux in the substrate material occupying the core area of the coil and in any coating deposited on the surfaces of the substrate.
FIG. 1B is a top view of FIG. 1A with magnetic film 112 formed on substrate 103 between conductive segments 109 and the surface of substrate 103 . Magnetic film 112 coats or partially coats the surface of substrate 103 . In one embodiment, magnetic film 112 is a magnetic oxide. In an alternate embodiment, magnetic film 112 is one or more layers of a magnetic material in a plurality of layers formed on the surface of substrate 103 .
Magnetic film 112 is formed on substrate 103 to increase the inductance of highly conductive path 114 . Methods of preparing magnetic film 112 include evaporation, sputtering, chemical vapor deposition, laser ablation, and electrochemical deposition. In one embodiment, high coercivity gamma iron oxide films are deposited using chemical vapor pyrolysis. When deposited at above 500 degrees centigrade these films are magnetic gamma oxide. In an alternate embodiment, amorphous iron oxide films are prepared by the deposition of iron metal in an oxygen atmosphere (10 −4 torr) by evaporation. In another alternate embodiment, an iron-oxide film is prepared by reactive sputtering of an Fe target in Ar+O 2 atmosphere at a deposition rate of ten times higher than the conventional method. The resulting alpha iron oxide films are then converted to magnetic gamma type by reducing them in a hydrogen atmosphere.
FIG. 1C is a side view of some embodiments of the inductor of FIG. 1A including substrate 103 , the plurality of conductive segments 106 , the plurality of conductive segments 109 and magnetic films 112 and 113 .
FIG. 2 is a cross-sectional side view of some embodiments of highly conductive path 203 including encapsulated magnetic material layers 206 and 209 . Encapsulated magnetic material layers 206 and 209 , in one embodiment, are a nickel iron alloy deposited on a surface of substrate 212 . Formed on magnetic material layer layers 206 and 209 are insulating layers 215 and 218 and second insulating layers 221 and 224 which encapsulate highly conductive path 203 deposited on insulating layers 215 and 218 . Insulating layers 215 , 218 , 221 and 224 , in one embodiment are formed from an insulator, such as polyimide. In an alternate embodiment, insulating layers 215 , 218 , 221 , and 224 are an inorganic oxide, such as silicon dioxide or silicon nitride. The insulator may also partially line the holes, perforations, or other substrate subtending paths. The purpose of insulating layers 215 and 218 , which in one embodiment are dielectrics, is to electrically isolate the surface conducting segments of highly conductive path 203 from magnetic material layers 206 and 209 . The purpose of insulating layers 221 and 224 is to electrically isolate the highly conductive path 203 from any conducting layers deposited above the path 203 and to protect the path 203 from physical damage.
The field created by the conductive path is substantially parallel to the planarized surface and penetrates the coating. In one embodiment, the conductive path is operable for creating a magnetic field within the coating, but not above the coating. In an alternate embodiment, the conductive path is operable for creating a reinforcing magnetic field within the film and within the substrate.
FIG. 3 A and FIG. 3B are perspective views of some embodiments of inductor 301 and sense inductors 304 and 307 of the present invention. In one embodiment, sense inductor 304 is a spiral coil and sense inductor 307 is a test inductor or sense coil embedded in the substrate. Sense inductors 304 and 307 are capable of detecting and measuring reinforcing magnetic field or flux 309 generated by inductor 301 , and of assisting in the calibration of inductor 301 . In one embodiment, sense inductor 304 is fabricated on one of the surfaces substantially perpendicular to the surfaces of the substrate having the conducting segments, so magnetic field or flux 309 generated by inductor 301 is substantially perpendicular to sense inductor 304 . Detachable test leads 310 and 313 in FIG. 3 A and detachable test leads 316 and 319 in FIG. 3B are capable of coupling sense inductors 304 and 307 to sense or measurement circuits. When coupled to sense or measurement circuits, sense inductors 304 and 307 are decoupled from the sense or measurement circuits by severing test leads 310 , 313 , 316 , and 319 . In one embodiment, test leads 310 , 313 , 316 , and 316 are severed using a laser.
In accordance with the present invention, a current flows in inductor 301 and generates magnetic field or flux 309 . Magnetic field or flux 309 passes through sense inductor 304 or sense inductor 307 and induces a current in spiral sense inductor 304 or sense inductor 307 . The induced current can be detected, measured and used to deduce the inductance of inductor 301 .
FIG. 4 is a cutaway perspective view of some embodiments of triangular coil inductor 400 of the present invention. Triangular coil inductor 400 comprises substrate 403 and triangular coil 406 . An advantage of triangular coil inductor 400 is that it saves at least a process step over the previously described coil inductor. Triangular coil inductor 400 only requires the construction of three segments for each coil of inductor 400 , where the previously described inductor required the construction of four segments for each coil of the inductor.
FIG. 5 is a top view of some embodiments of an inductor coupled circuit 500 of the present invention. Inductor coupled circuit 500 comprises substrate 503 , coating 506 , coil 509 , and circuit or memory cells 512 . Coil 509 comprises a conductive path located at least partially above coating 506 and coupled to circuit or memory cells 512 . Coil 509 pierces substrate 503 , is interlaced with substrate 503 , and produces a magnetic field in coating 506 . In an alternate embodiment, coil 509 produces a magnetic field in coating 506 , but not above coating 506 . In one embodiment, substrate 503 is perforated with a plurality of substantially parallel perforations and is partially magnetic. In an alternate embodiment, substrate 503 is a substrate as described above in connection with FIG. 1 . In another alternate embodiment, coating 506 is a magnetic film as described above in connection with FIG. 1 . In another alternate embodiment, coil 509 , is a highly conductive path as described in connection with FIG. 1 .
FIG. 6 is a diagram of a drill 603 and a laser 606 for perforating a substrate 609 . Substrate 609 has holes, perforations, or other substrate 609 subtending paths. In preparing substrate 609 , in one embodiment, a diamond tipped carbide drill is used bore holes or create perforations in substrate 609 . In an alternate embodiment, laser 606 is used to bore a plurality of holes in substrate 609 . In a preferred embodiment, holes, perforations, or other substrate 609 subtending paths are fabricated using a dry etching process.
FIG. 7 is a block diagram of a system level embodiment of the present invention. System 700 comprises processor 705 and memory device 710 , which includes memory circuits and cells, electronic circuits, electronic devices, and power supply circuits coupled to inductors of one or more of the types described above in conjunction with FIGS. 1A-5. Memory device 710 comprises memory array 715 , address circuitry 720 , and read circuitry 730 , and is coupled to processor 705 by address bus 735 , data bus 740 , and control bus 745 . Processor 705 , through address bus 735 , data bus 740 , and control bus 745 communicates with memory device 710 . In a read operation initiated by processor 705 , address information, data information, and control information are provided to memory device 710 through busses 735 , 740 , and 745 . This information is decoded by addressing circuitry 720 , including a row decoder and a column decoder, and read circuitry 730 . Successful completion of the read operation results in information from memory array 715 being communicated to processor 705 over data bus 740 .
CONCLUSION
Embodiments of inductors and methods of fabricating inductors suitable for use with integrated circuits have been described. In one embodiment, an inductor having a highly conductive path fabricated from a plurality of conductive segments, and including coatings and films of ferromagnetic materials, such as magnetic metals, alloys, and oxides has been described. In another embodiment, an inductor capable of being fabricated from a plurality of conductors having different resistances has been described. In an alternative embodiment, an integrated test or calibration coil capable of being fabricated on the same substrate as an inductor and capable of facilitating the measurement of the magnetic field or flux generated by the inductor and capable of facilitating the calibration the inductor has been described.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
|
The invention relates to an inductor comprising a plurality of interconnected conductive segments interwoven with a substrate. The inductance of the inductor is increased through the use of coatings and films of ferromagnetic materials such as magnetic metals, alloys, and oxides. The inductor is compatible with integrated circuit manufacturing techniques and eliminates the need in many systems and circuits for large off chip inductors. A sense and measurement coil, which is fabricated on the same substrate as the inductor, provides the capability to measure the magnetic field or flux produced by the inductor. This on chip measurement capability supplies information that permits circuit engineers to design and fabricate on chip inductors to very tight tolerances.
| 8
|
The invention herein described was made in the course of or under a contract, or a subcontract thereunder, with the United States Department of the Air Force.
BACKGROUND OF THE INVENTION
This invention relates generally to lubrication systems and, more particularly, to emergency oil supply systems for gas turbine engines.
Typically, the high pressure and low pressure shafts of a gas turbine engine are supported by three main bearings each of which is cooled and lubricated by a constant flow of oil from a main supply system. Generally, oil is gravity fed from a main supply tank to the supply pump which then provides oil under pressure through a filter to the bearings. The oil which is sprayed on the bearings collects in sumps below and gravity drains into scavenge pumps which return the oil to the main supply tank.
Since the main oil pump is gravity fed from the oil tank, the oil supply to the pump can be disrupted to starve the pump whenever a maneuver of the aircraft causes a deviation of the engine from its normal upright position. For example, during inverted flight conditions, all of the oil flows to the ceiling of the oil tank and the main oil pump will supply air only. Another maneuver which disrupts the normal gravity feed procedure is when the aircraft is operating in a negative gravity condition. Again, the main lube pump will supply only air. Failure of the main lube supply pump or other components of the supply system can also disrupt the flow of oil to the bearings.
Some bearing applications are capable of withstanding such temporary oil interruptions without resultant overheating and failure. However, there are other bearings which are exposed to more extreme operating conditions and which cannot meet the requirements of withstanding such unavoidable lube oil interruptions. One of the parameters which relates to a bearing's ability to withstand short periods of dry operation is its so-called "DN value," which represents the bore size and associated shaft speed. For example, a bearing for a high-speed core rotor will have a higher DN value and will be less capable of running dry than will a low pressure turbine shaft which necessarily has a lower DN value. Another factor which may affect this ability is the heat transfer characteristics of the housing which surrounds the bearing. For example, while a housing made of titanium material is preferable for weight purposes, the poor heat transfer characteristics make is less desirable from the standpoint of retaining the bearing heat.
It is therefore an object of the present invention to provide a means by which a high speed core rotor shaft bearing can withstand periods of oil interruption.
Another object of the present invention is the provision in lubrication systems for supplying oil to a bearing during periods of negative-G operating conditions.
Yet another object of the present invention is the provision for augmenting a gravity feed lube oil system during periods of negative-G operating conditions and during periods in which the engine is operating in the inverted position.
Still another object of the present invention is to provide an emergency lube oil supply without significantly modifying the existing systems.
Still another object of the present invention is to provide an emergency lube oil system which is economical and effective in use.
These objects and other features and advantages become more readily apparent upon reference to the following description when taken in conjunction with the appended drawings.
SUMMARY OF THE INVENTION
Briefly, in accordance with one aspect of the invention, an auxiliary lube oil line is installed to provide fluid communication between an existing hydraulic tank and the bearing to be lubricated. A pump which is constantly making up oil to the hydraulic tank from the main lube tank tends to keep the hydraulic tank full and under pressure at all times including during periods of negative-G operation. Whenever there is an interruption of the oil flow from the main lube tank to the bearing, a valve in the auxiliary oil line is opened to provide oil to the bearing on a temporary emergency basis.
By another aspect of the invention, check valves are placed in the system on either side of the bearing to be lubricated, one in the line from the main lube tank and one from the line from the hydraulic tank. When the pressure in the main oil supply line is lost, the check valve in that line will close to prevent oil from flowing to the remaining engine components, while at the same time the pressure in the hydraulic tank will open the valve in the auxiliary line and allow the oil to flow to the bearing. If normal operation is subsequently restored, the sequence is reversed and the hydraulic tank will be replenished by the make-up system.
In the drawings as hereinafter described, the preferred embodiment is depicted; however, various other modifications and alternative constructions can be made thereto without departing from the true spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the lube oil system incorporating the auxiliary oil supply system of the present invention.
FIG. 2 is an end view of the lubrication loop portion of the invention with a portion thereof being sectioned to illustrate internal parts thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Typically, an aircraft engine has three bearing support structures or frames, the front frame, the fan frame and the turbine frame, each of which contains one or more bearings for supporting the rotating system. Shown in FIG. 1 is the bearing structures and rotating elements which are associated with the fan frame portion of the engine which provides support for both the fan rotor and for the high pressure rotor. The low pressure rotor shaft 11 which is connected to the fan rotor at its forward end and the low pressure rotor at the aft end receives partial support from the No. 2 bearing 12, a ball thrust bearing which supports the rear of the fan rotor 13 and the front of the low pressure shaft 11 in the fan frame. The outer race of the No. 2 bearing 12 has an antirotation pin 14 to prevent rotation thereof and the inner race rotates with the fan rotor 13 at a relatively low speed as compared with the high pressure rotor shaft. Lubrication is provided to the No. 2 bearing by the forward and rear oil jets, 16 and 17, respectively, which receive lubrication oil along line 18 in a manner described hereinafter. A bearing housing 19 surrounds the No. 2 bearing 12 and an oil/air seal 21 prevents the leakage of oil around the rotating parts while the lubrication oil is returned by way of a sump to the lubrication oil pump. Oil from the rear sump is returned by way of scavenge line 22.
The No. 3 bearing 26 is a ball-thrust bearing located in the fan frame which provides support to the front of the high pressure rotor shaft 27 and carries the thrust load of the high pressure rotor. A bearing housing 28 surrounds the No. 3 bearing and oil/air seals 29 prevent lubrication oil from leaking around the rotating parts. Lubrication is provided to the No. 3 bearing by way of the line 31 from the main lube tank, a lubrication loop 32, a forward oil jet 33 and an aft jet (not shown). The oil is supplied directly to the bearing and drains by gravity from the sump into the gearbox where it then returns to the main oil tank in a manner to be described hereinafter.
Lubrication oil is supplied from a combination lubrication/hydraulic oil tank which is shown in the bottom of FIG. 1 and is of the type described in U.S. Pat. No. 3,612,083, issued on Oct. 12, 1971 and assigned to the assignee of the present invention. The tank comprises an outer shell or housing 34 having an internal wall member 36 which divides the housing into two compartments, a lube oil compartment 30 and a hydraulic oil compartment 35. The tank is formed with an inlet 37 and an outlet 38 for connection of compartment 30 with a fluid system such as an aircraft engine lubrication system having a lube supply pump 39 and a scavenge pump 41. In like manner, an inlet 42 and an outlet 43 are provided to connect compartment 35 with the fluid system of an aircraft engine hydraulic system having a hydraulic return pump 44 and a hydraulic supply pump 46. A de-aerator tank 47 provides for the separating of the air from the oil when it returns to the tank inlet 37. The oil comes into the conduit 48 and into a jet pump 49 where a high velocity vortical or cyclonic flow is induced. The resulting separated air is then vented through a port 51 to a tank outlet 52, and the de-aerated oil passes out the tangential outlet 53, the conduit or standpipe 54 to the outlet 38. It will be noted that the tangential outlet 53 telescopes over the standpipe 54 so that when the tank is disposed in a nose-down attitude, tangential velocity of the de-aerated oil effluxing from the tangential outlet 53 is sufficient to force the oil to the pump 39. The air space above the oil is suitably vented to the tank outlet 52 through a conduit 55 having a vent port 60 which is closable by gravity valve means 65.
In order to ensure that a sufficient quantity of oil is delivered to the pump 39 when the tank is disposed in the nose-down attitude, the discharge from the tangential outlet should preferably exceed the requirements of the pump 39. To this end, the jet pump 49 acts to pump oil from the compartment 30 into the de-aerator tank 47 through a lube make-up conduit 56 so as to maintain a sufficient supply of oil to the tangential outlet 53.
It will be recognized, however, that when the aircraft is in a negative-G situation or in an inverted position, the oil will not be in the bottoms of the sumps and will therefore not be picked up by the scavenge pumps 41. Accordingly, there will be no oil returned by way of the conduit 48 and therefore the pump 49 will not work to make up oil along the conduit 56. This is one of the operating conditions to which the present invention relates.
Referring now to the hydraulic compartment 35, an inlet conduit 57 carries oil from the inlet 42, through a jet pump 58 and into the compartment 35, and a feed conduit 59 carries hydraulic oil from the compartment 35 to the outlet 43. The jet pump 58 acts (under predetermined conditions of pressure) to automatically pump oil from the lubrication compartment 30 into the hydraulic compartment 35 by way of conduit 61 to maintain a predetermined level of fluid in the hydraulic compartment.
As part of the system which maintains a predetermined level of oil in the hydraulic compartment 35, a valve means 62 is provided to include a float 63 adapted to open and close a valve port 64 which communicates with the hydraulic compartment 35 by way of a passage 66 so as to vent the compartment 35 and establish a predetermined oil level within the compartment during normal level flight operation.
In operation, when the flow of the hydraulic fluid through conduit 59 exceeds the return flow through conduit 57, thereby reducing the fluid level and pressure level within the compartment 35, return fluid is pumped by way of conduit 61 through the jet pump 58 to the compartment 35. During this period the oil level in compartment 35 is at a reduced level so that the valve port 64 is open to allow a venting of the compartment 35. When the oil reaches the predetermined level at which the float 63 closes the port 64, the backpressure in the compartment 35 will be sufficient to prevent pumping action by the pump 58 and the volume of oil in the compartment 35 will remain constant until a demand is made of it from the feed conduit 59 at which time the float 63 will open the port and the process will be repeated. In this way, the hydraulic compartment 35 is maintained with a full supply of oil at all times.
In order to prevent inadvertent fluid exchange between the compartments 30 and 35 during nose-up and nose-down attitudes and during inverted flight or negative-G conditions, suitable gravity valve means 67 is provided to include an inlet valve port 68, an outlet valve port 69 in series flow communication with the valve port 64 and a suitable closure member 71 adapted to close port 68 during inverted flight or negative-G conditions and close port 69 when the tank is in the nose-up attitude. A suitable standpipe or conduit 72 extends from the valve port 69 to a position which would be above the oil level in compartment 30 when the tank is in the nose-down attitude so as to prevent fluid exchange during this condition.
Also communicating with the hydraulic compartment 35 is a standpipe 73 extending upwardly into the compartment 35 and having at its base a check valve 74 which leads to the auxiliary lubrication oil line 76 and to the oil loop 32. Referring now to FIG. 2, the oil loop 32 is shown to comprise a semicircular conduit 77 having an inlet end 78 and a first discharge port 79 with associated bracket 81. During normal operation, lube oil passes from the discharge port 79 to the gearbox and to the aft oil jets for the No. 3 bearing. Fluidly communicating with the other end of the conduit 77 is a check valve 82 which is installed in a receptacle 83 whose port 84 fluidly communicates with the No. 3 bearing as shown by the arrows. For purposes of description, the check valve shown is one having a spring 86 and associated ball 87 which engages a port 88 to close the valve 82 from flow in either direction during predetermined conditions. Leading into the other end of the receptacle 83 is another semicircular conduit 89 which fluidly connects to the receptacle port 84 from line 76 by way of the connector 91. This conduit 89 comes into use only during emergency periods when lubrication oil is not being supplied to the conduit 77 for one reason or another.
In operation, when there is a sufficient amount of oil in the lower part of the lubrication compartment 30, the lube supply pump 39 supplies oil to line 92 and hence to the lines 18 and 31 where it is in turn supplied to the Nos. 2 and 3 bearings, respectively. As the oil enters from line 31 to the semicircular conduit 77, the pressure pushes the ball 87 against the spring 86 and opens the port 88 to allow oil to flow through the port 84 to the No. 3 bearing. At the same time, oil flows into the conduit 89 and the auxiliary lubrication line 76 where it exerts pressure against the ball 93 of the check valve 74. In this way the check valve 74 prevents lube oil from entering the hydraulic compartment 35 by way of the line 76, and the pressure in the valve 74 prevents the hydraulic oil pressure in the compartment 35 from opening the check valve 74. If for any reason the oil supply to the pump 39 and hence to the semicircular conduit 77 is cut off, such as for example one of the reasons discussed hereinabove, then the check valve 82 closes and the pressure in the conduit 89 is relieved such that the check valve 74 is allowed to open by reason of the higher pressure in the hydraulic compartment 35. When this occurs, lubrication oil from a compartment 35 commences to flow into line 76, the conduit 89 and the port 84 to supply lubrication oil to the No. 3 bearing on a temporary basis. If oil pressure is subsequently restored in the conduit 77, the check valve 82 opens, the check valve 74 closes and the system is automatically restored to its normal operation. The hydraulic tank 35 will then be replenished by the make-up system described hereinabove.
It will be understood that while the present invention has been described in terms of a preferred embodiment, it may take on any number of other forms while remaining within the scope and intent of the invention. For example, it will be recognized that the valving system for controlling the flow in the auxiliary supply portion of the invention has been described in terms of two ball and spring-type check valves while there are a number of various types of systems which could adequately provide the function as contemplated. Further, although the lubrication oil tank has been described in some detail, it will be recognized that various other types and designs could just as well be adapted for use with the present invention.
|
In a lubrication system where the main oil supply to rotating components is susceptible to interrupted flow, an auxiliary system is implemented to temporarily meet the emergency lubrication needs. Provision is made by an auxiliary line to supply the components with a flow of lubricant from the existing hydraulic tank which is kept full and under pressure. This emergency flow is initiated by the opening of a valve in the auxiliary line and, on the other side of the components to be lubricated, by the closing of a check valve to prevent the further flow of emergency oil to the remaining engine components.
| 8
|
This application claims the benefit of provisional U.S. Application No. 60/087,364, filed May 29, 1998, which is hereby incorporated by reference for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention.
This invention relates generally to a method and device for down mixing compressed digital audio bit stream, and more particularly to a method and device for down mixing the multiple channels of a compressed audio bit stream into a lesser number of audio channels.
2. Description of the Prior Art
Audio compression techniques are used wherever there is an economic benefit to be obtained by reducing the amount of digital information required to represent the audio signals. Examples are the Dolby AC-3, Digital Theatre Systems (DTS), and the MPEG audio layer compression algorithms. The Dolby AC-3 compression format has been selected as the audio format for the high definition television (HDTV) standard in the U.S. It is also widely adopted for use in Digital Versatile Disk (DVD) films.
The AC-3 digital compression algorithm can encode 5.1 channels of source audio from a pulse code modulation (PCM) representation into a serial bit stream at data rates ranging from 32 kbps to 640 kbps. The 0.1 channel refers to a fractional bandwidth channel intended to convey only low frequency (subwoofer) signals. Typically, a compression ratio of 1:10 can be achieved using the AC-3 algorithm. Typical applications are in satellite or terrestrial audio broadcasting, delivery of audio over metallic or optical cables, or storage of audio on, magnetic, optical, semiconductor, or other storage media.
The AC-3 algorithm achieves a high compression ratio by coarsely quantizing a frequency domain representation of the audio signal. The first step in the encoding process is to transform the representation of audio from a sequence of PCM time samples into a sequence of blocks of frequency coefficients. The individual frequency coefficients are represented in floating point representation as a binary exponent and a mantissa. These exponents are encoded according to an adaptive coding process and fed to a bit allocation process. The mantissas are then quantized, the degree of quantization determined by the bit allocation process.
The decoding process is basically the inverse of the encoding process. A decoder must synchronize to the encoded bit stream check for errors, and de-format the various types of data such as the encoded spectral envelope and the quantized mantissas. The decoding process mainly comprises the following four steps: (1) the spectral envelope is decoded to produce the exponents; (2) the exponents are fed into the bit allocation process; (3) the bit allocation routine determines the number of bits used to unpack and de-quantize the mantissas; and (4) the exponents and mantissas of the frequency coefficients are transformed back into the time domain to produce the decoded PCM time samples. A more detailed description of the decoding process is set forth below.
DECODING PROCESS OF THE AC-3 BIT STREAM
The AC-3 encoder uses a time-domain-aliasing-cancellation (TDAC) filter bank to transform an input audio sequence x(n) form time domain signals into frequency domain coefficients, or more specifically, DCT (Discrete Cosine Transform) coefficients. The audio sequence is sampled using a 512-point sampling window h(n) to produce a windowed data:
w(n)=h(n)x.sub.f (n) (1)
where x f (n) is the f th block sample of 512 input data, and x f-1 denotes the (f-1) th block sample of 512 input data. The x f (n) and x.sub.(f-1) (n) samples overlap by 256 points.
The windowed data w(n) is transformed into DCT coefficients through either a 512-point transform or two 256-point transforms according to the data content. The 512-point transform is called the long DCT transform, and the 256-point transform is called the short DCT transform. For the long DCT transform,,the long DCT coefficients y f (k) are obtained from the following formula: ##EQU1## For the short DCT transform, the windowed data w f (n) are segmented into two 256-point data, w f1 (n) and w f2 (n), and transformed into two sets of short DCT coefficients y f1 (k) and y f2 (k): ##EQU2##
To reconstruct the original data, an inverse transform is applied to the DCT coefficients. For long DCT coefficients, the inverse transform formula is ##EQU3## For short DCT coefficients, two types of inverse DCT transforms are used: ##EQU4##
After the inverse DCT transform, an overlap-and-add procedure is executed. For long transforms, the w f (n) windowing domain coefficients are multiplied by a synthesis window f(n) and then overlapped and added with previous w f-1 (n) coefficients to obtain the original data:
xƒ(n)=w.sub.ƒ (n)ƒ(n)+w.sub.ƒ-1 (256+n)ƒ(256+n)0≦n≦255 (6)
For short transforms, the windowing domain coefficients are combined together: w.sub.ƒ (n)=w.sub.ƒ1 (n)+w.sub.ƒ2 (n), and processed through similar operation as the long transforms.
DOWNMIXING
In many reproduction systems, the number of loudspeakers will not match the number of encoded audio channels. For example, the left and right speakers of a typical personal computer are used to output the 5 channels of an AC-3 compressed audio program. In order to reproduce all of the sound effects, down mixing is required. Down mixing is a technique in which the 5 (or 5.1) audio channel signals are intermixed, generating a reduced number of audio channel signals while reserving high audio quality.
Prior art methods of down mixing are performed in the time domain. Basically, the down mixing process is of the form: ##EQU5## where L(n), C(n), R(n), S L (n), and S R (n) are the original left, center, right, left surround, and right surround channel signals respectively. The variables c and s are the center and surround mixing level, typically chosen to be between 1 to 0.5. L 0 (n) and R 0 (n) are the resulting left and right output channels after down mixing.
FIG. 1 shows a prior art decoder for down mixing five channels of audio signals into two channels. Inverse discrete cosine transform (IDCT) and overlap-and-add (OA) are performed individually on each, audio channel. The overlap-and-add procedure is required because in the encoding process, overlapping blocks of time samples are multiplied by a time window and transformed into the frequency domain. Due to the overlapping blocks, each PCM input sample is represented in two sequential transformed blocks, and thus have to be reversed in the decoding process.
The inverse discrete cosine transform (IDCT) procedure transforms the audio data from frequency domain coefficients into windowing domain coefficients, and the overlap-and-add (OA) procedure reconstructs time domain audio data from the windowing domain coefficients. The windowing domain coefficients refer to the coefficients still requiring the OA procedure. Due to the complexity of the IDCT and OA transformations, it would be desirable to reduce the number of IDCT and OA operations that is required in the down mixing process.
FIG. 2 shows an audio decoder with a down mixer in the windowing domain. The audio decoder comprises five inverse discrete cosine transform circuits IDCT -- 1, IDCT -- 2, IDCT -- 3, IDCT -- 4, and IDCT -- 5, a down mixer, and two overlap-and-add circuits OA -- 1 and OA -- 2. The inverse discrete cosine transform circuits receive the DCT coefficients of the five audio channels generated from a pre-processor (not shown). The pre-processor receives a compressed audio bit stream, performs error correction and block de-formatting, and separates the DCT coefficients in different channels. These processes are known in the art.
The IDCT circuits receive DCT coefficients of the five audio channels, and output windowing domain coefficients to the down mixer. The windowing domain coefficients are intermixed by the down mixer, generating windowing domain coefficients for the left and right channels. The left and right channel windowing domain coefficients are then transformed by the first and second overlap-and-add circuits OA -- 1 and OA -- 2 into time domain coefficients, which are then output to speaker amplification units (not shown in the figure).
The prior art decoder shown in FIG. 2 reduces the number of overlap-and-add circuits, but still requires five inverse discrete cosine transformation circuits to transform the DCT coefficients into windowing domain coefficients.
What is needed, therefore, is a method and device for performing the down mixing process in the frequency domain so as to reduce the amount of computation and hardware complexity for an AC-3 decoder.
SUMMARY OF THE INVENTION
Improved down mixing of digital audio signals is achieved by performing down mixing in the frequency domain. An apparatus for decoding a digital audio bit stream comprising a first set of frequency domain coefficients representing a first set of time domain audio signals from a plurality of audio channels is presented. The apparatus comprising: a means for performing down mixing of the first set of frequency domain coefficients to produce a second set of frequency domain coefficients representing a reduced number of audio channel signals; a means for transforming the second set of frequency domain coefficients into a set of windowing domain coefficients; and a means for performing overlap-and-add function on the set of windowing domain coefficients to generate a second set of time domain signals for a reduced number of audio channels.
An algorithm for transforming short DCT coefficients into long DCT coefficients to facilitate the process of down mixing the frequency coefficients is presented. The short DCT coefficients are multiplied with a set of transformation coefficients, with the transformation coefficients being approximated by polynomial expansion coefficients.
One advantage of the present invention is to provide a simple method to reduce the total number of multiplications required for down mixing the audio channels of an AC-3 encoded audio signal. This reduces the complexity of the decoder device, reducing the overall construction cost.
Another advantage is that by simplifying the computation complexity, it is capable to use software program to perform the AC-3 decoding process, rather than using a dedicated hardware decoder.
Other features, advantages and embodiments of the invention will be apparent to those skilled in the art from the following description, accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a prior art decoder for down mixing digital audio bit streams in the time domain.
FIG. 2 is a drawing of a prior art decoder for down mixing digital audio bit streams in the windowing domain.
FIG. 3 is a block diagram of a decoder for down mixing in the frequency domain, using both long discrete cosine transforms and short discrete cosine transforms.
FIG. 4 is a block diagram of a preferred embodiment of the present invention. The decoder comprises virtual transformers for transforming the short DCT coefficients into long DCT coefficients, and performs down mixing in the frequency domain.
DESCRIPTION OF THE INVENTION
Appendix A is a paper submitted to the IEEE Transactions on Speech and Audio Processing on Dec. 24, 1997. The paper describes the principles incorporated in the present invention for down mixing an AC-3 bit stream.
For the convenience of description, equations (1) to (6) are written using matrix representation. For the inverse discrete cosine transform of the long DCT coefficients, equation (4) can be rewritten as: ##EQU6## where Y f is a 256×256,diagonal matrix comprising of the long DCT coefficients extracted by the pre-processor, and ##EQU7##
For the inverse discrete cosine transform of the short DCT coefficients, equation (5) can be rewritten as: ##EQU8## where Y f1 and Y f2 are 128×128 diagonal matrices comprising of the short DCT coefficients extracted by the pre-processor. The matrix Y f1 comprise the first portion of the short DCT coefficients extracted by the pre-processor, and the matrix Y f2 comprise the second portion of the short DCT coefficients. The terms S 1 + and S 2 + are denoted by: ##EQU9## For the overlap-and-add process, equation (6) can be rewritten as: ##EQU10## where F 1 and F 2 are 256×256 diagonal matrices with the entries defined as <F 1 > nn =f(n) and <F 2 > nn =f(256+n).
FIG. 3 shows an audio decoder for down mixing in two DCT domains (the long DCT domain and short DCT domain). Audio decoder 300 comprises a selector 302, a long down mixer 304, a short down mixer 306, two long inverse discrete cosine transform blocks L-IDCT -- 1 308 and L-IDCT -- 2 310, two short inverse discrete cosine transform blocks S-IDCT -- 1 312 and S-IDCT -- 2 314, two signal adders 316 and 318, and two overlap-and-add blocks OA -- 1 320 and OA -- 2 322.
The audio decoder 300 performs down mixing, inverse discrete cosine transforms, and overlap-and-add functions to generate a reduced number of audio channels than was originally encoded in the input digital bit stream.
The selector 302 receives DCT coefficients from signal lines 324a to 324e, and determines whether the incoming coefficients are long DCT coefficients (Y f ) or short DCT coefficients (Y f1 and Y f2 ). The long and short DCT coefficients are directed to the long down mixer 304 and short down mixer 306 respectively. The long down mixer 304 performs the down mixing to produce the down mixed long DCT coefficients using the following algorithm: ##EQU11## where Y f (L D ) and Y f (R D ) are the down mixed DCT coefficients for the left and right channels. The matrices Y f (L), Y f (C), Y f (R), Y f (S L ), Y f (R L ) comprise the long DCT coefficients extracted by the pre-processor for the left, center, right, left surround, and right surround channels. The matrix I is an identity matrix, and the matrices C and S are 256×256 diagonal matrices denoted by: ##EQU12## Here c and s are the mixing coefficients for the center and surround channels, typically chosen between 0.5 to 1.
The short down mixer 306 performs the down mixing on the short DCT coefficients to generate the down mixed short DCT coefficients using the following equations: ##EQU13## where Y f1 (L D ), Y f1 (R D ), Y f2 (L D ), and Y f2 (R D ) are the down mixed short DCT coefficients for the left and right channels. Here C and S are 128×128 diagonal matrices comprising the center and surround mixing coefficients.
The down mixed long DCT coefficients from the long down mixer 304 are sent to the inverse discrete transformers L-IDCT -- 1 308 and L-IDCT -- 2 310 to process the DCT coefficients for the left and right channels. The L-IDCT -- 1 308 and L-IDCT -- 2 310 transforms the long DCT coefficients into the long windowing domain coefficients according to the following algorithm: ##EQU14##
Likewise, the output coefficients from the short down mixer 306 are sent to the inverse discrete transformers S-IDCT -- 1 312 and S-IDCT -- 2 314 to process the short DCT coefficients for the left and right channels. The S-IDCT -- 1 312 and S-IDCT -- 2 314 transforms the DCT coefficients into short windowing domain coefficients according to the following equations: ##EQU15##
The short windowing domain coefficients generated by the short inverse discrete cosine transformers S-IDCT -- 1 312 and S-IDCT -- 2 314 are combined with the long windowing domain coefficients at the signal adders 316 and 318. The combined signals from the signal adders 316 and 318 are then sent to the overlap-and-add blocks OA -- 1 320 and OA -- 2 322, and transformed into time domain signals according to the algorithm: ##EQU16## where X f (L 0 ) and X f (R 0 ) are the down mixed time domain audio signals for the left and right channels. The time domain audio signals are then sent to amplification units or loud speakers.
FIG. 4 shows a preferred embodiment of the present invention. To reduce the number of inverse discrete cosine transforms required for the down mixing process, the short DCT coefficients are first transformed to long DCT coefficients, and then down mixing are performed on the long DCT coefficients. The decoder 400 comprises five virtual transformers VT -- 1 402a, VT -- 2 402b, VT -- 3 402c, VT -- 4 402d, VT -- 5 402e, a down mixer 404, two inverse discrete cosine transformers IDCT -- 1 406a and IDCT -- 2 406b, and two overlap-and-add blocks OA -- 1 408a and OA --2 408b.
The virtual transformers receive incoming signals from the five channels, and determine whether the frames contain short DCT coefficients or long DCT coefficient's. The short DCT coefficients are transformed into long-DCT coefficients using the following equation: ##EQU17## where
V=[V.sub.1 V.sub.2 ]=[L.sub.1 ·H.sub.1 ·F.sub.1 ·S.sub.1.sup.+ L.sub.2 ·H.sub.2 ·F.sub.2 ·S.sub.2.sup.+ ] (25)
Here Y f1 and Y f2 comprise the short DCT coefficients, and ##EQU18## The matrices H 1 , H 2 are diagonal matrices with entries <H 1 > nn =h(n), 0≦n≦255, <H 2 > nn =h(n+256), 0≦n≦255; and F 1 , F 2 , S 1 + , S 2 + are similar to those denoted in equations (12), (13), and (14). Equation (25) can be rewritten as: ##EQU19## Which can be further simplified by approximating the terms which are insignificant using 2 nd or 3 rd order polynomial expansion. It can be shown that most of the terms of V 1 (k 1 ,k 2 ) concentrates near k 2 =k 1 /2, so the terms farther away from k1/2 can be approximated by polynomial coefficients without losing much accuracy.
Rewrite the first term of (29) as ##EQU20## We can separate the terms of the above equation into three portions, one center portion contains the terms at the neighborhood of k2=k1/2, one portion before the center portion, and the remaining portion after the center portion. ##EQU21## Here the center portion has a length of 2M points. We then approximate the first and third terms in equation (30) using p-th order polynomials: ##EQU22## Here a and b are the polynomial expansion coefficients ##EQU23## respectively. Calculating the first and third terms in equation (30) using polynomial approximations is much faster than expanding the summation of V 1 ·Y f1 with all the cosine terms.
Furthermore, it can be shown that there is a one-to-one correspondence between V 1 (k 1 ,k 2 ) and V 2 (k 1 ,k 2 ):
V.sub.2 (k.sub.1,k.sub.2)=(-1).sup.(k1+k2) ×V.sub.1 (255-k.sub.1,127-k.sub.2) (33)
Therefore, we can calculate V 2 once we have obtained the terms for V 1 . This can be used in the calculation of ##EQU24## By combining the results of equations (31) and (35), we obtain the long DCT coefficients of equation (29).
After the virtual transformers VT -- 1 402a to VT -- 5 402e turns the short DCT coefficients to long DCT coefficients (when appropriate), the long DCT coefficients are sent to the down mixer 404. The down mixer 404 down mixes the long DCT coefficients using equation (16) described above. The down mixed long DCT coefficients are then sent to the inverse discrete cosine transformers 406a and 406b. Then the windowing domain coefficients generated by the inverse discrete cosine transformers 406a, 406b are sent to the overlap-and-add blocks 408a and 408b, which generate time domain audio signals for the left and right channels.
While the above is a full description of the specific embodiments, various modifications, alternative constructions and equivalents may be used. For example, down mixing is not limited for used in the AC-3 algorithm. Other audio compression algorithms having more than 2 audio channels, such as MPEG-2 or DTS, may require down mixing to be performed when the number of speaker amplifiers are less than the number of audio channels in the digital-bit stream. Therefore, the above description and illustrations should not be taken as limiting the scope of the present invention which is defined by the appended claims.
|
Improved down mixing of audio channels of compressed digital audio signals by down mixing in the frequency domain. Fast virtual transform is applied to transform short DCT coefficients into long DCT coefficients, and down mixing is performed on the long DCT coefficients. Inverse discrete cosine transform is performed on the down mixed set of long DCT coefficients, generating signals in the windowing domain. The windowing domain signals are then overlapped and added to generate time domain signals suitable for further amplification. Down mixing in the frequency domain reduces the number of computations required.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to Japanese patent application No. JPAP11-086099 filed on Mar. 29, 1999, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a portable electronic terminal apparatus, and more particularly to a portable electronic terminal apparatus which includes a flip panel and a plurality of displays.
2. Discussion of the Background
Recently, the amount of information for electronic apparatuses to exchange has greatly been increased through data communications verification because of rapid proliferation of portable communications equipment and an establishment of the corresponding infrastructure. In such a circumstance, portability as well as data communications capability has become more important, especially in a portable electronic apparatus (e.g., a cellular mobile phone, a personal assistant device, and the like).
In general, it is difficult to obtain both portability and visibility at the same time in a portable electronic apparatus. Such an apparatus needs to be lighter and smaller for increased portability. For instance, the area reserved for the display of a portable electronic apparatus can be reduced to increase portability. Typically, a portable electronic apparatus has a single display on which various kinds of information are selectively shown as user instructions; such as a screen scroll function, a function for switching over to another function, and so forth. In such a portable electronic apparatus, the user is usually required to perform complex manipulation of the display to finally read incoming mail and/or information received from information service providers.
As one example of the portable electronic apparatus, a mobile cellar phone, as illustrated in FIG. 1, is provided to overcome the above-mentioned problem. The mobile cellar phone of FIG. 1 includes a main body 51 , a display 51 , an antenna 52 , and a loudspeaker 53 . In this mobile cellar phone, a mechanical key pad is not used, instead a touch-sensitive display is employed so as to fit in a relatively small area. Since the touch-sensitive display does not provide a tactile “click” response, the user is required to keep watching the display to make sure the input is entered properly. Therefore, the operability of the mobile cellar phone of FIG. 1 is reduced.
SUMMARY OF THE INVENTION
The present invention provides a novel portable electronic terminal apparatus which includes a main body, an information input mechanism, a plurality of displays, a communications mechanism, and a flip panel. The main body has a hollow section. The information input mechanism enables input of information, including data and instructions. A plurality of displays display the information input through the input mechanism. The communications mechanism transmits and receives the input information. The flip panel is movably mounted on the main body and is configured to rotate to open and close about a side edge portion of the flip panel. This flip panel is retracted in the hollow section of the main body when closed. In addition, one of the plurality of displays is mounted on the side of the flip panel that is exposed when closed.
One of the plurality of the displays may be mounted on a surface of the hollow section of the main body.
Another display may be mounted on another side of the flip panel.
One of the displays operates when the flip panel is closed, and the other display operates when the flip panel is opened.
Each of the displays may be a polymer-film liquid crystal display.
The displays may selectively be used by a user instruction input through the information input mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a diagram showing an overall view of a conventional mobile cellar phone;
FIG. 2 is a diagram showing an overall view of a portable electronic terminal apparatus according to an embodiment of the present invention;
FIG. 3 is a diagram showing the location of an open button of the portable electronic terminal apparatus of FIG. 2;
FIG. 4 is a diagram showing the portable electronic terminal apparatus of FIG. 2 with a flip panel opened;
FIG. 5 is a diagram showing a structure of a display included in the portable electronic terminal apparatus of FIG. 2;
FIGS. 6 and 7 are diagrams for showing an exemplary way of reading incoming mail on the portable electronic terminal apparatus of FIG. 2;
FIGS. 8 and 9 are diagrams showing a modified portable electronic terminal apparatus based on the portable electronic terminal apparatus of FIG. 2; and
FIGS. 10 and 11 are diagrams showing another modified portable electronic terminal apparatus based on the portable electronic terminal apparatus of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing preferred embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the present invention 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 which operate in a similar manner.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIG. 2 thereof, there is illustrated a portable electronic terminal apparatus 100 according to an exemplary embodiment of the present invention. The portable electronic terminal apparatus 100 includes a main body 1 , an antenna 2 , a loudspeaker 3 , a flip panel 4 , a first display 5 , a data entry panel 6 , a microphone 7 , and a button 8 .
In this exemplary embodiment, the main body 1 has a front surface divided into upper, middle, and lower regions to which the loudspeaker 3 , the flip panel 4 , and the data entry panel 6 are provided, respectively. The antenna 2 is mounted inside the main body 1 so as to protrude from the top surface of the main body 1 . The microphone 7 is mounted on a portion of the lower region closer to the bottom surface of the main body 1 , and the button 8 is provided to a side surface of the main body 1 near the upper region. The flip panel 4 has a left side edge portion which is movably mounted in the left side edge of the middle region of the main body 1 so that the flip panel 4 can rotate to open and close about the left side edge portion. The first display 5 is mounted on the front surface of the flip panel 4 . The data entry panel 6 includes a ten-key pad, for example, and other instruction keys. In addition, the portable electronic terminal apparatus 100 further includes an open button 9 for opening the flip panel 4 . The open button 9 is mounted on a side surface of the main body 1 close to the flip panel 4 , as illustrated in FIG. 3 .
When the open button 9 is pressed, the flip panel 4 is opened, as illustrated in FIG. 4 . As illustrated in FIG. 4, the portable electronic terminal apparatus 100 further includes a second display 10 , a third display 11 , a hook 12 , and a dent 13 . A hollow section 14 is created when the flip panel 4 is opened. The second display 10 is mounted on a rear side of the flip panel 4 . The second display 10 may be integral with the first display 5 . The third display 11 is mounted on a portion of the main body 1 opposite to the second display 10 with the flip panel 4 closed so as to appear next to the second display 10 with the flip panel 4 opened. The hook 12 is provided to a side edge of the rear surface of the flip panel 4 so as to hook up to the main body 1 with the dent 13 mounted on the main body 1 . The hollow 14 is to receive the flip panel 4 when it is closed. For the open/close mechanism of the flip panel 4 , the portable electronic terminal apparatus 100 is further provided with a hook receiver (not shown) and a spring (not shown). The hook receiver is mounted on a portion of the main body 1 closer to the dent 13 and is engaged with the hook 12 when the flip panel 4 is closed. The spring is mounted on a portion of the left side edge of the flip panel 4 so as to provide a tension to the flip panel 4 to open. The above-mentioned hook receiver is associated with the movement of the open button 9 so that the flip panel 4 is opened, as illustrated in FIG. 4, with the tension of the spring when the open button is pressed and is closed, as illustrated in FIG. 2, when the user closes the flip panel 4 .
Each of the first and second displays 5 and 10 may be a thinner display (i.e., a polymer-film liquid crystal display) so that the flip panel 4 can be made thinner.
Referring to FIG. 5, an exemplary structure of a display when the first and second a displays 5 and 10 are united in one piece is explained. In FIG. 5, an exemplary structure of a display includes a reflection plate 20 , first polarizing plates 21 and 22 , first transparent electrodes 23 and 24 , liquid crystal layers 25 and 26 , second transparent electrodes 27 and 28 , phase plates 29 and 30 , second polarizing plates 31 and 32 . That is, the first display 5 includes the first polarizing plate 21 , the first transparent electrode 23 , the liquid crystal layer 25 , the second transparent electrode 27 , the phase plate 29 , and the second polarizing plate 31 . Further, the second display 10 includes the first polarizing plate 22 , the first transparent electrode 24 , the liquid crystal layer 26 , the second transparent electrode 28 , the phase plate 30 , and the second polarizing plate 32 . The first display 5 is mounted on a front surface of and the second display 10 is mounted on a rear surface of the reflection plate 20 so that a double-sided display is configured with the flip panel 4 .
When the flip panel 4 is closed, the first display 5 is supplied with power but the second and third displays 10 and 11 are not supplied with power. That is, the second and third displays 10 and 11 can only be supplied with power when the flip panel 4 is opened. In addition, the user can set a condition in which the second and third displays 10 and 11 are not supplied with power through the data entry panel 6 . Accordingly, the second and third displays 10 and 11 will not be supplied with power even when the flip panel 4 is accidentally opened. As a result, it becomes possible to avoid an increase of a power consumption by an accidental opening of the flip panel 4 .
Referring to FIGS. 6 and 7, an exemplary way of using the portable electronic terminal apparatus 100 will be explained. When the portable electronic terminal apparatus 100 is not used, it stays in an idle status, as illustrated in FIG. 6 . In the idle status, the flip panel 4 is closed and the first display 5 displays minimum information on it. The minimum information may include strength of the electric field (i.e., signal strength), the time of day, date, incoming mails, and so forth.
To read incoming mails, the user opens the flip panel 4 so that the second and third displays 10 and 11 show up, as illustrated in FIG. 7 . In this case, the second display 10 shows a list of incoming mails and the third display 11 shows the contents of a selected incoming mail.
With the above-described structure, the portable electronic terminal apparatus 100 can conveniently display multiple pages of information. Moreover, it obviates the necessity for the user to enter the complex instructions through the data entry panel 6 to read incoming mails. Thus, the user can read incoming mails in much the similar way to read a book by turning pages.
Next, a first modification made to the portable electronic terminal apparatus 100 is explained with reference to FIGS. 8 and 9. In FIG. 8, a first modified portable electronic terminal apparatus 200 is shown. The first modified portable electronic terminal apparatus 200 of FIG. 8 is similar to the portable electronic terminal apparatus 100 , except for a flip panel 204 and a knob 215 .
The flip panel 204 of FIG. 8 is configured to have a top edge portion which is mounted on the top edge of the middle region of the main body 1 . That is, the flip panel 204 can rotate about the top edge portion to open and close while the flip panel 4 of FIG. 2 rotates about the left side edge portion. The knob 215 is engaged with a bottom portion of the flip panel 204 when the flip panel 204 is closed and the flip panel 204 is retracted in the main body 1 , as illustrated in FIG. 8 . To open the flip panel 204 , the user needs to push or slide the knob 215 to release its engagement with the bottom portion of the flip panel 204 . Consequently, the flip panel 204 is opened towards the side of the loudspeaker 3 , as illustrated in FIG. 9 . Because of this direction of opening, the flip panel 204 is kept out of the way of the user's hand holding the main body 1 .
Next, a second modification made to the portable electronic terminal apparatus 100 is explained with reference to FIGS. 10 and 11. In FIG. 10, a second modified portable electronic terminal apparatus 300 is shown. The second modified portable electronic terminal apparatus 300 of FIG. 10 is similar to the portable electronic terminal apparatus 100 of FIG. 2, except for a fixed display panel 316 and a flip panel 317 . The fixed display panel 316 is fixed on the middle region of the main body 1 . The flip panel 317 includes a secondary display 318 , as illustrated in FIG. 11 . The flip panel 317 is configured to have a bottom edge portion which is mounted on the bottom of the lower region of the main body 1 . That is, the flip panel 317 can rotate about the bottom edge portion to open and close while the flip panel 4 of FIG. 2 rotates about the left side edge portion. With this configuration, the data entry panel 6 can be protected by the flip panel 317 when it is closed and both of the data entry panel 6 and the secondary display 318 will show up when the f lip panel 317 is opened. Thus, the display size can be extended without increasing the size of the terminal apparatus.
Numerous additional modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.
|
A portable electronic terminal apparatus includes a main body, an information input mechanism, a plurality of displays, a communications mechanism, and a flip panel. The main body has a hollow section. The information input mechanism inputs various kinds of information including data and instructions. Each of the displays shows the various kinds of information input through the input mechanism. The communications mechanism transmits and receives the various kinds of information input through the input mechanism. The flip panel is movably mounted on the main body and is configured to rotate to open and close about a side edge portion of the flip panel. This flip panel is retracted in the hollow section of the main body when the flip panel is closed. In addition, one of the displays is mounted on the flip panel.
| 8
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to safety applications in industrial environments, and in particular, to distribution networks for safety sensors and devices.
[0002] Industrial environments typically include numerous mechanical operations, such as doors opening and closing, conveyor systems moving, and so forth. Such mechanical operations may be hazardous if the state is not known or fully appreciated. For example, if a door in the industrial environment is propped open, such as for inspection or diagnostics of machinery, and a conveyor system moves, or if a door in the industrial environment is closed, such as at a receiving station, and the conveyor system moves, a catastrophic condition could potentially result, such as human injury and/or property damage.
[0003] Safety sensors and safety distributions systems are known techniques for increasing the protection of personnel and equipment in such environments. Safety sensors may monitor, among other things, the status of doors and the motion of equipment. Safety sensors may comprise, for example, various modules with integrated proximity sensors, connectors or other mechanisms for detection, and switches for electrical signaling. Safety sensors are typically dispersed throughout the industrial environment and often attach to a one or more centralized safety distribution boxes as part of a safety sensor distribution network.
[0004] In operation, a safety signal may be routed to each particular safety sensor and back, such that if electrical continuity of the safety signal is detected, a safe condition is believed to be likely. On the other hand, if electrical continuity of the safety signal is not detected, such as the safety sensor breaking electrical continuity due to detection of an open door that should be closed, an unsafe condition may be presumed, an alert may be triggered, and the related industrial process may be stopped.
[0005] For additional safety, redundant signals may also be routed to each particular safety sensor and back, such that if electrical continuity is lost among any one of the safety signals, an unsafe condition may again be presumed. In addition, the safety signals are often routed serially through each safety sensor via the safety distribution box, such that if electrical continuity is lost due to any one of the safety sensors, an unsafe condition may again be presumed.
[0006] The safety distribution box often, in turn, couples to a power supply, a dedicated safety relay or safety programmable logic controller (“PLC”) and/or a general PLC. PLC's typically include a processor executing software stored in memory and numerous input and output connections for interacting with the industrial environment, including for monitoring safety signals and triggering an alert upon detecting an unsafe condition.
[0007] Shorting plugs that electrically short together safety signals are also typically used in such environments for maintaining flexibility. If, for example, a safety sensor is no longer needed, the safety sensor may be removed and a shorting plug may be installed in the old safety sensor's place at the safety distribution box. As such, electrical continuity of the safety signals may be maintained.
[0008] However, bypassing safety sensors that are still in use in the industrial environment with shorting plugs results in a loss of safety monitoring in the system. As a result, the potential for catastrophic conditions occurring increases.
SUMMARY OF THE INVENTION
[0009] The present inventors have recognized that individualized status signals routed in parallel to each of the potential safety sensor locations provides substantially increased protection. A shorting plug that electrically shorts together an individualized status signal to a voltage reference level at a safety sensor location, in addition to electrically shorting together the safety signals for electrical continuity as described above, provides individualized status information for each potential safety sensor location in addition to the serial safety information provided by the safety signals.
[0010] A PLC may implement logic, such as by executing computer software, to monitor the individualized status signals in addition to monitoring the safety signals. A table, which may be stored and periodically updated in the PLC, may indicate the presence or absence of safety sensors for each potential location. If electrical continuity in one or more safety signals are broken, such as by a safety sensor indicating an unsafe condition, or if an individualized status signal indicates the absence of a safety sensor and the corresponding table indicates that a safety sensor should be present, the PLC may trigger an alert, which may result in stopping one or more industrial processes, lighting a warning light, sounding an alarm and/or sending an electronic mail or SMS text message.
[0011] The shorting plug may electrically short together a status signal to a positive DC voltage reference level, such as +24 Volts DC, though in other embodiments, other voltage references or ground could be used. Installing the shorting plug may also illuminate a light emitting diode (“LED”) as a result of the electrical shorting which may be visually inspected. The LED may be located on the distribution box, or in an alternative embodiment, on the shorting plug itself. The shorting plug may also have preferred colors, such as red, and/or a preferred connector styles for ensuring its use in the safety system.
[0012] As such, in accordance with embodiments of the present invention, installation of shorting plugs in the place of safety sensors can be readily recognized and detected, thereby allowing verification of such uses, and possibly corrective actions.
[0013] Another aspect of the present invention provides a remote monitoring device, such as a PLC, coupled to one or more adapter ports, with each adapter port coupled to one or more safety sensors, wherein adapter ports are coupled via cabling with cable endings of the same type, such as female-to-female cable ends, or male-to-male cable ends. As such, an adapter port, and in turn, a safety sensor, may not be circumvented simply by coupling together adjacent cables.
[0014] These and other objects, advantages and aspects of the invention will become apparent from the following description. The particular objects and advantages described herein may apply to only some embodiments falling within the claims and thus do not define the scope of the invention. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made, therefore, to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0016] FIG. 1 is a logical drawing of a distribution box, shorting plugs, safety sensors and remote devices in accordance with an embodiment of the present invention;
[0017] FIG. 2 is an isometric view of a distribution box in accordance with an embodiment of the present invention;
[0018] FIG. 3 is an isometric view of a shorting plug in accordance with an embodiment of the present invention;
[0019] FIG. 4 is a logical pin out drawing for a primary electrical connector for use with a distribution box in communicating with one or more remote devices in accordance with an embodiment of the present invention;
[0020] FIG. 5 is a logical pin out drawing for a secondary electrical connector for use with a distribution box in communicating with a safety sensor, which may also receive a shorting plug, in accordance with an embodiment of the present invention;
[0021] FIG. 6 is a schematic diagram of circuitry for a distribution box which may accommodate, for example, eight potential safety sensors, shorting plugs or combinations thereof, in accordance with an embodiment of the present invention; and
[0022] FIG. 7 is a logical drawing of a safety distribution system using a remote device, adapter ports, safety sensors and cabling with cable endings of the same type in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] Referring now to FIG. 1 , various aspects of an embodiment of the present invention will now be described in the context of a safety distribution system 10 . The safety distribution system 10 may comprise a distribution box 12 with a primary electrical connector half 14 and a plurality of secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 .
[0024] The primary electrical connector half 14 may be used for communicating with one or more remote devices, including a power supply 40 , a dedicated safety relay or safety PLC 42 and/or a general PLC 44 . The power supply 40 , the safety PLC 42 and/or the general PLC 44 may be located together in a single enclosure 46 and may be in proximity to a warning light tower 48 or other alarm indicating device. The safety PLC 42 and the general PLC 44 may each include a processor executing software for monitoring the safety sensors, and in alternative embodiments, the functionality may be combined into a single PLC or other capable device.
[0025] The primary electrical connector half 14 may extend from the housing of the distribution box 12 for coupling to and communicating with one or more remote devices via a primary electrical cable 60 having an opposing electrical connector half. The primary electrical cable 60 may route signals of different varieties, including power signal conductors 62 , which provides a positive DC voltage reference level via +24V DC signal and a ground via Common signal, pairs of input and output safety signal conductors 64 , which may provide redundant serially connected safety signals throughout the safety system, and individualized status signal conductors 66 , which may provide an individual status signal for each potential safety sensor location. Within the single enclosure 46 , the power signal conductors 62 may couple to the power supply 40 , the safety signal conductors 64 may couple to the safety PLC 42 , and the status signal conductors 66 may couple to the general PLC 44 . Alternative embodiments, however, may provide more or fewer signals and in alternative arrangements, such as single PLC for safety and status signals, or a power supply local to or integrated within the distribution box 12 .
[0026] The secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 each are used to communicate with one or more safety sensors of various configurations and types, and in this example, safety sensors 50 , 52 , 54 , 56 and 58 . Safety sensors may include, for example, safety switches for detecting the change in position of objects and/or machinery, such as the SensaGuard™ system available from Rockwell Automation, Inc. of Milwaukee, Wis. Intermediate cables, such as cables 70 and 72 , cables 78 and 80 , cables 82 and 84 , and cables 86 and 88 , may be used for coupling the distribution box 12 to the safety sensors, such as safety sensors 50 , 52 , 54 , 56 , and 58 , respectively, as the safety sensors may be widely dispersed throughout the industrial environment. Safety sensors 50 , 52 , 54 , 56 and 58 have two jointly acting electrical switches controlled by a sensed condition, with one switch across a different input and output pair.
[0027] Through the primary electrical connector half 14 , the safety signal conductors 64 redundantly join the secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 , and safety sensors coupled thereto, in series from first to last, such that safety signal outputs of each secondary electrical connector half are coupled to safety signal inputs of a next secondary electrical connector half until reaching the last secondary electrical connector half. In this way, the safety signal conductors 64 couple serially from the safety PLC 42 to the primary electrical connector half 14 , via the primary electrical cable 60 , then to the first secondary electrical connector half 16 , then to any safety sensor attached to the first secondary electrical connector half 16 , then back out of the first secondary electrical connector half 16 , then to the next secondary electrical connector half 18 , and so forth. At the last secondary electrical connector half 30 , the safety signal conductors 64 continue to couple serially to the primary electrical connector half 14 , then back to the safety PLC 42 via the primary electrical cable 60 .
[0028] The safety PLC 42 may monitor electrical continuity of the safety signals 64 . If electrical continuity is lost on any of the serially connected safety signals 64 , such as by removal a safety sensor from a connector half, or by a safety sensor triggering an unsafe condition, or by faulty operation of a single safety signal, the safety PLC 42 detects the condition and responds accordingly by triggering an alert, such as illuminating a red light at the light tower 48 , sounding an alarm, and/or sending an electronic mail or SMS text message, and putting the system and/or machine into a safe state, such as stopping one or more industrial processes or machines.
[0029] If a safety sensor is not to be attached at a secondary electrical connector half, a shorting plug may be used in its place to maintain electrical continuity. For example, in the safety distribution system 10 , the safety signal conductors 64 couple serially from the safety PLC 42 to the primary electrical connector half 14 , via the primary electrical cable 60 , then to the first secondary electrical connector half 16 , then through a shorting plug 90 attached, which maintains serial electrical continuity across the first secondary electrical connector half 16 , then to the next secondary electrical connector half 18 , and so forth. The shorting plug 90 may have unique characteristics for distinguishing it from other types of shorting plugs and connectors, such as unique shapes, colors and/or markings.
[0030] In addition to safety signal conductors 64 , the safety distribution system 10 and the distribution box 12 also utilizes the status signal conductors 66 . The status signal conductors 66 provide an individualized status signal conductor to each potential safety sensor location via each secondary electrical connector half. The status signal conductors 66 may default to a particular condition when monitored, such as ground or floating high impedance, and upon insertion of a shorting plug at particular secondary electrical connector half, the corresponding status signal may be driven to a different condition, such as a DC voltage level, via electrical shorting by the shorting plug. This may allow, for example, detection of a shorting plug where a safety sensor is expected, thereby triggering an alert and putting the system and/or machine into a safe state.
[0031] In the safety distribution system 10 , the status signal conductors 66 couple individually, in parallel, from the general PLC 44 to the primary electrical connector half 14 via the primary electrical cable 60 . Then, a first status signal of the status signal conductors 66 couples to the first secondary electrical connector half 16 , a second status of the status signal conductors 66 couples to the next secondary electrical connector half 18 , and so forth, until each potential safety sensor location is coupled to a status signal. If a safety sensor is attached at a secondary electrical connector half, the respective status signal may simply default to the first condition, such as grounding or floating. However, if a shorting plug is attached to the secondary electrical connector half, the respective status signal may then be driven to the second condition, such as the DC voltage reference level, via the shorting plug.
[0032] In an alternative embodiment, safety signal conductors 64 and status signal conductors 66 may both be monitored by the safety PLC 42 , or may both be monitored by the general PLC 44 or by another device.
[0033] Referring now to FIG. 2 , an isometric view of the distribution box 12 in accordance with an embodiment of the present invention is shown. The distribution box 12 may have varying standard and/or non-standard shapes, such as appearing long and rectangular with beveled edges, contours, mounting shapes and/or holes adequate for mechanically and functionally integrating into the industrial environment.
[0034] The primary electrical connector half 14 may be round with exterior circumferential threading 100 to allow an opposing electrical connector half, such as the connector on the primary electrical cable 60 , to attach. The primary electrical connector half 14 also includes a plurality of pins 102 , for example, nineteen pins here, for coupling the power signal conductors 62 , the pairs of input and output safety signal conductors 64 and the individualized status signal conductors 66 , and possibly others, to the power supply 40 , the safety PLC 42 and/or the general PLC 44 .
[0035] The secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 may be round in shape with interior circumferential threading 102 to allow an opposing electrical connector half, such as a connector and cable leading to a safety sensor, or a connector on a shorting plug, to attach. The secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 also each include a receiving block 104 for receiving the power signal conductors 62 , the safety signal conductors 64 and a particular status signal of the status signal conductors 66 and routing to the safety sensor or shorting plug.
[0036] In alternative embodiments, other connector shapes, sizes, configurations and/or styles for the primary electrical connector half 14 and/or the secondary electrical connectors halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 may be used.
[0037] The distribution box 12 may also include labels 106 in proximity to the primary electrical connector half 14 and the secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 . The labels 106 may be manually updated with text or symbols for increased safety in the industrial environment, such as indicating no safety sensor in a particular position, and hence a shorting plug is expected, or a safety sensor in a particular position, and hence a safety sensor (and not shorting plug) is expected.
[0038] The distribution box 12 may also include a plurality of light emitting diodes (“LED's”) (not shown), including, for example, a power LED which may be green when lit for indicating the distribution box 12 is receiving power, and a plurality of status LED's which may be amber when lit for indicating if a particular status signal is being driven to the second condition by a shorting plug as described above with respect to FIG. 1 . Each LED may be visually inspected and compared to the industrial environment and operating software for increased safety.
[0039] Referring now to FIG. 3 , an isometric view of the shorting plug 90 in accordance with an embodiment of the present invention is shown. The shorting plug 90 may be generally cylindrical in shape, though other standard and/or non-standard shapes may apply, including beveled edges and ergonomic contours. The electrical connecting end of the shorting plug 90 may be round with exterior circumferential threading 150 to allow attachment to one of the secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 . The shorting plug 90 also includes a plurality of pins 152 , for example, eight pins here, for coupling with the receiving block 104 of one of the secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 .
[0040] In an alternative embodiment, the shorting plug 90 may also include an LED that may be lit when attached to a secondary electrical connector half for indicating that the particular status signal is being driven to the second condition as described above with respect to FIG. 1 . The LED may be visually inspected and compared to the industrial environment and operating software for increased safety. The shorting plug may also have a preferred color, such as red, and/or a preferred connector style, for ensuring its use in the system.
[0041] Referring now to FIG. 4 and to Table 1 below, a logical pin out drawing and related description for the primary electrical connector half 14 is shown in accordance with an embodiment of the present invention. The example primary electrical connector half 14 here has nineteen connector pins 201 - 219 , with certain connector pins being no-connects and/or reserved for future use, an electrical shrouding 222 and a notch 224 for facilitating a keyed insertion. Table 1 also includes wiring colors for distinguishing each conductor signal in use.
[0000]
TABLE 1
Connector Pin
Description
Wiring Color
201
—
—
202
Safety A+ (OSSD)
Red
203
Safety B (OSSD)
Grey
204
Aux J2
Red/Blue
205
—
—
206
Common
Blue
207
Aux J1
Grey/Pink
208
Aux J3
White/Green
209
Aux J5
White/Yellow
210
Aux J7
White/Grey
211
Lock Command
Black
212
Ground
Green/Yellow
213
Aux J6
Yellow/Brown
214
Aux J4
Brown/Green
215
—
—
216
Safety B+ (OSSD)
Yellow
217
Safety A (OSSD)
Pink
218
Aux J8
Grey/Brown
219
+24 V DC
Brown
[0042] The power signal conductors 62 may include the Common signal at connector pin 206 , the Ground signal at connector pin 212 , and the +24V DC signal at connector pin 219 .
[0043] The safety signal conductors 64 may include an input Safety A+(output signal switching device (“OSSD”)) signal at connector pin 202 , serially routed through the safety sensors (or shorting plugs) via the distribution box 12 , with a corresponding output Safety A (OSSD) signal at connector pin 217 , and another input Safety B+(OSSD) signal at connector pin 216 , also serially routed through safety sensors (or shorting plugs) via the distribution box 12 , with another corresponding output Safety B (OSSD) signal at connector pin 203 . If a loss of electrical continuity is detected in either serially routed path, the system may trigger an alert and put the system and/or machine into a safe state accordingly.
[0044] The status signal conductors may include the Aux J1 signal at connector pin 207 , the Aux J2 signal at connector pin 204 , the Aux J3 signal at connector pin 208 , the Aux J4 signal at connector pin 214 , the Aux J5 signal at connector pin 209 , the Aux J6 signal at connector pin 213 , the Aux J7 signal at connector pin 210 and the Aux J8 signal at connector pin 218 . If, for example, the distribution box 12 has only four secondary electrical connector halves, then only four status signal conductors, such as Aux J144, may be used. However, if, for example, the distribution box 12 has eight secondary electrical connector halves, then all eight status signal conductors, Aux J1-J8, would be used. Alternative embodiments may provide additional conductor signals, connector pins and/or arrangements for further variations.
[0045] The Lock Command signal at connector pin 211 may be used by the safety PLC 42 , the general PLC 44 and/or any other remote device for locking the configuration. The connector pins 201 , 205 and 215 in this embodiment are reserved for future use.
[0046] Referring now to FIG. 5 and to Table 2 below, a logical pin out drawing and related description for the secondary electrical connector half 16 is shown in accordance with an embodiment of the present invention. The exemplar secondary electrical connector half 14 here has eight connector pins 231 - 238 , an electrical shrouding 242 and a notch 244 for facilitating a keyed insertion.
[0000]
TABLE 2
Connector Pin
Description
231
Aux
232
+24 V DC
233
Lock Command
234
Safety B+ (OSSD)
235
Safety A (OSSD)
236
Safety B (OSSD)
237
Common
238
Safety A+ (OSSD)
[0047] The power signal conductors 62 may include coupling of the +24V DC signal at connector pin 232 and the Common signal at connector pin 237 , of the secondary electrical connector half 16 , from corresponding signals of the primary electrical connector half 14 . The safety signal conductors 64 may include coupling the input Safety A+(OSSD) signal at connector pin 238 , the output Safety A (OSSD) signal at connector pin 235 , the input Safety B+(OS SD) signal at connector pin 234 and the output Safety B (OS SD) signal at connector pin 236 , of the secondary electrical connector half 16 , from corresponding signals of the primary electrical connector half 14 . The status signal conductors 66 may include coupling the Aux signal at connector pin 231 of the secondary electrical connector half 16 from a particular one of the status signal conductors 66 from the primary electrical connector half 14 . A Lock Command signal may also be coupled to connector pin 233 of the secondary electrical connector half 16 from a corresponding signal of the primary electrical connector half 14 .
[0048] Referring now to FIG. 6 , circuitry 300 for the distribution box 12 , which may accommodate, for example, eight potential safety sensors, shorting plugs or combinations thereof, is shown in accordance with an embodiment of the present invention. As described above with respect to FIGS. 1 , 4 and 5 , the power signal conductors 62 may comprise coupling of the +24V DC signal at connector pin 219 of the primary electrical connector half 14 to connector pin 232 at each of the secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 , and coupling the Common signal at connector pin 206 of the primary electrical connector half 214 to connector pin 237 at each of the secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 . The circuitry 300 may also include an LED 314 in series with a resistor 316 , coupled between the +24V DC signal and the Common signal, wherein the LED 314 illuminates upon receiving power.
[0049] The safety signal conductors 64 may comprise coupling the input Safety A+(OSSD) signal at connector pin 202 of the primary electrical connector half 14 to the input Safety A+(OSSD) signal at connector pin 238 of the first secondary electrical connector half 16 . Next, a safety sensor or shorting plug (not shown) allows coupling the input Safety A+(OSSD) signal at connector pin 238 of the first secondary electrical connector half 16 to the output Safety A (OSSD) signal at connector pin 235 of the first secondary electrical connector half 16 . Next, the output Safety A (OSSD) signal at connector pin 235 of the first secondary electrical connector half 16 couples to the input Safety A+(OSSD) signal at connector pin 238 of the next secondary electrical connector half 18 . Another safety sensor or shorting plug (not shown) then allows coupling the input Safety A+(OSSD) signal at connector pin 238 of the secondary electrical connector half 18 to the output Safety A (OS SD) signal at connector pin 235 of the secondary electrical connector half 18 . Next, the output Safety A (OS SD) signal at connector pin 235 of the secondary electrical connector half 18 couples to the input Safety A+(OSSD) signal at connector pin 238 of the next secondary electrical connector half 20 . This serial coupling continues from secondary electrical connector half to next secondary electrical connector half until reaching the last secondary electrical connector half 30 . At the last secondary electrical connector half 30 , the output Safety A (OSSD) signal at connector pin 235 couples to the output Safety A (OSSD) signal at connector pin 217 of the primary electrical connector half 14 .
[0050] In a similar, redundant fashion, the input Safety B+(OS SD) signal at connector pin 216 of the primary electrical connector half 14 couples to the input Safety B+(OSSD) signal at connector pin 234 of the first secondary electrical connector half 16 . Again, the safety sensor or shorting plug (not shown) allows coupling the input Safety B+(OSSD) signal at connector pin 234 of the first secondary electrical connector half 16 to the output Safety B (OSSD) signal at connector pin 236 of the first secondary electrical connector half 16 . Next, the output Safety B (OSSD) signal at connector pin 236 of the first secondary electrical connector half 16 couples to the input Safety B+ (OSSD) signal at connector pin 234 of the next secondary electrical connector half 18 . Another safety sensor or shorting plug (not shown) then allows coupling the input Safety B+(OSSD) signal at connector pin 234 of the secondary electrical connector half 18 to the output Safety B (OSSD) signal at connector pin 236 of the secondary electrical connector half 18 . Next, the output Safety B (OSSD) signal at connector pin 236 of the secondary electrical connector half 18 couples to the input Safety B+(OSSD) signal at connector pin 234 of the next secondary electrical connector half 20 . This serial coupling also continues from secondary electrical connector half to next secondary electrical connector half until reaching the last secondary electrical connector half 30 . At the last secondary electrical connector half 30 , the output Safety B (OSSD) signal at connector pin 236 couples to the output Safety B (OSSD) signal at connector pin 203 of the primary electrical connector half 14 .
[0051] The status signal conductors 66 may comprise individually coupling the Aux J1-J8 status signals from the primary electrical connector half 14 to each of the respective secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 . For example, the Aux J1 signal at connector pin 207 of the primary electrical connector half 14 individually couples to the Aux signal at connector pin 231 of the secondary electrical connector half 16 ; the Aux J2 signal at connector pin 204 of the primary electrical connector half 14 individually couples to the Aux signal at connector pin 231 of the next secondary electrical connector half 18 ; and so forth.
[0052] If a shorting plug (not shown) is attached to one of the secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 , the shorting plug couples together the Aux signal at connector pin 231 of that secondary electrical connector half to the +24V DC signal at connector pin 232 of that secondary electrical connector half. As such, a remote device monitoring the status signal conductors 66 , such as the general PLC 44 , may detect the +24V DC signal, which may be accordingly interpreted by the remote device as a shorting plug present at that secondary electrical connector half. The remote device may then execute software to read a table from memory which indicates the expected presence or absence of safety sensors for each secondary electrical connector half associated with a status signal, and then trigger an alert and/or put the system and/or machine into a safe state if the table indicates that a shorting plug should be present.
[0053] If, on the other hand, a safety sensor (not shown) is attached to the secondary electrical connector half, the safety sensor does not couple the Aux signal at connector pin 231 of the secondary electrical connector half to the +24V DC signal at connector pin 232 of the secondary electrical connector half. As such, the remote device may interpret the status signal in its default condition as indicating no shorting plug is present at that secondary electrical connector half Once again, the remote device may execute software to read the table from memory which indicates the expected presence or absence of safety sensors for each secondary electrical connector half associated with a status signal, and in this case, trigger an alert and/or put the system and/or machine into a safe state if the table indicates that a shorting plug should be present.
[0054] Each of the status signal conductors 66 may also couple to an LED that illuminates upon a shorting plug coupling together the Aux signal at connector pin 231 of a secondary electrical connector half to the +24V DC signal at connector pin 232 of the secondary electrical connector half. For example, the Aux signal at connector pin 231 of the secondary electrical connector half 16 may also couple to an LED 302 in series with a resistor 304 to the Common signal at connector pin 237 of the secondary electrical connector half 16 ; the Aux signal at connector pin 231 of the secondary electrical connector half 18 may also couple to an LED 306 in series with a resistor 308 to the Common signal at connector pin 237 of the secondary electrical connector half 18 ; and so forth.
[0055] The Lock Command signal at connector pin 211 of the primary electrical connector half 14 also couples to the Lock Command signal at connector pin 233 for each of the respective secondary electrical connector halves 16 , 18 , 20 , 22 , 24 , 26 , 28 and 30 .
[0056] Referring now to FIG. 7 , a safety distribution system 400 is shown. The safety distribution system 400 may comprise an enclosure 402 in proximity to a warning light tower, or other alarm indicating device, and may contain a remote monitoring device 404 , such as a safety PLC. A group of safety signal conductors 406 , which may include a Safety A+(OSSD) signal 408 , a Safety B+(OSSD) signal 410 , a Safety A (OSSD) signal 412 and a Safety B (OSSD) signal 414 , as described with respect to FIGS. 1 and 4 - 6 above, are coupled to the device 404 for monitoring electrical continuity of the safety signal conductors 406 , which provide redundant loop back paths through safety sensors in the system.
[0057] The safety signal conductors 406 are coupled to a first electrical cable 420 having cable endings 422 and 424 of the same type, such as female cable end 422 and female cable end 424 . The first electrical cable 420 , in turn, couples to a first adapter port 426 via a first connector half 428 of the opposite type as the cable end 424 . The first adapter port 426 , in turn, couples the safety signal conductors 406 , via a second connector half 430 , to a safety sensor cable 432 and safety sensor 434 . The first adapter port 426 receives the safety signal conductors 406 back from the safety sensor cable 434 via the safety sensor cable 432 , and, in turn, couples the safety signal conductors 406 to a third connector half 436 .
[0058] A second electrical cable 440 having cable endings 442 and 444 of the same type, and similar to the first electrical cable 420 and cable endings 422 and 424 , couples between the first adapter port 426 , via the third connector half 436 , and a second adapter port 446 , via a first connector half 448 on the second adapter port 446 of the opposite type as the cable end 444 . Similar to as described above, the second adapter port 448 , in turn, couples the safety signal conductors 406 , via a second connector half 450 , to a safety sensor cable 452 and safety sensor 454 . The second adapter port 446 receives the safety signal conductors 406 back from the safety sensor cable 454 via the safety sensor cable 452 , and in turn, couples the safety signal conductors 406 to a third connector half 456 . This coupling may repeat multiple times via multiple cables and adapter ports until reaching a last adapter port 466 . At the last adapter port 466 , a shorting plug 480 may be coupled to a third connector half 476 of the last adapter port 476 to loop back the safety signal conductors 406 through each cable and adapter port to the device 404 . The device 404 may then monitor the safety signal conductors 406 for electrical continuity, and may trigger an alert and/or put the system and/or machine into a safe state if electrical continuity on any of the safety signal conductors 406 is lost.
[0059] Accordingly, the safety sensor 434 may not be bypassed simply by coupling the first electrical cable 420 to the second electrical cable 440 as the cable ends 424 and 442 are of the same type. Similarly, the safety sensor 454 may not be bypassed simply by coupling the second electrical cable 440 to the third electrical cable 460 as the cable ends 444 and 462 are of the same type. Also, the safety sensor 474 may not be bypassed simply by coupling the third electrical cable 460 to the shorting plug 480 as the cable end 464 and the connector half on the shorting plug 480 are of the same type.
[0060] In an alternative embodiment, male cable endings of the same type may be used. In addition, in alternative embodiments, another safety sensor instead of a shorting plug may be used, or one or more adapter port having differing numbers of connector halves, and subsequently attached safety sensors and/or shorting plugs, may also be used.
[0061] One or more specific embodiments of the present invention have been described above. It is specifically intended that the present invention not be limited to the embodiments and/or illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure. Nothing in this application is considered critical or essential to the present invention unless explicitly indicated as being “critical” or “essential.”
[0062] Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper,” “lower,” “above,” and “below” refer to directions in the drawings to which reference is made. Terms such as “front,” “back,” “rear,” “bottom,” “side,” “left” and “right” describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first,” “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.
[0063] When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0064] References to “a microprocessor” and “a processor” or “the microprocessor” and “the processor” can be understood to include one or more microprocessors that can communicate in a stand-alone and/or a distributed environment(s), and can thus be configured to communicate via wired or wireless communications with other processors, where such one or more processor can be configured to operate on one or more processor-controlled devices that can be similar or different devices. Furthermore, references to memory, unless otherwise specified, can include one or more processor-readable and accessible memory elements and/or components that can be internal to the processor-controlled device, external to the processor-controlled device, and can be accessed via a wired or wireless network.
[0065] The present invention may be part of a “safety system” used to protect human life and limb in a field, warehouse, factory or industrial environment. Nevertheless, the term “safety,” “safely” or “safe” as used herein is not a representation that the present invention will make the environment safe or that other systems will produce unsafe operation. Safety in an industrial process depends on a wide variety of factors outside of the scope of the present invention including: design of the safety system, installation and maintenance of the components of the safety system, and the cooperation and training of individuals using the safety system. Although the present invention is intended to be highly reliable, all physical systems are susceptible to failure and provision must be made for such failure.
|
In distribution networks for safety sensors and devices, aspects of the invention provide routing individualized status signals in parallel to potential safety sensor locations in addition to serially routing safety signals to provide substantially increased protection. A shorting plug that electrically shorts together an individualized status signal to a voltage reference level at a safety sensor location, in addition to electrically shorting together the safety signals for electrical continuity, provides individualized status information for each potential safety sensor location in addition to the serial safety information provided by the safety signals. Another aspect of the invention provides a remote monitoring device coupled to one or more adapter ports, with each adapter port coupled to one or more safety sensors, wherein adapter ports are coupled via cabling with cable endings of the same type, thereby preventing circumvention of a safety sensor simply by coupling together adjacent cables.
| 7
|
[0001] This application is a non-provisional United States patent application and claims priority and the filing date of United Kingdom application No. 0700520.0 filed Jan. 11, 2007 and incorporates the same by reference.
[0002] This invention relates to an apparatus and method for dispensing post-mix beverages. More especially the invention is concerned with a manually operable valve assembly for mixing a concentrate such as a syrup or flavor with a diluent such as still or carbonated water to form a post-mix beverage such as colas, fruit juices, etc. The invention has particular application to a hand-held multi-product beverage dispense valve assembly for dispensing any selected one of a plurality of post-mix beverages.
BACKGROUND OF THE INVENTION
[0003] In hand-held multi-product beverage dispense valve assemblies, also commonly known as bar guns, supplies of diluent and concentrate are fed to individual valves in a dispense head that can be held in the hand and has a plurality of buttons or the like for manual selection and operation to dispense diluent separately or in combination with a flavor. Typically, when dispensing such post-mix beverages, a large volume of diluent is mixed with a small volume of concentrate, for example a diluent to concentrate ratio of 6:1, to produce the desired post-mix beverage.
[0004] A commonly occurring problem in the known bar guns, is cross-contamination of beverages due to carry-over of concentrate after a beverage has been dispensed into subsequently dispensed beverages. This can arise in a number of ways. For example, concentrate flowing into the dispense nozzle may adhere to internal surfaces of the nozzle where it remains and is washed into subsequently dispensed beverages. Due to the high concentration of the concentrates used to produce the beverages, such contamination can have an adverse effect on the appearance of the beverage, particularly where the contaminating concentrate is highly colored, with the result that the beverage is rejected by the customer, even if the taste of the beverage is not affected. Carry-over of the concentrate may also occur where the valve controlling flow of concentrate discharges into a duct opening to the nozzle resulting in a volume of concentrate remaining in the duct downstream of the valve at the end of dispense that can be sucked out of the duct by the vacuum created by the flow of diluent when the next beverage is dispensed.
[0005] Another problem often encountered with the known bar guns is slow or incomplete draining at the end of the dispense that can also lead to cross-contamination of subsequently dispensed beverages by any undispensed beverage remaining in the gun at the end of the dispense.
[0006] Yet another problem found in many known bar guns is poor or incomplete mixing of the diluent and concentrate before the beverage is dispensed into a glass or other receptacle that can lead to stratification (different layers) of the beverage in the glass which can affect the appearance and taste of the beverage.
[0007] A further problem occurring in many known bar guns that dispense carbonated beverages is poor retention of carbonation levels in the dispensed beverage due to uncontrolled break-out of carbon dioxide during dispense, particularly within the gun.
[0008] Other problems commonly associated with known bar guns include poor hygiene due to the presence of areas within the gun, especially small holes and ports where deposits of beverage components especially the more viscous concentrates can build up and/or where insects can become trapped leading to blockages that affect the dispense.
SUMMARY OF THE INVENTION
[0009] The present invention has been made from a consideration of the foregoing and seeks to provide an apparatus and method for dispensing post-mix beverages that mitigates one or more of the foregoing problems and disadvantages of known bar guns.
[0010] More especially, it is a desired aim of the present invention to provide an apparatus and method for dispensing post-mix beverages in which the occurrence of cross-contamination of dispensed beverages is reduced.
[0011] It is a further desired aim of the present invention to provide an apparatus and method for dispensing post-mix beverages in which mixing of diluent and concentrate is enhanced before dispense of the beverage into a receptacle and/or in which substantially complete draining of the beverage into the receptacle occurs at the end the dispense in a short time.
[0012] It is yet another desired aim of the present invention to provide an apparatus and method for dispensing post-mix beverages in which hygiene levels are improved.
[0013] These and other preferred aims of the present invention will be more fully understood from the description hereinafter.
[0014] According to one aspect of the invention, there is provided apparatus for dispensing a post-mix beverage comprising a valve assembly for dispensing a diluent and a concentrate wherein dispense of the diluent starts before and finishes after dispense of the concentrate.
[0015] By this aspect of the invention, the concentrate is always added to a volume of diluent. Also, the presence of a volume of diluent reduces the risk of concentrate adhering to internal surfaces.
[0016] In at least one embodiment, the valve assembly may dispense the diluent with any selected one of a plurality of concentrates for dispense of a range of different beverages.
[0017] In at least one embodiment, the valve assembly may dispense the diluent with or without addition of concentrate. For example, the diluent may be still or carbonated water that can be dispensed with or without a concentrate such as a syrup or flavor.
[0018] In at least one embodiment, the valve assembly may dispense the concentrate into a stream of diluent that flows over a port through which the concentrate flows. In this way, the diluent picks up the concentrate when the port is open during dispense and the port is flushed with diluent at the end of the dispense when the port is closed.
[0019] According to another aspect of the invention, there is provided a method of dispensing a post-mix beverage comprising a valve assembly for dispensing a diluent, dispensing a concentrate and mixing the diluent and concentrate wherein dispense of the diluent starts before and finishes after dispense of the concentrate.
[0020] According to a further aspect of the invention, there is provided apparatus for dispensing a post-mix beverage comprising a valve assembly including a diluent valve for controlling flow of a diluent and a concentrate valve for controlling flow of a concentrate, and a chamber in which diluent from the diluent valve and concentrate from the concentrate valve are mixed, wherein the concentrate valve has an outlet through which concentrate can flow directly into the chamber when the outlet is open and which prevents flow of concentrate when the outlet is closed.
[0021] By this aspect of the invention, when the outlet of the concentrate valve is open, all the concentrate flowing through the outlet enters the mixing chamber for mixing with diluent and, when the concentrate valve is closed, no volume of concentrate downstream of the concentrate valve is present.
[0022] In at least one embodiment, the diluent dispense valve opens before and closes after the concentrate dispense valve. In this way, the concentrate is always added to a volume of diluent in the mixing chamber.
[0023] In at least one embodiment, the concentrate may flow through the outlet of the concentrate valve into a stream of diluent that flows over the outlet. In this way, the diluent picks up the concentrate when the outlet is open during dispense and the outlet is flushed with diluent at the end of the dispense when the outlet is closed.
[0024] In at least one embodiment, the valve assembly may include a plurality of concentrate valves and diluent from the diluent valve may be mixed with concentrate from any selected one of the concentrate valves.
[0025] According to another aspect of the invention, there is provided a method of dispensing a post-mix beverage comprising mixing a diluent and a concentrate in a chamber to produce a beverage wherein flow of concentrate to the chamber is controlled with a valve configured to admit concentrate directly to the chamber.
[0026] According to another aspect of the invention, there is provided a valve assembly including a diluent valve for controlling flow of a diluent and a concentrate valve for controlling flow of a concentrate, and a chamber in which diluent from the diluent valve and concentrate from the concentrate valve are mixed, wherein a flow deflector is provided in the chamber for promoting mixing of the diluent and concentrate.
[0027] By this aspect of the invention, mixing of the diluent and concentrate is improved by use of a flow deflector in the chamber. The flow deflector may also help to reduce break-out where the diluent contains a dissolved gas such as carbon dioxide so as to maintain carbonation levels in the dispensed beverage.
[0028] In at least one embodiment, the flow deflector is arranged to direct at least some of the diluent flow from the diluent valve to flow across an outlet from the concentrate valve so that concentrate from the concentrate valve flows into the diluent flowing across the outlet. In this way, the diluent picks up the concentrate when the outlet is open during dispense.
[0029] In at least one embodiment, the diluent dispense valve opens before and closes after the concentrate dispense valve. In this way, the concentrate is always added to a volume of diluent in the mixing chamber and the outlet is flushed with diluent at the end of the dispense when the outlet is closed.
[0030] In at least one embodiment, the valve assembly may include a plurality of concentrate valves such that diluent from the diluent valve may be mixed with concentrate from any selected one of the concentrate valves and the deflector promotes mixing of the diluent with concentrate from any selected concentrate valve.
[0031] According to a further aspect of the invention, there is provided a method of dispensing a post-mix beverage comprising mixing a diluent and a concentrate in a chamber to produce a beverage wherein mixing of the diluent and concentrate is promoted by a flow deflector arranged in the chamber.
[0032] According to another aspect of the invention, there is provided apparatus for dispensing a post-mix beverage comprising a valve assembly including a diluent valve for controlling flow of a diluent and a concentrate valve for controlling flow of a concentrate, and a chamber in which diluent from the diluent valve and concentrate from the concentrate valve are mixed, the concentrate valve having an outlet through which concentrate can flow into the chamber, means provided in the chamber for directing diluent from the diluent valve towards the outlet, and actuator means for operating the diluent valve and concentrate valve, said actuator means being configured for dispensing a mixture of diluent and concentrate wherein the diluent valve doses after the concentrate valve.
[0033] According to a still further aspect of the invention, there is provided a method of dispensing a post-mix beverage comprising providing a valve for admitting diluent to a mixing chamber at a first position, providing a valve for admitting concentrate to a mixing chamber at a second position, opening the diluent and concentrate valves, directing diluent towards the second position, and closing the diluent valve after the concentrate valve.
[0034] In the foregoing aspects of the invention, the apparatus may be in the form of a bar gun in which supplies of diluent and concentrate are fed to the gun in separate lines contained in a flexible hose that permits the gun to be held and maneuvered while operating the gun to dispense a selected beverage into a receptacle such as a glass via a nozzle.
[0035] In at least one embodiment, the diluent and concentrate lines are connected to respective flow control valves and the gun is provided with an array of buttons for manual operation to dispense diluent or a mixture of diluent and concentrate. Where a mixture of diluent and concentrate is dispensed, the diluent flow control valve may be opened before and closed after the concentrate flow control valve.In this way, the concentrate flows into the diluent during dispense and, at the end of the dispense, the nozzle is flushed with diluent to remove traces of concentrate.
BRIEF DESCRIPTION OF THE DRAWING
[0036] The invention will now be described in more detail by way of example only with reference to the accompanying drawings in which:
[0037] FIG. 1 is a perspective view of a bar gun embodying the invention;
[0038] FIG. 2 is a side view of the bar gun shown in FIG. 1 ;
[0039] FIG. 3 is a plan view of the bar gun shown in FIG. 1 ;
[0040] FIG. 4 is a front view of the bar gun shown in FIG. 1 ;
[0041] FIG. 5 is an exploded isometric view of the bar gun shown in FIGS. 1 to 4 ;
[0042] FIG. 6 is a plan view of the valve head assembly shown in FIG. 5 ;
[0043] FIG. 7 is a side view of the valve head assembly shown in FIG. 5 ;
[0044] FIG. 8 is a section on the line 8 - 8 of FIG. 6 ; and
[0045] FIG. 9 is an exploded isometric view of the valve head assembly shown in FIGS. 5 to 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] Referring first to FIGS. 1 to 5 of the accompanying drawings, there is shown apparatus for dispensing post-mix beverages in the form of a bar gun 1 . The gun 1 comprises a handle 3 for the user to grip and hold the gun 1 with a plurality of buttons 5 provided on the upper surface of the handle 3 at one end of the gun 1 for user actuation to dispense a selected beverage. In this embodiment, four buttons are provided of which three buttons 5 a , 5 b , 5 c control flow of concentrates such as syrups or flavors and a fourth button 5 d controls flow of diluent such as still or carbonated water. As described in more detail later, depression of the diluent button 5 d dispenses diluent only while depression of each concentrate button 5 a , 5 b , 5 c dispenses a mixture of concentrate and diluent.
[0047] It will be understood that other combinations of buttons may be employed depending on the number and/or type of post-mix beverages the gun can dispense. For example, more than or less than three concentrate buttons may be employed. More than one diluent button may be provided. For example, two diluent buttons may be provided, one for still water and one for carbonated water. All possible combinations of buttons are envisaged and within the scope of the invention.
[0048] The other end of the handle 3 is provided with a boss 7 for connecting a flexible hose 9 containing four lines (not shown) connected to remote sources (not shown) of the concentrates and diluent. The lines pass through the handle 3 and are connected to a dispense valve assembly 11 housed within the handle 3 and operable by the buttons 5 to dispense the selected beverage as described in more detail later. The diluent and concentrate lines may pass through a remote cooler (not shown) before passing through the hose 9 to the gun 1 for dispense of chilled beverages. A coolant re-circulation loop may be provided in the hose 9 for circulating a cooling medium to prevent the diluent and concentrate warming up in the hose 9 . Any suitable cooling medium may be employed.
[0049] As best shown in FIG. 5 , the body of the handle 3 comprises an assembly of a plurality of components, typically plastic moldings, including upper and lower main body parts 13 , 15 , a cover part 17 , a nozzle 19 and side grips 21 , 23 .
[0050] The valve assembly 11 is received in a cavity 25 in the lower body part and is secured to the lower body part 15 by a pair of screws 27 a , 27 b passed through holes 29 (one only shown) in a ledge 31 surrounding an opening 33 .
[0051] The nozzle 19 is connected at the upper end to the opening 33 to receive liquid discharged by the valve assembly 11 and tapers inwardly to a central hole (not shown) at the lower end for beverage dispense into a receptacle such as a glass (not shown).
[0052] A gasket 35 interposed between the ledge 31 and a flange 36 of the valve assembly 11 provides a fluid tight seal to prevent leakage of liquid discharged by the valve assembly 11 into the interior of the handle 3 .
[0053] The upper body part 13 locates on the lower body part 15 and closes the cavity 25 to conceal the valve assembly 11 . The upper body part 13 is secured to the valve assembly 11 by a pair of screws 37 a , 37 b inserted through holes 39 a , 39 b in the upper body part 13 , and the lower body part 15 is secured to the upper body part 13 by a screw 47 provided with a removable cover part 49 .
[0054] The buttons 3 are mounted on the upper body part 13 and retained by the cover part 17 that is secured to the upper body part 13 by a screw 41 engaging a threaded insert 42 secured in the cover part 17 . The cover part 17 is provided with a disc 43 carrying information to identify the beverage dispensed by each of the concentrate buttons 5 a , 5 b , 5 c.
[0055] The side grips 21 , 23 are similar and are located and retained on opposite sides of a central region of the lower body part 15 by tabs 45 a , 45 b.
[0056] The boss 7 has a transverse through bore 51 closed at the ends by a pair of caps 53 , 55 secured together by screws 57 a , 57 b and provided with discs 57 , 59 carrying advertising, branding or other product information.
[0057] Referring now to FIGS. 6 to 9 , the dispense valve assembly 11 is shown in more detail and includes nipples 61 a , 61 b , 61 c for connecting each of the concentrate lines to a respective concentrate flow control valve and a nipple 61 d for connecting the diluent line to a diluent flow control valve.
[0058] Each concentrate flow control valve includes a respective valve chamber 63 a , 63 b , 63 c in which a concentrate valve piston 65 a , 65 b , 65 c is slidably received for movement between open and dosed positions.
[0059] Each concentrate valve piston 65 a , 65 b , 65 c is biased to the closed position in which the piston closes a port at the lower end of the associated concentrate valve chamber 63 a , 63 b , 6 c by a separate spring 67 a , 67 b , 67 c respectively acting between an upper end of the piston and the valve chamber.
[0060] Each piston 65 a , 65 b , 65 c has a head 69 a , 69 b , 69 c respectively carrying an O-ring 71 a , 71 b , 71 c respectively that provides a fluid-tight seal with the associated port preventing leakage of concentrate in the dosed position.
[0061] Each piston 65 a , 65 b , 65 c also carries an O-ring 72 a , 72 b , 72 c respectively that provides a fluid-tight seal with the bore of the valve chamber 63 a , 63 b , 63 c for sling movement of the piston 65 a , 65 b , 65 c.
[0062] Each O-ring 72 a , 72 b , 72 c is of larger diameter than the O-ring 71 a , 71 b , 71 c whereby each piston 65 a , 65 b , 65 c is also biased to the closed position by concentrate pressure in the valve chamber 63 a , 63 b , 63 c . As a result, a fluid-tight seal that prevents leakage of concentrate in the closed position can be obtained using a weaker spring making it easier to operate the concentrate flow control valves.
[0063] The diluent flow control valve includes a valve chamber 63 d in which a valve piston 65 d is received for movement between open and closed positions.
[0064] The valve piston 65 d is biased to the closed position in which the piston closes a port at the lower end of the diluent valve chamber 63 d by a spring 67 d acting between the piston 65 d and a piston retainer 68 secured at the upper end of the valve chamber 63 d by a pair of screws 70 a , 70 b and sealed by an O-ring 74 .
[0065] The diluent piston 65 d has a head 69 d carrying an O-ring 71 d that provides a fluid-tight seal with the port preventing leakage of diluent in the dosed position.
[0066] The diluent piston 65 d also carries an O-ring 72 d that provides a fluid-tight seal with the bore of the retainer 68 for sliding movement of the piston 65 d between the open and closed positions.
[0067] The O-ring 72 d is of smaller diameter than the O-ring 71 d whereby the diluent piston 65 d is also biased to the closed position by diluent pressure in the valve chamber 63 d . As a result, a fluid-tight seal that prevents leakage of diluent in the closed position can be obtained using a weaker spring making it easier to operate the diluent flow control valve.
[0068] The head 69 d of the diluent piston 65 d projects through the port and a deflector plate 73 is secured to the head 69 d by a screw 75 . A washer 76 loosely connects the screw 75 to the deflector plate 73 for assembly/disassembly purposes. The head 69 d and deflector plate 73 are configured so that, when the diluent piston 65 d is in the open position, at least part of the diluent flow is directed towards the concentrate flow control valve ports. In a modification (not shown), the deflector plate 73 may be integral with the piston head 69 d . In another modification (not shown), the deflector plate 73 is mounted on or integral with the nozzle 19 .
[0069] The concentrate valve pistons 65 a , 65 b , 65 c and diluent valve piston 65 d are operable to control the flows of concentrate and diluent admitted to the nozzle 19 by a control lever assembly 77 in response to the actuation of the buttons 5 a , 5 b , 5 c , 5 d.
[0070] The lever assembly 77 includes a respective lever 77 a , 77 b , 77 c for each concentrate piston 65 a , 65 b , 65 c and a lever 77 d for the diluent piston 65 d.
[0071] Each concentrate lever 77 a , 77 b , 77 c is pivotally mounted at one end on a pivot pin 79 that extends through aligned holes 81 a in a mounting block 81 and is secured by a circlip 82 . The other, actuator end of each concentrate lever 77 a , 77 b , 77 c freely rests on and is supported at the actuator end of the diluent lever 77 d.
[0072] The diluent lever 77 d is pivotally mounted intermediate its ends on the pivot pin 79 and the end remote from the actuator end is coupled to the upper end of the diluent piston 65 d.
[0073] The concentrate and diluent buttons 5 a , 5 b , 5 c , 5 d are aligned with the actuator ends of the corresponding concentrate and diluent levers 77 a , 77 b , 77 c , 77 d respectively and are operable to control flow of diluent only or a mixture of diluent and concentrate into the nozzle 19 .
[0074] In use of the bar gun, when the diluent button 5 d is depressed, the diluent lever 77 d pivots about the pivot pin 79 and lifts the diluent piston 65 d against the biasing of the return spring 67 d and diluent pressure from the closed position to the open position in which the piston head 69 d is moved to open the port and allow diluent to flow from the valve chamber 63 d into the nozzle 19 for discharge into receptacle placed under the nozzle 19 .
[0075] The actuator ends of the concentrate levers 77 a , 77 b , 77 c rest on and are supported by the diluent lever 77 d and can fall under gravity as the diluent lever 77 d pivots in response to depression of the diluent button 5 d until the concentrate levers 77 a , 77 b , 77 c come into contact with the concentrate pistons 65 a , 65 b , 65 c . However, no force is applied to the concentrate levers 77 a , 77 b , 77 c and the concentrate pistons 65 a , 65 b , 65 c remain in the closed position under the biasing of the associated return springs 67 a , 67 b , 67 c and concentrate pressure so that only diluent flows into the nozzle 19 when the diluent button 5 d is depressed. When one of the concentrate buttons 5 a , 5 b , 5 c is depressed, the associated concentrate lever 77 a , 77 b , 77 c pivots about the pin 79 and causes the diluent lever 77 d to also pivot about the pin 79 . The concentrate levers 77 a , 77 b , 77 c are initially spaced above the top of the associated concentrate piston 65 a , 65 b , 65 c . As a result, when any of the concentrate buttons 5 a , 5 b , 5 c is depressed, the diluent lever 77 d initially pivots to lift the diluent piston 65 d and allow diluent to flow into the nozzle 19 before the concentrate lever 77 a , 77 b , 77 c actuated by the selected button 5 a , 5 b , 5 c contacts the associated concentrate piston 65 a , 65 b , 65 c . Further depression of the selected button 5 a , 5 b , 5 c causes the actuated concentrate lever 77 a , 77 b , 77 c to lower the associated piston 65 a , 65 b , 65 c against the biasing of the return spring 67 a , 67 b , 67 c and concentrate pressure from the closed position to the open position in which the piston head 69 a , 69 b , 69 c is moved to open the port and allow concentrate to flow from the valve chamber 63 a , 63 b , 63 c into the nozzle 19 where it mixes with the diluent for discharge of the selected beverage into a receptacle placed under the nozzle 19 .
[0076] When the concentrate button 5 a , 5 b , 5 c for the selected beverage is released, the associated concentrate piston 65 a , 65 b , 65 c returns to the closed position under the biasing of the associated return spring 67 a , 67 b , 67 c and concentrate pressure to shut-off flow of concentrate into the nozzle 19 before the diluent piston 65 d returns to the dosed position under the biasing of the return spring 67 d and diluent pressure.
[0077] In this way, when a beverage is selected in which diluent is mixed with a concentrate, the flow of diluent into the nozzle 19 starts before the flow of concentrate and continues after the flow of concentrate into the nozzle 19 stops. The deflector plate 73 is positioned under the port from the valve chamber 63 d of the diluent flow control valve and directs at least part of the diluent flow into the nozzle 19 to flow over the ports from the valve chambers 63 a , 63 b , 63 c of the concentrate flow control valves. This has a number of benefits and advantages.
[0078] Firstly, the flow of concentrate jets into a flow of the diluent as it passes over the concentrate port This results in enhanced mixing of the concentrate and diluent within the nozzle before the beverage is dispensed from the nozzle into the receptacle. This in turn leads to a more uniform mixing and improved appearance of the beverage in the receptacle.
[0079] Secondly, the flow of concentrate is prevented from impinging directly on internal surfaces of the nozzle. This inhibits adhesion of concentrate to the internal surface of the nozzle where it may remain after dispense of the beverage and contaminate subsequently dispensed beverages. The nozzle may be made of a material that further inhibits adhesion such as polyester.
[0080] Thirdly, the internal surfaces of the nozzle and concentrate ports are washed with diluent at the end of dispense when the concentrate flow control valve has closed. This removes all traces of concentrate from the internal surfaces of the nozzle and exposed surfaces of the concentrate ports within the nozzle. This in turn ensures that the entire volume of concentrate flowing into the nozzle when the concentrate flow control valve is open is dispensed into the receptacle to produce the desired quality of beverage. Moreover, the risk of contamination of subsequently dispensed beverages by carry over of concentrate from a previously dispensed beverage is significantly reduced. As a result of this self-cleaning function, nozzle hygiene is improved.
[0081] Fourthly, the concentrate valve pistons shut-off the flow of concentrate at the point of discharge into the nozzle itself so that no volume of concentrate remains downstream of the concentrate valve after dispense that can be sucked into and contaminate subsequently dispensed beverages.
[0082] Fifthly, the distribution of the diluent within the nozzle is enhanced by the deflector plate which assists in maintaining carbonation levels in the dispensed beverage when the diluent contains a dissolved gas such as carbon dioxide by helping to reduce break-out of the gas during dispense.
[0083] Sixthly, the distribution of the diluent within the mixing chamber formed by the nozzle due to the deflector plate leads to further improvements in the overall mixing and quality of the dispensed beverage. A further improvement may also be achieved by employing a tapered or cone-shaped mixing chamber that promotes mixing of the diluent and concentrate within the nozzle before dispense.
[0084] Seventhly, the flow of diluent within the nozzle is at least partially directed towards the internal surfaces of the nozzle by the deflector plate enabling a larger nozzle outlet to be used. As a result, admission of air into the nozzle at the end of dispense is improved leading to better 30 draining of the nozzle and reduced risk of beverage remaining in the nozzle and contaminating subsequently dispensed beverages. In addition, air may also be admitted to the nozzle to prevent a vacuum being created within the nozzle by the flow of diluent during dispense thereby helping to maintain carbonation levels where the diluent contains carbon dioxide or other gas by reducing break-out of the gas. Preventing formation of a vacuum may also help to maintain the correct mixing ratio of diluent and concentrate by preventing changes to the diluent and/or concentrate flows that could otherwise occur. The larger nozzle outlet may also make handling and use of the bar gun easier by increasing the angle at which the nozzle can be held when dispensing beverage into a receptacle without beverage collecting and remaining in the nozzle at the end of the dispense.
[0085] Other benefits and advantages of the above-described bar gun will be apparent to those skilled in the art. It will be understood that the invention is not limited to the embodiment above-described and various modifications and improvements can be made without departing from the various concepts described herein. For example, while the invention has been described with particular reference to a bar gun, it will be appreciated that any of the features could be employed in other forms of apparatus for dispensing post-mix beverages including post-mix beverage towers and dispensers. Moreover, any of the features may be employed separately or in combination with any other features and the invention extends to and includes all combinations and sub-combinations of one or more features described herein in any form of apparatus for dispensing post-mix beverages.
|
This invention discloses dispensing post-mix beverages, and a manually operable valve assembly for mixing a concentrate such as a syrup or flavor with a diluent to form a post-mix beverage, such as a hand-held multi-product beverage dispense valve assembly for bar guns. The present invention reduces cross-contamination of dispensed beverages, completes draining of the beverage at the end of the dispense in a short time, and improves hygiene.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to efficient means for the generation of electrical or other power utilizing energy from geothermal sources and, more particularly, relates to arrangements including efficient super-heated steam generation and pumping equipment for long-life application in deep hot water wells for the useful transfer of thermal energy to the earth's surface.
2. Description of the Prior Art
While geothermal energy sources have been employed for the generation of power to a limited extent, generally known prior art systems operate with low efficiency and have additional disadvantages. In the few installations in which dry steam is supplied by wells at the earth's surface, the steam may be fed after removal of solid matter, from the well head directly to a turbine. On the other hand, most geothermal wells are characterized by yields of a mixture of steam and hot water along with corrosive solutes at the earth's surface, so that the water must be separated from the steam before the latter is used in a turbine.
In both kinds of installations, low pressure steam normally results, requiring the use of special turbines and yielding relatively inefficient power generation as compared to generation of power using normally operated fossil fuel or nuclear powered electrical generation equipment. Rarely do geothermal wells actually produce truly super-heated steam with only minor amounts of undesired gases and with no liquid water. The presence of significant amounts of liquid water presents problems in addition to the separation problem. If the water is only moderately hot, extraction of thermal energy from it may be expensive, or, at least, inefficient. Further, whether or not its heat content is used, the water must be handled. The water usually bears considerable concentrations of silica and of corrosive alkali salts, including chloride, sulfate, carbonate, borate, and the like ions, all of which dissolved materials present precipitation problems at the point at which any part of the water may abruptly flash into steam. If the alkaline water is allowed to escape at the installation, severe chemical and thermal pollution of streams or rivers may result. Finally, there is evidence that the removal of large amounts of water from geothermal reservoirs may lead, in a generally unpredictable manner, to undesirable land subsidence in the vicinity of thermal well installations.
A major advance in the art of extraction and use of geothermal energy is reflected in the H. B. Matthews' U.S. Pat. application Ser. No. 300,058 for a "Geothermal Energy System and Method", filed Oct. 24, 1972, issued July 23, 1974 as U.S. Pat. No. 3,824,793, and assigned to the Sperry Rand Corporation. The prior Matthews invention provides means for efficient power generation employing energy derived from geothermal sources through the generation of dry super-heated steam and the consequent operation of sub-surface equipment for pumping extremely hot well water at high pressure to the earth's surface. Clean water is injected at a first or surface station into the deep well where thermal energy stored in hot solute-bearing deep well water is used at a second or deep well station to generate super-heated steam from the clean water. The resultant dry super-heated steam is used at the well bottom for operating a turbine-driven pump for pumping the hot solute-bearing well water to the first station at the earth's surface. The water is pumped at all times and locations in the system at pressures which prevent flash steam formation. The highly energetic water is used at the surface or first station in a binary fluid system so that its thermal energy is transferred to a closed-loop surface-located vapor generator-turbine system for driving an electrical power alternator. Cooled, clean water is regenerated by the surface system and is re-injected into the well for operation of the steam turbine therein. Undesired solutes may be pumped back into the earth in the form of a concentrated brine via a separate well.
In contrast to the poor performance of prior art systems, the prior Matthews invention is characterized by high efficiency as well as by many other advantageous features. It is not limited to use with the rare dry steam sources, and it is devoid of the water and steam separation problems attached to prior art systems used with mixed steam and hot water supply wells. Since the novel power system operates with dry, highly super-heated steam, existing efficient heat transfer elements and efficient high pressure turbines may readily be employed. According to the invention, the very large calorific content of high temperature water subjected to high pressure is efficiently employed. Since high pressure liquid is used as the thermal transfer medium, undesired flash steam formation is prevented, along with its undesired attendant deposition of dissolved materials. Because the dissolved salts are efficiently pumped back deep into the earth as remotely as need be from the geothermal source, surface pollution effects are avoided and there is relatively little risk of land sinkage in the vicinity of the geothermal source.
SUMMARY OF THE INVENTION
The present invention is an improvement over that of the aforementioned Matthews patent and provides long life and efficient operation of the parts employing water re-injected into the well from the earth's surface, such as for conversion into the working fluid needed for driving the deep well turbine-driven pump and for providing a lubricating liquid in fluid bearings supporting the rotors of that turbine-pump system. The flow of clean water is unavoidably subjected to the possibility of contamination by solid matter during its recycling passage through the associated closed loop because of the effects of rust or corrosion or simply because of the unclean initial state of the system, a condition generally unavoidable because of the complex assembly and installation problems associated with it. While some such debris may be removed at the above-surface part of the loop by an ordinary filter, it is particularly desirable to provide filtration immediately before the re-injected water reaches the turbine-driven pump system so that all particles are removed from the stream that may have entered it especially from the long vertical pipe returning the reinjected water from the surface. The present invention provides such improved filtration means and additionally affords a novel surface-located arrangement for cleaning and flushing the content of the filter at the will of the operator. This event is accomplished at the earth's surface without removal of any part of the deep well installation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagramatic representation of the invention particularly illustrating apparatus located at the earth's surface and its connections to the deep well apparatus.
FIG. 2 is an elevation view in cross section of the novel deep geothermal well filter system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates in the left part of the drawing the general structure and characteristics of that portion of a geothermal energy extraction system which is immersed in a deep well extending into strata far below the surface of the earth, preferably being located at a depth below the surface such that a copious supply of extremely hot water under high pressure is naturally available, the active pumping structure being located adjacent the hot water source and within a generally conventional well casing pipe 10. The configuration in FIG. 1 is seen to include a well head section 1 located at the earth's surface and a main well section 2 extending far downward from well head section 1 below the earth's surface. At the subterranean source of hot, high pressure water, the main well section 2 joins a steam generator input section 3. The steam generator section 4, the steam turbine section 5, a rotary bearing section 6, and a hot water pumping section 7 follow in close cooperative succession at increasing depths.
Extending downward from the well head section 1 at the earth's surface, the well casing pipe 10 surrounds in preferably concentric relation an innermost stainless steel or other high quality alloy steel pipe or conduit means 8 for supplying a flow of relatively cool and relatively pure water at the bottom of the well for purposes yet to be explained. A second relatively large pipe or conduit 9 of similar quality and surrounding pipe 8 is also provided within well casing 10, extending from well head 1 to the energy conversion and pumping system at the bottom of the well and permitting turbine exhaust steam to flow to the surface of the earth, as will be described.
It will be seen from FIG. 1 that relatively clean and cold water is pumped down the inner pipe 8 from the earth's surface station through the novel filter 11 of the present invention. As will be described in connection with FIG. 2, filter 11 is devised to store particulate matter entering it from above, and to store it until its release is commanded. When the latter event occurs, the stored debris or sediment is flushed out of filter 11 through the generally horizontal conduit 14 into the space between pipes 9 and 10, which pipes form conduit means normally occupied by the pumped hot water. The debris very readily flows through the hot geothermal water loop or may fall back into the well itself and is thus removed from the scene of the deep well apparatus.
The filtered clean water normally leaves filter 11 and, at tee 12 is divided between two branch paths. As is described in the aforementioned Matthews patent, a first branch path feeds clean lubricating water through pipes 13 and 17 for lubricating a system of bearings within the turbine-pump system bearing section 6. The second branch path feeds clean water through pressure regulator system 15 and via distribution pipe or pipes 16 to the input manifold 22 of a steam generator 18 formed between the generally concentric walls of alloy pipes 9 and 9a. Accordingly, high pressure steam is generated and delivered to a steam turbine located within turbine section 5.
The function of the steam turbine located at section 5 and supported on bearings located within bearing section 6 is to drive a hot water pump located at pump section 7. Hot, high pressure water is thus impelled upward by the rotating pump vanes 20 between the rotating conical end 23 of the pump and an associated pump shroud 19; the hot water is pumped upward at high velocity in the annular conduit between pipes 9 and 10, thus permitting use of the thermal energy it contains at the earth's surface. More important, the hot water is pumped upward to the earth's surface at a pressure preventing it from flashing into steam and thus undesirably depositing dissolved salts at any point of incipient flashing.
Accordingly, it is seen that the extremely hot, high-pressure well water is pumped upward, flowing in the annular region defined between alloy pipes 9 and 10. Heat supplied by the hot well water readily converts the clean water flowing into manifold 22 of the steam generator 18 into highly energetic, dry, super-heated steam. The clean water, before flowing through tee junction 12 and pressure regulator 15, is at a very high pressure due to its hydrostatic head and normally also to pressure added by a surface pump yet to be discussed, so that it may not flash into steam. The pressure regulator system 15 controls the pressure of the clean water flowing therethrough so that it readily may be vaporized and superheated in the volume 18 of the steam generator. The highly energetic steam drives the deep well steam turbine and is redirected to flow upward to the earth's surface after expansion to form relatively cool steam flowing within the annular conduit defined between alloy pipes 8 and 9. Thermal energy is recovered, as will be discussed, at the earth's surface 11 primarily from the loop containing hot, high pressure water, but may also be retrieved from the turbine exhaust steam.
As described in the aforementioned Matthews patent, the hot, high pressure water within well casing 10 is fed by pipe 10a to a conventional surface thermal plant 25 which may include in the usual manner a vapor generator system in which a major part of the energy in the hot geothermal fluid is converted into high pressure vapor for driving an alternator supplying electrical energy on power lines 24, 24. The condensed fluid is pumped by pump 26 back deep into the earth via well 27. Thus, the geothermal fluid flow loop is effectively completed and fluid and dissolved mineral salts are returned into deep strata of the earth.
Still referring to FIG. 1, a closed loop for supplying and re-injecting clean water into the deep well geothermal system will next be described. The steam exhausted upwardly from the driving turbine at section 5 of that well is conveyed by pipes 9 and 9a to a heat exchanger element 32 of a conventional heat exchanger 31 and, after condensation therein, flows through the normally open valve 36. Heat exchanger 31 may be operated by supplying cooling water in a third loop including a conventional cooling tower (not shown) to pipe 34 connected through heat exchanger element 33 and output pipe 35 back to the same fluid cooling tower. Alternatively, known expedients may be employed for extraction of additional energy during the condensation process for use by power plant 25.
The clean water condensate flowing through normally open valve 36 is pumped by a conventional pump 37 back through the normally open valves 38 and 40 into pipe 8a through tee junction 50 for injection into the deep well pipe 8 at a pressure substantially above that of the pumped hot well water. Replenishment water may be supplied by opening the valve 41 from a clean water source 42. A conventional filter 39 may be interposed between the normally open valves 38 and 40.
Referring now to FIG. 2, the downwardly extending cold water input conduit means 8 is enlarged by a tapered section 61 that is in turn affixed to a downwardly extending filter casing 63 serving as the primary container for the novel filter system 11. At the end of filter casing 63, a second tapered section 71 couples the clean filtered water flow into a pipe 72 substantially of the same diameter as pipe 8, from whence the clean water may flow through the tee junction 12 of FIG. 1, as previously explained. Contained within the tapered sections 61 and 71 and the extended filter casing 63 is a multiply-apertured cavity-forming pipe 64 which actively serves as the filter element of the present invention. Cavity-forming pipe 64 is fastened as by welding, at 60 to the inner surface of the tapered section 61 and extends downward therefrom in generally concentric relation with filter casing 63. An upper portion of the filter cavity-forming pipe 64 contains a series of apertures such as aperture 62. These may be regularly spaced, if desired, though such is not strictly necessary for the practice of the invention. Nor is it necessary that all of the apertures 62 be of the same shape or dimensions. The apertures 62 serve to permit flow of the downward moving clean water from the interior of the filter cavity 64 into the space between that cavity and filter casing 63 as generally indicated by arrows 59. In this manner, the reinjected clean water stream flows on through the filter 11, pipe 72, and tee 12 to be used as previously discussed.
The cavity-forming pipe 64 is further equipped near its bottom with a differential pressure valve 57 of generally conventional nature. The armature of valve 67, being in the general shape of a frustrum of a cone, is adapted to seat itself in a conically-shaped bore in the partition 66 forming a bottom of the filter. The valve armature is urged against its seat by the spring 70, being guided by the cooperative action of pin 68 and of tubular guide 69 which slides over pin 68. The region in cavity 64 below the valve 66, 67 is sealed except for being coupled through the filter exhaust conduit 14, also shown in FIG. 1, to the space between pipe 9 and the well casing 10.
In normal operation, the armature of valve 67 of FIG. 2 remains closed and the condensate from condenser element 32 (FIG. 1) is pumped by pump 37 back into the cold water input pipe 8. Also in normal operation, the flow of the re-injected clean water through the filter 11 is indicated by the arrows 59. However, solid particles, especially the more dangerous of those that are large and therefore are usually heavy, do not tend to flow through apertures 59, but instead tend to fall directly downward into the cavity formed by filter pipe 64. By this means, such undesired particles are collected below the level 65. As is evident from the previous discussion, any accumulation of such undesired debris may be removed by the operator simply by operation of certain elements located at the earth's surface, as illustrated in FIG. 1. The operator would temporarily open valve 47 and operate high pressure pump 48 after having closed other valves in the system. By this means, very high pressure clean water is pumped from source 42 through pump 48, pipe 49, and tee junction 50 into the clean water input pipe 8. While the normally re-injected water flowing through filter 11 is at a pressure substantially above the pumped hot geothermal well water, pump 48 when operated injects clean water into pipe 8 and, therefore, into filter 11 at a higher pressure, such higher pressure forcing the armature of valve 67 downward against spring 70. Any debris collected in the interim operating period in the solid section of the cavity-forming pipe 64 below the level 65 is thereupon flushed through valve 66, 67 and pipe 14 into the hot well water. Having disposed of the accumulated debris, the operator moves the aforementioned valves in the reverse sense and the system for supplying clean water for pipe 8 reverts to normal operation.
It is seen that the invention provides a way in which an inaccessible filter in a deeply buried geothermal well may be cleaned according to a predetermined schedule without any serious interruption in the operation of the power conversion system and without dismantling any part of it. In the invention, a pressure activated valve is inserted in a passage between the up-stream side of the filter and the hot well water conduit. This valve is normally closed, thus preventing flow of clean water from the filter into the contaminated well water. When the injected water is raised to a pressure arbitrarily above that of the hot well water by action taken at the earth's surface, the filter valve opens, thereupon permitting clean water to flow from the filter into the hot well water, flushing all sediment out of the filter as it flows. When the injected water pressure is then lowered to its normal level with reference to that of the hot well water, the filter valve closes and normal operation of the geothermal apparatus resumes.
While the invention has been described in its preferred embodiments, it is to be understood that the words which have been used are words of description rather than of limitation and that changes within the purview of the appended claims may be made without departure from the true scope and spirit of the invention in its broader aspects.
|
A geothermal energy transfer and utilization system abstracts thermal energy stored in hot solute-bearing well water to generate super-heated steam from an injected flow of clean water; the super-heated steam is then used for operating a turbine-driven pump at the well bottom for pumping the hot solute-bearing water at high pressure and always in liquid state to the earth's surface, where it is used by transfer of its heat to a closed-loop vapor generator-turbine-alternator combination for the generation of electrical or other power. Cooled, clean water is regenerated by the surface-located system for re-injection into the deep well and the residual concentrated solute-bearing water is pumped back into the earth. The invention features filter apparatus installed within the well at the location of the vapor generator-turbine-pump apparatus for removal of solid matter from the re-injected water before its use for lubrication of turbine and pump bearings and before conversion into a working fluid for driving the deep well turbine.
| 8
|
SUMMARY OF THE INVENTION
My invention concerns an improved method of recovering petroleum, especially viscous petroleum, from a subterranean, petroleum-containing formation, said formation being penetrated by at least two wells, including one injection well and one production well, both of said injection and production wells being in fluid communication with a substantial portion of the formation, said injection and production wells defining a recovery zone within the formation.
More particularly my invention is concerned with an improvement for overcoming the condition which occurs in steam flooding operations, known as "steam-override", or in other words for achieving better vertical conformance. This condition results from the fact that vapor phase steam, being of less specific gravity than petroleum and other fluids present in the pore spaces of the formation, tends to gravitate toward the upper portion of the formation and to sweep out preferentially this upper portion. Once this has occurred, then all the subsequently injected steam tends to follow the same path in the upper portion and to exert little or no sweeping action on the petroleum-saturated lower portions, and the condition is known as steam-override.
It would appear that steam-override might be cured by simply converting the production well to injection and the injection well to production and forcing steam low into the formation around the new injection well in order to sweep out the hot oil banked around the lower portion of the new injection well. However, wells in formations that have reached this condition of steam-override are normally gravel pack completions across the whole oil column, and steam injected low in the new injection well will quickly sweep oil from the near well bore area and then rise into the established override zone, with the result that the main body of oil banked around the lower portion of the new injection well is still bypassed. Therefore it is necessary not only to force steam low into the formation around the new injection well but also to prevent the injected steam from readily reaching the established override zone.
In one embodiment according to the method of my invention the condition of steam-override is overcome and vertical conformance is improved by the combination of:
1. reversing the functions of the injection and production wells,
2. blocking the override region in the upper portion of the formation around the new injection well so that steam can no longer flow therethrough, and
3. closing all passages of egress for steam injected into the new injection well except those having access to the lower portion of the formation so that steam flowing through those passages sweeps the lower portion of the formation.
Other embodiments involve the above steps of blocking the override region and closing passages of egress for steam but:
(a) with the difference that the functions of the injection and production wells are not reversed but are maintained the same, or
(b) an infill well between the injection and production wells is utilized as a production well, or
(c) the blocking agent for blocking the override region is used to sweep petroleum towards a production well, or
(d) some combination of the above embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and benefits of the invention will be more fully set forth below in connection with the best mode contemplated by the inventor of carrying out the invention, and in connection with which there are illustrations provided in the drawings, wherein:
FIG. 1 illustrates a vertical plan view of a subterranean formation penetrated by an injection well and a production well in a state-of-the-art steam drive oil recovery method such as is taught in the prior art, illustrating how the injected steam migrates to the upper portion of the formation as it travels through the recovery zone within the formation between the injection well and production well. The action of steam overriding and bypassing a significant amount of the petroleum saturated portion of the oil recovery zone is shown in this drawing.
FIG. 2 illustrates the same view of the subterranean formation as FIG. 1 after the steps of this invention have been taken to close off all passages of fluid communication between the production well and the formation except those communicating with a top fraction less than half and a bottom fraction less than half of the formation and to block the override region in the upper portion of the formation around the production well. Two embodiments are illustrated in FIG. 2, one with solid arrows representing reverse steam flooding using the injection and production wells as production and injection wells respectively, and one with dashed arrows representing forward steam flooding using the injection and production wells in their original intended way.
FIG. 3 illustrates a vertical plane view of a subterranean formation penetrated by an injection well, a production well, and an infill well in a state-of-the-art steam drive oil recovery method such as is taught in the prior art, illustrating how the same steam override condition as in FIG. 1 occurs also when an infill well is used.
FIG. 4 illustrates the same view of the subterranean formation as FIG. 3 after the steps of this invention have been taken to close off all passages of fluid communication between the production well and the formation except those communicating with a top fraction less than half and a bottom fraction less than half of the formation and to block the override region in the upper portion of the formation around the production well. Again two embodiments are illustrated in FIG. 4, one with solid arrows representing reverse steam flooding using the injection and production wells as production and injection wells respectively, and one with dashed arrows representing forward steam flooding using the injection and production wells in their original intended way.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The problem of steam override which occurs inherently in prior art steam drive enhanced oil recovery processes, for which the process of our invention is intended as an improvement, is best understood by referring to FIG. 1, which illustrates how a relatively thick, viscous oil-containing formation 1 is penetrated by an injection well 2 and a production well 3 in a conventional steam drive oil recovery process as is taught in the prior art. Each of wells 2 and 3 is lined through formation 1 with a section of well casing known as a liner 10, having perforations as shown in the Figures, through which perforations fluid can flow between the formation and the wells. Steam is injected into the formation via well 2, passing through the perforations in well 2 and out into the viscous oil formation. Conventional practice is to perforate or establish fluid flow communication between well 2 and the formation throughout the full vertical thickness of the formation, both with respect to injection well 2 and production well 3. Notwithstanding the fact that steam is injected into the full vertical thickness of the formation, it can be seen that steam migrates in an upward direction as it moves horizontally through the formation while passing from well 2 toward production well 3. The result of this movement is the creation of a steam swept zone 4 in the upper portion of the formation and zone 5 in the lower portion of the formation through which little or no steam has passed. Since little or no steam has passed through zone 5, very little oil has been recovered from zone 5. Once steam breakthrough at production well 3 occurs, continued injection of steam into the formation via well 2 will not cause any significant amount of steam to flow into section 5 for the following two reasons.
(1) The specific gravity of vapor phase steam is significantly less than the specific gravity of petroleum and other liquids present in the pore spaces of the formation; therefore, gravitational forces will cause steam vapors to be confined largely to the upper portion of the formation. This phenomenon is referred to in the art as steam override.
(2) Steam passing through the upper portion of the formation displaces and removes petroleum from the pore spaces of that portion of the formation, thus desaturating the zone and increasing the relative permeability of that portion of the formation significantly as a consequence of removing viscous petroleum therefrom. Thus, any injected fluid will travel even more readily through the desaturated portion 4 of the formation than it will through the portion 5 which is near original viscous petroleum saturation level.
The term "steam injection" as used herein is to be understood as referring to the injection of steam, either alone or in combination with some other substance which improves the effectiveness of steam drive oil displacement. For example, non-condensable gases such as nitrogen or carbon dioxide may be mixed or co-mingled with steam injected into the formation for the purpose of improving oil recovery efficiency. Miscible fluids, such as hydrocarbons in the range of C1 to C10, may be mixed with the steam, usually in the concentration range of from 1-25 and preferably 5-10% by weight. The presence of hydrocarbons co-mingled with steam injected into a viscous oil formation improves the effectiveness of the injected fluid for reducing oil viscosity and therefore improves the oil displacement effectiveness of the process. In yet another embodiment, air and steam are co-mingled in the ratio of from 0.05-2.0 standard cubic feet of air per pound of steam, which accomplishes a low temperature, controlled oxidation reaction within the formation and achieves improved thermal efficiency under certain conditions. So long as a major portion of the fluid injected into injection well 2 comprises vapor phase steam, the problem of steam override and channeling will be experienced in the steam drive oil recovery process no matter what other materials are included in the injected fluid in addition to steam, and the process of our invention may be applied to any steam drive oil recovery process with the resultant improvement of oil recovery.
FIG. 1 shows the condition of steam override which is commonly found after steam has been injected at injection well 2 for a period of time and has broken through at production well 3. Region 4 has been swept by steam so that it is now highly permeable, but region 5 is essentially unaffected and is still petroleum-saturated, since steam rides easily over region 5 through the permeable region 4. The interface between regions 4 and 5 is indicated by 7.
The method of this invention in its simplest form is illustrated by FIG. 2, in which two embodiments are shown, the first as indicated by solid arrows and the second by dashed arrows. For both embodiments a section of non-perforated casing 22 is cemented inside the liner 10 of well 3, bridging over and sealing off the perforations of the middle portion of the liner so that fluid communication between formation 1 and well 3 is limited to the top and bottom perforations of well 3. Packer 23 is then set on tubing 21 inside bridging casing 22, and a second tubing 20 is hung above packer 23, so that a dual completion is achieved, and dual injection can be carried out in well 3. After the dual completion is finished, steps are taken to block off the steam override region radially outwardly from well 3 by use of a blocking agent introduced through tubing 20 into the formation surrounding the upper perforations of well 3. The blocking action which is to be accomplished is three-dimensional, not just at the well liner itself. The object is to obstruct fluid flow within the formation surrounding the upper perforations of well 3, not merely the flow between the formation and well 3. In other words plugging the perforations only would not accomplish the desired blocking. One way to achieve the desired three-dimensional blocking is by injection through tubing 20 and out through perforations of well 3 of warm production water alternating with flue gas or other suitable gas, so that alternate zones of liquid and gas are formed out in the formation as indicated in FIG. 2 by the alternate L and G zones in region 24. Such alternating liquid and gas injections have a jamming effect on the permeability of the formation so that fluid flow through the region containing the L and G Zones is effectively obstructed. Similar use of alternate liquid and gas injections in known in the art--see for example U.S. Pat. No. 3,244,228.
In the first embodiment (shown by solid arrows in FIG. 2) steam is injected in well 3 through tubing 21, either concurrently with the jamming step or following it, and sweeps outwardly through the lower perforations of well 3 into formation 1. The jammed region prevents the steam from passing therethrough and forces it to pass low through the hitherto unswept portion of the formation as shown by FIG. 2. The hitherto unswept region shown as 5 in FIG. 1 is thereby reduced in size to the region shown as 14 in FIG. 2, and a significant portion of the hot oil that had been banked around the bottom of well 3 is produced from well 2. Thus vertical conformance has been improved.
In the second embodiment, (as shown by the dashed arrows in FIG. 2) instead of injecting steam through tubing 21 in well 3 and producing at well 2 the procedure is to continue injecting steam through well 2 and using tubing 21 for producing through well 3. At the same time the alternate liquid and gas injections are continued into the upper portion of the formation via upper tubing 20. In this way a considerable amount of additional crude oil recovery is achieved before high water cut (from the encroaching water of the L and G zones) dictates switching over to using tubing 21 of well 3 for steam injection and well 2 for producing as in the first embodiment above.
To recapitulate, the advantages of establishing (1) the non-perforated casing 22 to seal off the middle portion of the well 3 liner and (2) the jammed region 24 are that the following procedures and combinations thereof can be carried out with resulting substantial improvements in recovery of oil that is otherwise overridden by steam and left behind as oil banked around the bottom of well 3:
reverse the functions of wells 2 and 3, so that steam is injected at 3 and production is taken at 2;
after establishing the jammed region, do not stop the alternate liquid and gas injections but continue them so as to utilize the L and G zones as a moving front driving production ahead of it;
retain the functions of wells 2 and 3, so that steam is injected at 2 and production is taken at 3, optionally while continuing the alternate injection of liquid and gas through tubing 20.
FIG. 3 illustrates the steam override condition which is found when an infill well 6 exists between the injection or center well 2 and the production or corner well 3 in a state-of-the-art steam drive operation. Infill well 6 has perforations only at the lower end in order to force the steam to sweep low in the formation surrounding well 6, and consequently unswept region 9 is reduced to a fairly low magnitude. Unswept region 5 surrounding well 3 however is unsatisfactorily large, just as in FIG. 1.
FIG. 4 illustrates the method of this invention for the case where an infill well 6 exists between the center well 2 and the corner well 3. Once again as with the two-well pattern of FIG. 2, two embodiments are illustrated, the first as indicated by solid arrows and the second by dashed arrows. For both embodiments corner well 3 is prepared in the same way as well 3 was in FIG. 2, i.e. with the non-perforated casing section 22 cemented inside liner 10 and with the region 24 of the formation surrounding the upper perforations of well 3 blocked so as to obstruct fluid flow within the formation.
In the first embodiment with an infill well (shown by solid arrows in FIG. 4) steam is injected in well 3 through tubing 21, either concurrently with the jamming step or following it, and sweeps outwardly through the lower perforations of well 3 into formation 1 toward infill well 6. The jammed region 24 prevents the steam from passing therethrough and forces it to pass low through the hitherto unswept portion of the formation as shown by FIG. 4. The hitherto unswept region shown as 5 in FIG. 3 is thereby reduced in size to the region shown as 12 in FIG. 4, and a significant portion of the hot oil that had been banked around the bottom of well 3 is produced from infill well 6. Thus vertical conformance has been improved.
In the second embodiment (as shown by the dashed arrows in FIG. 4) instead of injecting steam through tubing 21 and producing at well 6 the procedure is to continue injecting steam through well 2 and using tubing 21 for producing through well 3. At the same time the alternate liquid and gas injections are continued into the upper portion of the formation via upper tubing 20. In this way a considerable amount of additional crude oil recovery is achieved before high water cut (from the encroaching water of the L and G zones) dictates switching over to using tubing 21 of well 3 for steam injection and well 6 for producing as in the first embodiment above. In a useful modification of the second embodiment well 6 may be either used as an injection well or closed in with no fluid flow.
To recapitulate, the advantages of establishing (1) the non-perforated casing 22 to seal off the middle portion of the well 3 liner and (2) the jammed region 24 are that the following procedures and combinations thereof can be carried out with resulting substantial improvements in recovery of oil that is otherwise overridden by steam and left behind as oil banked around the bottom of well 3:
reverse the function of well 3, so that steam is injected at well 3 and production is taken at well 6;
after establishing the jammed region, do not stop the alternate liquid and gas injections but continue them so as to utilize the L and G zones as a moving front driving production ahead of it;
retain the function of well 3, so that steam is injected at well 2 and production is taken at wells 3 and 6, optionally while continuing the alternate injection of liquid and gas through tubing 20.
While particular embodiments of the invention have been described above in accordance with the applicable statutes this is not to be taken as in any way limiting the invention but merely as being descriptive thereof. All such embodiments are intended to be included within the scope of the invention which is to be limited only by the following claims.
|
The condition known as steam override is overcome by the use of a blocking agent to obstruct fluid flow in part of the override region combined with the closing of all passages of egress for injected steam except those having access to the region where by-passed oil has been banked.
| 4
|
This application is a continuation of application Ser. No. 08/512,004, filed Aug. 7, 1995, now U.S. Pat. No. 5,575,114.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to hopper windows, more specifically to a window assembly which is usually cast in a concrete cellar foundation wall, in which the window is opened by tilting the window sash out of the window frame, inwardly toward the cellar.
2. Description of the Prior Art
During construction of a building, when concrete is being poured for a cellar wall, the cellar window is often cast into the concrete wall. It is desirous to be able to cast the window frame in the concrete without the sash, in order to avoid damage to the window glass.
After the concrete foundation is completed, it is desirable to use the window opening to pass construction materials and tools to and from the interior of the building without damage to, or interference from, the sash and associated tilt mechanism.
Fully installed hopper windows often are difficult to set to a variety of angles of tilt, and are difficult to clean on both sides of the window pane from the inside of the cellar.
The window is subject to dampness, sand and grime, and is used intermittently with relatively long periods of inactivity. This makes complicated continuously adjustable and settable tilt mechanisms impractical.
The prior art is replete with tilt window designs in which the sash may be set to various angles.
U.S. Pat. No. 1,388,121, patented Aug. 16, 1921, by H. P. Porter, discloses a tilt-in window sash, the bottom end of which is pivotally attached by pull-out pins, or locking bolts, to a pair of vertical supports of a frame that holds the window sash.
A folding linkage is pivotally attached by a permanent bracket or keeper to the sash a short distance from the top of the sash, and is pivotally attached by a pivot pin and locking latch to a keeper on one of the supports at about the same height. The keeper is pivoted like scissors, at its center.
The arms of the scissors are brought together one over the other when the window sash is closed, that is, when it is parallel with the supports.
When the window sash is drawn from the top of the sash by hand, out of the frame to the limit of inward tilt set by the spread of the arms, the arms are opened to an obtuse, almost straight angle.
The folding linkage sets the limit of inward tilt by engaging cam edges on the linkage arms with flanges on the attachment brackets or keepers as the arms approach 180 degrees separation from one another.
The window sash can be tilted to any one of a plurality of predetermined positions, between closed and the limit of inward tilt, where it is held in the selected position by spring-biased interlocking corrugations and ribs on the arms at the scissor pivot.
The window sash can be freed for removal from the frame by pulling out the locking bolt at the bottom of the window sash and opening the locking latch on the pivot pin of the keeper on the support.
U.S. Pat. No. 1,696,607, patented Dec. 25, 1928, by R. W. Hysert, discloses a window which includes two vertical parallel supports preferably stamped from sheet metal.
Each support has two independent slots which are a uniform, longitudinal slot or sash guide-way at one end of the support, and a keyway shaped longitudinal slot or brace guide-way at the other end of the support.
In one design the two slots are stamped in a single metal sheet which forms the support. In another design, a metal sheet is formed with a longitudinal channel, and contains a riveted stop about midway of the support. A portion of the channel to one side of the stop is the sash guide-way. A second sheet of metal with a stamped in keyway shaped brace guideway is brazed into the channel on the other side of the stop.
A window sash arranged between the supports is pivotally attached to the supports by pivots which extend laterally from the bottom end of the window sash into the sash guide-ways.
On each side of the sash, a straight brace is pivotally attached at one end to the sash, and at the other end has a pin that extends into the brace guide-way of the adjacent support. The pin is held in the brace guide-way by a head on the pin that locates behind a lateral wall of the brace guide-way. The pin and head are installed and removed from the brace guide-way by way of the wider opening at the top of the guide-way provided by the keyway shape.
The window sash is opened by pulling the top of the sash out from between the supports. The sash falls to an angle from the supports that is permitted by the length of the brace between the bottom of the brace guide-way to which it falls in the brace guide-way, and the pivotal attachment of the brace to the window sash. This is the first open position of the window sash.
A second, more open position is obtained by further drawing the top of the window sash downward in an arc whereby the window sash pivots on the pivotal attachment of the brace to the window sash and the pivot at the bottom of the window sash moves upward in the sash guide-way to the upper end of the guide-way.
U.S. Pat. No. 1,760,072, patented May 27, 1930 by W. C. Lea, discloses a sash attached to a pair of supports by a link bar which is pivotally attached to the side of the sash about midway between the top and bottom of the sash, and pivotally attached to a bracket which is screwed to one end of the support. The support has a track which extends from the bracket to the other end of the support.
One end of the sash has a sliding member which rides in the track. A tapered screw on the sliding member spreadingly engages a pair of movable rods, the outer surfaces of which engage friction members that bear against the track increasingly as the screw is extended between the rods.
Either front or back face of the sash can be made to face inward to a room, by sliding the end of the sash having the sliding member, through a normal taken from the pivot attachment on the side of the sash, to the track.
U.S. Pat. No. 1,919,371, patented Jul. 25, 1933 by W. J. Klemm, discloses a window sash pivoted at the bottom end in a pair of bearing assemblies which slide in vertical tracks, one on each side of the sash.
An arm which is pivotally attached by a first end to the window sash at about the center of the sash is pivotally attached by the second end to a slider which moves in the track. The slider has a wedge projection.
When the window is closed, the sash can be reciprocated vertically in the track. At the start of angling the sash out of the track, the slider moves down, forcing the wedge projection between legs of a cam brake that cams outward into the sides of the track preventing further vertical downward movement of the slider and preventing vertical reciprocation of the window. The window sash then rotates about the pivot at the first end of the arm as it angles further away from the tracks and the bottom end of the sash slides up in the track until it comes up against an abutment formed in the sheet metal of the track, which stops further rotation of the sash.
SUMMARY OF THE INVENTION
It is one object of the invention to provide a hopper window in which the sash can be tilted out of the window frame to any angle between the window's closed position and a predetermined angle.
It is another object that the sash can be tilted to any angle between the window's closed position and a predetermined angle, and that it will remain at that any angle without further adjustment or outside assistance.
It is another object that the predetermined angle can be changed to a new predetermined angle.
It is another object that the sash can be easily and quickly removed from and installed in the window frame.
It is another object that installation and removal of the sash can be done without tools.
It is another object that the adjustment mechanism of the window is not easily affected by sand and other cellar type contamination.
It is another object that moving parts of the window are removed from the window frame when the sash is removed.
It is another object that a significant portion of the window can be made from extruded plastic.
It is another object that the window mechanism is simple and inexpensive to make.
Other objects and advantages will be readily apparent from the ensuing description.
A hopper window includes in combination, a frame and a sash, the frame including a pair of parallel extruded jambs. One jamb includes a track having a first end, a second end, and stop means mounted on the track between the first end and the second end.
The sash includes pivot means extending from a second end of the sash into the track between the stop means and the second end of the track. An arm pivotally attached at one end to the sash between the first end of the sash and the second end of the sash is attached to a shoe means on the other end of the arm.
The shoe means is slidably mounted on the track for travel along the track between the first end of the track and the stop means.
The shoe means engages the track in generally constant resistance to travel along the track such that the sash can be drawn by hand against the generally constant resistance, to any angle from the track set by the location of the shoe in the track between the first end of the track and the stop means, and the sash is held at the aforesaid any angle by the generally constant resistance to travel of the engaging.
The track includes a pair of longitudinal flanges and a longitudinal back wall, the shoe means being slidably mounted between the flanges and the back wall, and being attached to the arm between the flanges.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention be more fully comprehended, it will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a front view of a hopper window of the present invention.
FIG. 2 is a side view of extruded stock for the window frame of the hopper window of FIG. 1.
FIG. 3 is a side view of a portion of the extruded stock of FIG. 2, prepared to be a vertical jamb in a frame assembly.
FIG. 4 is a section view of the window of FIG. 1 as viewed in a side view, along 4--4.
FIG. 5 is the assembly of FIG. 4, with a stop means attached to a track of a vertical jamb.
FIG. 6 is a side view of the assembly of FIG. 5, with an installed sash tilted from the track of the vertical jamb.
FIG. 7 is a side view of the assembly of FIG. 5, with an installed sash tilted from the track of the vertical jamb.
FIG. 8 is a side view of the assembly of FIG. 5, with an installed sash tilted from the track of the vertical jamb.
FIG. 9 is a side view of the assembly of FIG. 5, with an installed sash tilted from the track of the vertical jamb.
FIG. 10 is a side view of the assembly of FIG. 5, with the stop means relocated to another position in the track, and with an installed sash tilted from the track of the vertical jamb.
FIG. 11 is a side view of the assembly of FIG. 5, with an installed sash in the window-closed position.
FIG. 12 is a side view of the assembly of FIG. 5, with an installed sash positioned for removal of a shoe from the track.
FIG. 13 is a bottom view of an arm with shoe and bracket, of the invention.
FIG. 14 is a side view of the arm with shoe and bracket, of FIG. 13.
FIG. 15 is a cross section view of the shoe of FIG. 13, taken along 15--15. The shoe is captured within a track that is not shown in FIG. 13.
FIG. 16 is a cross section view of the bracket of FIG. 13, taken along 16--16.
FIG. 17 is a top view of an inner friction head of the shoe of FIG. 15.
FIG. 18 is a side view of the inner friction head of FIG. 17.
FIG. 19 is a bottom view of the inner friction head of FIG. 17.
FIG. 20 is a cross section view of the inner friction head of FIG. 17, taken along 20--20
FIG. 21 is a cross section view of the inner friction head of FIG. 17, taken along 21--21.
FIG. 22 is a top view of the shoe of FIG. 13 being installed in a track. An arm and a rivet are removed for clarity of the drawing.
FIG. 23 is a cross section view of the shoe of FIG. 13, taken along line 15--15.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the invention in detail, it is to be understood that the invention is not limited in its application to the detail of construction and arrangement of parts illustrated in the drawings since the invention is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology or terminology employed is for the purpose of description only and not of limitation.
In FIG. 1, hopper window 30 is closed. Window sash 34 is fully seated in window frame 40, generally parallel with jambs 50, 52, head 54, and sill 56. Latch 60 is closed.
The invention is described herein with reference to jamb 52. It will be understood that the relationship between sash 34 and jamb 50 is about the same as it is between the sash and jamb 52.
Referring to FIG. 2, stock 66, extruded from rigid exterior grade polyvinylchloride, is used to make the head, sill and jambs. It includes track 70 which is shown in end view at the top of FIG. 4.
In FIG. 3, one end of each jamb is prepared prior to assembly of the frame, by removing portions of inward extending flanges 74 to form a lateral opening 78 in track 70. Flanges 74 extend from side walls 76.
Phantom lines 82 which are used to show side walls 76 in the jambs are included in FIGS. 1-7, and dropped from other figures so as not to obscure other features under discussion.
Referring to FIG. 4, stock 66 sections which comprise head 54, jambs 50, 52, and sill 56, are fastened together by screws, or by welding, cement, or other permanent means to make frame 40, without concern about later insertion of sash 34 in the frame because all attachment and sliding hardware for mounting the sash in the frame is exclusively part of the sash.
The assembled frame has a pair of the continuous extruded tracks 70, one in each jamb for operation of the sash as will be explained later. The continuous tracks 70 in the head and sill are a by-product of the assembly, and contribute to a saving in costs by using common stock.
Removable stop 80 in FIG. 5 is inserted into track 70 and screwed or otherwise reversibly fastened 86 to back wall 84 of the jamb which happens to be the back wall 90 of the track. Stop 80 may be moved to another location along the track in order to adjust operation of the sash as will be explained later. Track 70 is uniform adjacent to either side of stop 80 regardless of the selected location of stop 80, in this element of extruded stock.
In FIG. 6, sash 34 is installed in frame 40, and is extended at an acute angle 120 from the track by being drawn from the track by end 114 of sash 34 in direction 118.
At end 92 of the sash, pivot pin 94 extends laterally into track 70 of adjacent jamb 52. Arm 98 is attached at end 102 to sash 34 by pivot rivet 100 of bracket 104.
Shoe 116, attached to end 110 of arm 98, is slidingly mounted in track 70. The shoe is confined in the longitudinal cavity that extends the length of the track and is bounded by side walls 76, back wall 90, and flanges 74.
Sash 34 is at shallow angle of extension 120 from the track. End 92 of the sash rests on sill 56.
In FIG. 7, as sash 34 is drawn 118 from the track, shoe 116 slides down in track 70 until it runs into stop 80. Arm 98 limits the distance that bracket 104 can move from the track. End 92 of the sash continues to rest on sill 56 due to the weight of the sash. Sash 34 is at a first stage angle of maximum extension 124.
In FIG. 8, as sash 34 is drawn 118 further from the track, shoe 116 within track 70 comes against stop 80 with no where to go, arm 98 prevents further movement of bracket 104 away from the track, and end 92 of the sash rises as pivot pin 94 moves upward in track 70 until, as shown in FIG. 9, the upward movement of end 92 is stopped by stop 80, and sash 34 is almost perpendicular to track 70. Sash 34 is at a second stage angle of maximum extension.
The range of stage 1 angle of maximum extension is predetermined by the location of stop 80 in the track, and is changed to a new predetermined angle of maximum extension by setting the stop at a new location in the track.
In FIG. 10, stop 80 is attached lower in track 70. This establishes a new angular limit 128 for the first stage angle of maximum extension. The second stage angle of maximum extension is predetermined by the length of arm 98, the location of pivot rivet 100 on sash 34, or the length of sash between pivot rivet 100 and pivot 94, and how close pivot 94 can get to shoe 116 in track 70.
In FIG. 11, sash 34 is fully seated in frame 40, parallel with track 70. End 92 of the sash is resting on sill 56. In this configuration, shoe 116 is held by flanges 74 in track 70, slightly below lateral opening 78.
In FIG. 12, sash 34 is positioned for removal of the sash from frame 40. End 92 of the sash is hand displaced upward from sill 56. Sash 34 is extended at an acute angle from track 70, the acute angle being adjusted so that shoe 116 is in lateral opening 78 clear of flanges 74 so that the shoe can be pulled laterally away from the jamb out of opening 78. Once the shoe is free from the track, enough lateral play is provided in pivot rivet 100 and flexibility in arm 98 to permit rotation of arm 98 upon pivot rivet 100, out of frame 40. End 92 of sash 34 is removed from the frame by angling the sash from the track toward the perpendicular to the track, then tilting one side of the sash so that there is differential movement between pivot pins 94 in jambs 50 and 52, until the pins come out of the tracks in jambs 50 and 52.
Referring now to FIGS. 13-15, 22, and 23, chamfers 134 ease the way for entry of shoe 108 into a lateral opening of a jamb. Shoe 108 can rotate on arm 98 about rivet 136. Arm 98 can rotate on bracket 104 about pivot rivet 100. Washer 106 prevents rotational interference between arm 98 and bracket 104. Holes 112 are provided for attaching bracket 104 to the sash.
Shoe 108 comprises an outer friction shoe 140 and an inner friction shoe 146. Outer friction shoe 140 and inner friction shoe 146 are biased apart by spring 150 which bears against shoe 140 thrust face 182 and shoe 146 thrust face 198. Shoe 108 is compressed in FIG. 15, and relaxed in FIG. 23. The limit of maximum expansion 158 between shoes 140 and 146 is set by the length of rivet 136. The limit of maximum expansion is greater than the distance between flanges 74 and back wall 90 of track 70 so that friction wall 166 presses against back wall 90, and friction wall 170 presses against flanges 74. Head 154 of rivet 136 is recessed in shoe 140 so that the head does not contact wall 90. Bearing collar 188 receives arm 98. Opening 176 holds rivet 136, and rivet sleeve 138 which includes upper spring guide 130 and lower spring guide 132. Longitudinal lip 72 strengthens flange 74, and encloses friction wall 170 in a U channel with flange 74 and wall 76 of the track.
Wall 190 of the outer friction shoe surrounds guide wall 194 of the inner friction shoe. The limit of maximum compression of shoe 108 is determined by end 208 of wall 190 and limit shoulder 204 of inner friction shoe 146 when they meet.
Shoe 108 provides a constant friction between the shoe and the track as it travels within the track. The friction is sufficient to overcome the thrust along the track imparted by arm 98 to the shoe, which sash imparts to the arm from the natural tendency of the sash to tilt under the force of gravity. The friction permits hand tilting of the sash by an operator, and keeps the sash at whatever stage one angle of tilt that is set by the operator.
Referring to FIGS. 17-22, adjacent to and flanking each friction wall 170 is a cam 174 which engages end 212 of flange 74 at lateral opening 78 when shoe 108 is inserted in lateral opening 78 and is moved toward 216 the center of track 70. Regardless which side 218, 220, 222, or 224 is facing into track 70, a pair of cams 174 engage the flange when the shoe is pulled in direction 216 into the track by arm 98 (not shown). As the shoe enters under flanges 74, cams 174 transfer the longitudinal motion into compressive force which forces inner friction shoe 146 toward the back of the track so that it can move under flanges 74 so that it can slide in track 70.
Preferably the shape of the shoe is such that it will fit in the track by rotating to two or more positions. For example, any one of four approximately 90 degree apart positions for the square design of FIGS. 13-22, and any one of three positions for a triangular design shoe.
Although the present invention has been described with respect to details of certain embodiments thereof, it is not intended that such details be limitations upon the scope of the invention. It will be obvious to those skilled in the art that various modifications and substitutions may be made without departing from the spirit and scope of the invention as set forth in the following claims.
|
A sash of a hopper window is linked to a shoe which engages a track in constant resistance to travel along the track such that the sash can be tilted by hand to any angle from the track within a predetermined range of angles, and will remain at the angle unaided.
| 4
|
This is a continuing application of application Ser. No. 886,701 filed July 18, 1986, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel chemical dispenser for dispensing a predetermined volume of chemical solution into a body of water such as the water in a toilet tank. More particularly, it relates to a dispenser wherein the chemical solution contained in the dispenser is effectively isolated from the body of water during the periods of quiescence. Also, the rate of release of the chemical solution may be controlled by passive means within the dispenser.
2. Description of the Prior Art
There are many types of dispensers for releasing various chemicals such as detergents, disinfectants, etc. into toilet tanks. Depending upon the chemical being utilized there is a need for the dispenser to release the chemical at varying rates. For example, a disinfectant solution to be effective should be released into the tank during the latter portion of the flushing cycle so that the solution is not flushed away. It is desirable in each of these dispensers to provide a means for isolating the chemical solution from the tank during quiescent periods. This prevents unnecessary and wasteful leakage of chemicals into the tank. Dispensers for achieving such isolation of chemicals are generally categorized as passive or active.
Passive dispensers achieve their purpose without moving parts by proper dimensioning of the ports and internal passages of the dispenser. For example, U.S. Pat. No. 4,208,747 (Dirksing), describes a chemical solution dosing dispenser for dispensing the solution into a toilet tank when the toilet is flushed. This device employs a trapped air bubble in the siphon tube to provide an air lock which, in the quiescent period between flushes, isolates the solution in the dispenser from the water in the tank. To form the air bubble Dirksing forms the upper end of his siphon tube into a hook that has a constricted diameter and which forms a pocket in which air can collect during the filling cycle when water from the toilet tank is entering the dispenser.
A disadvantage of the Dirksing device is, however, its manufacture is complicated by the fact that the operation of the device is highly dependent upon its relative internal dimensions.
Active dispensers achieve their isolating function with some type of moving component such as a valve. The valve is designed to open or close at various times in the flushing cycle in order to release the proper amount of chemical solution only during desired portions of the cycle. Active dispensers are necessarily more complex than passive dispensers and are subject to consumer misuse. Such dispensers are also more difficult to produce since manufacturing tolerances of the various parts are more critical than other dispensers and since they require more parts and assembly operations.
One example of an active dispenser is shown in U.S. Pat. No. 3,778,849 (Foley). The Foley device utilizes two valves in conjunction with ports and tubes having predetermined dimensions. The valves open and close in response to varying pressures which change as a function of the water level within the toilet tank.
It is an object of this invention to provide a toilet tank dispenser having a passive means for forming an air lock. It is another object of this invention to provide a toilet tank dispenser for dispensing a chemical solution into the water in the tank at a controlled rate. It is a further object to provide such a dispenser wherein this rate may be varied without changing the dimensions of the dispenser.
SUMMARY OF THE INVENTION
These and other objects of this invention are achieved by a preferred embodiment which comprises, in a dispenser for the releasing of a substance into a toilet tank, said dispenser having an inlet/outlet means for alternately receiving and discharging liquid into and from said dispenser, said dispenser having an air vent tube for communicating the interior of said dispenser to atmospheric pressure, the improvement comprising a porous member situated in the water flow path within said dispenser for limiting the rate of flow of water.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the invention showing in phantom a tablet of a predetermined chemical compound in the bottom of the dispenser.
FIG. 2 is a front elevational view in cross-section of the embodiment shown in FIG. 1.
FIG. 3 is a view of FIG. 2 during a portion of the filling cycle.
FIG. 4 is a view of FIG. 2 during the quiescent period.
FIG. 5 is a view of FIG. 2 during the discharge or flushing cycle.
FIG. 6 is an elevational view in cross-section of an alternative embodiment of the invention during a portion of the filling cycle.
FIG. 7 is a view of FIG. 6 during the initial portion of the discharge cycle.
FIG. 8 is a view of FIG. 7 during a later portion of the discharge cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a diagrammatic perspective view of a dispenser 10 constructed in accordance with the principles of this invention. Dispenser 10 may be constructed with a variety of conventional thermoplastic molding techniques using any suitable materials compatible with the chemicals to be used within the dispenser. Dispenser 10 includes a base or support 12 which forms the base upon which the remaining structures of the dispenser are molded. Dispenser 10 includes a container 14 having an inlet/outlet siphon tube 16 and a vent tube 18. Tablet 20 may be any one of several conventional disinfectant materials generally used within toilet tanks and designed to slowly dissolve to provide the proper concentration of solution within container 14. Dispenser 10 is also provided with a hook 22 for hanging the dispenser within the interior of a toilet tank 24. Hook 22 may be adjusted vertically within sliding channel 26 in order to place the base 12 and all components associated therewith at the proper elevation within tank 24. It will be understood that, while dispenser 10 is shown as a siphon type device, the invention is equally applicable to gravity fed devices.
The structure of the invention embodied within dispenser 10 is best understood by a description of the operation of the invention as depicted in FIGS. 3, 4 and 5. FIG. 3 shows the dispenser 10 during the filling cycle with the level of water 30 rising in tank 24. As the water passes upwardly past the end 32 of inlet/outlet tube 16, water will continue rising in tube 16 thereby pushing the air within the interior of container 14 out the vent tube 18. As will be noted by reference to the drawings, the U-shaped portion of inlet/outlet siphon tube 16 is filled with a porous material 40 which permits passage of the air and water, although at a decreased rate. As will be understood by those skilled in the art, this causes the water entering siphon tube 16 to trickle over into leg 44 and necessarily produces an air bubble 42 in the top of siphon tube 16. As the water level continues to rise in tank 24, the water level within container 14 will also rise until, as shown in FIG. 4, a quiescent period is reached where the water level in the tank equals the water level in the vent tube 18. During this quiescent period the air bubble 42, no longer being forced to one side of porous member 40 by the pressure of in-flowing water, will stabilize at the top of the U-shaped portion of inlet/outlet siphon tube 16 so that a portion of air bubble 42 appears in both the upward and downward legs of tube 16, thus isolating the interior of the dispenser from the tank.
During the flushing part of the cycle as depicted in FIG. 5, the level of water 30 in the tank drops faster than the level of solution in container 14. The rate at which container 14 empties is restricted by the size of inlet/outlet siphon tube 16 and by the density of porous member 40. The difference in these rates necessarily results in container 14 releasing most of its contents into tank 24 after the initial flushing stage so that most of the chemical solution is not needlessly flushed away. The solution in container 14 continues to be siphoned through tube 16 so long as the level of water in the tank is below port 32 and the level in container 14 is above inlet port 46. The remaining solution in the bottom of container 14 below inlet port 46 will remain in a concentrated state to enable rapid recovery of the dispenser 10 in preparation for the next flushing cycle.
Referring now to FIG. 6, an alternative embodiment of the invention is shown by dispenser 60 wherein parts similar to those shown in FIGS. 1 through 5 are given the same numbers in FIGS. 6, 7 and 8. It will be noted that the major distinction between the embodiment of FIGS. 3, 4 and 5 and FIGS. 6, 7 and 8 is that the latter does not include any porous material in the inlet/outlet siphon tube 16 but rather includes porous material 62 in an enlarged portion 64 of vent tube 18.
It will be understood that during the filling portion of the cycle shown in FIG. 6, water will enter port 32 of inlet/outlet siphon tube 16 and push air and water through vent tube 18, trickling into downward leg 44 until the quiescent state (not shown) is obtained during which an isolating air lock is provided in the top of siphon tube 16. During the initial part of the flushing cycle shown in FIG. 7, the water level in tank 24 will drop faster than the water level in container 14 because of the resistance provided by porous member 62. Once the water level has dropped below the porous member 62, the rate at which the chemical solution is siphoned from container 14 will increase significantly. It will be understood that this increase in release rate occurs well after the initial period of the flushing cycle so that most of the chemical solution remains in the tank instead of being flushed away.
While the porous/inlet embodiment shown in FIGS. 3, 4, and 5 results in a steady rate of discharge of the contents of container 14, the porous/vent embodiment shown in FIGS. 6, 7 and 8 results in a slow discharge rate up until a predetermined point in the cycle at which the rate is suddenly increased. Both embodiments, however, passively provide an air lock without the need to be concerned about the dimensions of siphon tube 16. Furthermore, the release rate of each embodiment may be easily altered, without changing the dimensions of the dispenser, by merely utilizing different porous materials.
It will be understood by those skilled in the art that numerous improvements and modifications may be made to the preferred embodiment of the invention disclosed herein without departing from the spirit and scope hereof.
|
A toilet tank dispenser for passively isolating the chemical solution in the dispenser from the tank during quiescent periods. The dispenser also provides means for releasing a chemical solution into the water in the tank at a release rate which may be easily varied. The isolation and release rate are achieved and controlled by a porous member inserted in the water flow path of the dispenser.
| 4
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This utility patent application is based upon, and claims filing date priority from, a prior U.S. Provisional Patent application entitled “Riding Trowel CVT Clutch Module,” by inventor Jeffrey Lynn Fielder, Ser. No. 61/884,456, filed Sep. 30, 2013, which is hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] I. Field of the Invention
[0003] The present invention relates generally to motorized riding trowels for finishing concrete. More particularly, the present invention relates to transmissions for powered riding trowels of the type classified in United States Patent Class 404, Subclass 112, and particularly to CVT transmission systems for such trowels.
[0004] II. Description of the Prior Art
[0005] It has long been recognized by those skilled in the art that freshly placed concrete must be appropriately finished. Proper and timely finishing insures that desired surface characteristics including appropriate smoothness and flatness are achieved. Motorized riding trowels are ideal for finishing very large areas of plastic concrete quickly and efficiently, and such trowels have become a standard in the industry.
[0006] A typical power riding trowel comprises two or more bladed rotors that project downwardly and frictionally contact the concrete surface for finishing. These rotors are driven by one or more motors mounted on the frame. Typically the motors drive suitable reduction gearboxes (i.e., 20:1 reduction) to power the rotors. The riding trowel operator sits on top of the frame and controls trowel movement with a steering system that tilts the axis of rotation of the rotors. The weight of the trowel and the operator is transmitted frictionally to the concrete by the revolving blades. The unbalanced frictional forces caused by rotor tilting enable the trowel to be steered.
[0007] Holz, in U.S. Pat. No. 4,046,484 shows a pioneer, twin rotor, self propelled riding trowel. U.S. Pat. No. 3,936,212, also issued to Holz, shows a three rotor riding trowel powered by a single motor. Although the designs depicted in the latter two Holz patents were pioneers in the riding trowel arts, the devices were difficult to steer and control.
[0008] Prior U.S. Pat. No. 5,108,220 owned by Allen Engineering Corporation, the same assignee as in this case, relates to an improved, fast steering system for riding trowels. Its steering system enhances riding trowel maneuverability and control. The latter fast steering riding trowel is also the subject of U.S. Pat. No. Des. 323,510 owned by Allen Engineering Corporation.
[0009] Allen Engineering Corporation U.S. Pat. No. 5,613,801 issued Mar. 25, 1997 discloses a power riding trowel equipped with twin motors. The latter design employs a separate motor to power each rotor. Steering is accomplished with structure similar to that depicted in U.S. Pat. No. 5,108,220 previously discussed.
[0010] Allen U.S. Pat. No. 5,480,257 depicts a twin engine powered riding trowel whose guard structure is equipped with an obstruction clearance system. When troweling areas characterized by projecting hazards such as pipes or ducts, or when it is necessary to trowel hard-to-reach areas adjacent walls or the like, the guard clearance structure may be retracted to apply the blades closer to the target region.
[0011] Allen U.S. Pat. No. 5,685,667 depicts a twin engine riding trowel using “contra rotation.” For enhanced stability and steering, the rotors rotate in a direction opposite from that normally expected in the art.
[0012] As freshly poured concrete “sets,” it soon becomes hard enough to support the weight of the specialized finishing trowel, so pan finishing can begin. By starting panning while concrete is still “green,” within one to several hours after pouring depending upon the concrete mixture involved, “super-flat” and “super-smooth” floors can be achieved. The advent of more stringent concrete surface finish specifications using “F” numbers to specify flatness (ff) and levelness (fl), dictates the use of pans on a widespread basis.
[0013] The panning process comprises three different recognizable stages. In the initial “brake open” stage, the rotors are ideally driven between 40 and 65 RPM. As the concrete hardens, the pan floating stage occurs, involving rotor speeds between 70 and 95 RPM. The last phase of pan floating, the “fuzz stage,” uses an increased rotor speed of between 95-125 RPM. At present these RPM requirements are achieved simply by varying motor speed.
[0014] Pan finishing is normally followed by medium speed blade finishing, after the pans are removed from the rotors. An enhancement is the use of “combo blades” during the intermediate “fuzz stage” as the concrete continues to harden. So-called “combo-blades” are a compromise between pans and normal finishing blades. They present more surface area to the concrete than normal finishing blades, and attack at a less acute angle. The rotors are preferably turned between 100 to 135 RPM at this time. Finishing blades are then used, and they are rotated between 120 to 150 RPM. Finally, the pitch of the blades is changed to a relatively high contact angle, and burnishing begins. This final trowel finishing stage uses rotor speeds of between 135 and 165 RPM.
[0015] Modern large, high power riding trowels can deliver substantial horsepower. During use, however, the drive train, the gearboxes, the rotors and the motors are subject to substantial stresses. Motor loading varies as the rotor RPM requirements change. Furthermore, ideal rotation speeds can vary depending upon the concrete, whose frictional characteristics vary between the freshly poured and stricken off stage, the subsequent green stages, and the end stages occurring after final curing and hardening. The motors function most efficiently at a given operating point in their characteristic horsepower-RPM and torque-RPM curves. Especially with diesel engines, optimum torque and horsepower requirements are achieved over a limited RPM range.
[0016] The engines on most riding trowels directly power the reduction drive gear boxes connected to the rotor shafts. The incoming shaft speed of the conventional rotor gear box is the same as the motor output RPM. The gearbox output shaft speed (i.e., rotor speed) is reduced, approximately 20:1. Engine RPM is usually the key variable related to output power. However, with engine speed increases, excessive power may be developed and the finishing mechanism may rotate too fast. For example, the initial panning stage requires relatively high power because of the viscous character of the still-wet concrete, but relatively low rotor speeds are desired. Since the rotors are driven through a fixed ratio, established by the gearbox and pulleys, optimum engine power often cannot be obtained during panning without risking excessive rotor speeds.
[0017] It has thus proven desirable to provide a CVT riding trowel wherein the engine and gear boxes can operate at ideal speeds over a wide range of finishing conditions.
[0018] U.S. Pat. No. 5,967,696 Oct. 19, 1999 issued to Allen Engineering Corporation depicts a CVT riding trowel, i.e., a trowel with a variable ratio transmission. The trowel described in the latter patent includes a CVT drive train powering a pair of rotors. The rotors are shaft-driven by reduction gear boxes. The CVT system comprises a variable ratio pulley driven by the motor. A second variable ratio pulley drives the gear box input shaft, with a drive belt entrained between the twin, variable ratio pulleys. Means are provided to change the effective diameters of a pair of belt-coupled pulleys. The varying ratio between the pulleys establishes a variable, overall drive gear ratio. However, it has been found that with the latter design, the CVT pulleys do not operate at a high-enough speed to promote efficiency.
[0019] Other continuously variable transmission devices not specific to riding trowels are seen in U.S. Pat. Nos. 8,682,549, 8,668,607, 8,686,886, 7,063,633, 6,994,643, 7,081,057, 7,090,600, 6,569,043, 6,120,399, 6,958,025, 6,953,400, 6,155,940, and 5,377,774.
[0020] It has recently been realized that improved efficiency of the overall power train results where the CVT transmission system, in a riding trowel for example, can operate at what would otherwise be classified as an excessive speed. For example, the first stage couplings or pulleys in a conventional CVT system operate at the drive motor output shaft speed or RPM. Variable gear reduction offered to the gearbox drive shaft then reduces applied RPM from that of the motor. It has been discovered that a CVT system that first increases the RPM speed from the motor, to operate the CVT pulleys at higher-than-expected speed, results in efficiency gains. Subsequent gear reduction to the gearbox drive shaft enables the motor to run at its desired speed at maximum intervals, while facilitating proper gear box speed. At the same time, over-torque of the CVT pulleys is avoided and belt breakage is avoided.
SUMMARY OF THE INVENTION
[0021] This invention provides a continuously variable ratio transmission (i.e., “CVT”) module ideally for powered concrete finishing riding trowels and the like that couples between the drive motor or motors and the lower drive train. CVT modules may be employed with single engine or multiple engine riding trowels, and they are ideal for diesel applications, natural gas engines, and traditional gasoline powered motors.
[0022] The preferred riding trowel comprises one or more engines for powering downwardly projecting rotors whose blades frictionally contact the concrete surface. The rotors are driven by reduction gear boxes that are shaft activated. By tilting the rotors steering forces are developed. The CVT module is mechanically interposed between the motor output shaft and the lower gear box input shaft, being connected with conventional V-belts entrained about suitably positioned pulleys.
[0023] The CVT configuration facilitates higher power applications by reducing the torque and subsequently the belt tension in the CVT. Belt tension is directly related to the torque on the rotating pulleys. Power is the product of torque and speed. Therefore increasing the speed of the CVT pulleys will result in lower torque. The CVT module input section steps up the applied motor speed, rather than stepping it down. With the enhanced CVT first stage input speed, and resultant torque and RPM characteristics, overall efficiency is achieved. Subsequent CVT pulley sections reduce speed sufficiently to drive the gearbox shafts at a desired speed.
[0024] Thus a basic object of my invention is to increase efficiency of a powered riding trowel, or other motor-powered device, when employing a CVT transmission.
[0025] A basic object of my invention is to provide a CVT module for power finishing trowels or similar motor-powered equipment.
[0026] It is also an object to accommodate larger engines in a riding trowel of the type described. It is a feature of the invention that engines up to sixty horsepower may be employed without damaging the drive train.
[0027] A related object is to optimize trowel efficiency and CVT efficiency by allowing the CVT transmission to operate at speeds higher than the motor output shaft speed, and to gear down the output speed to match the required rotor gearbox speed.
[0028] Another related object is to properly modify the torque and rotational speed of key components in a complex CVT-equipped powered riding trowel.
[0029] Yet another object is to provide an enhanced, modular CVT system ideal for riding trowels that enables the rotors to operate at a variety of speeds while allowing the drive motor or motors to operate at optimum speeds.
[0030] Another important object is to provide a CVT system whereby motor speeds can be varied during concrete finishing operations, while rotor speeds are substantially maintained.
[0031] Conversely, an important object is to enable rotor speed to be varied substantially as desired during different finishing stages, while maintaining substantially constant motor speed and motor torque.
[0032] A basic object, that is intertwined with all of the above, is to increase the efficiency of a CVT power unit by allowing it to run at higher-than-normal speeds (i.e., 6000 RPM) while maintaining the proper motor and gearbox speeds employed by the riding trowel.
[0033] Another basic object of my invention is to provide an optimum, overall gear ratio at all times during the riding trowel finishing process.
[0034] Another important object is to lock the drive train into different gear ratios that are selected during different finishing stages to maintain the desired operating parameters.
[0035] A related object is to provide a CVT module for ridding trowels that is ideal either during panning or blading.
[0036] A still further object of our invention is to provide a CVT module for riding trowels that increases production and efficiency.
[0037] A still further object of my invention is to provide a modularized CVT system of the character described that may be quickly installed or removed from riding trowels during service and/or maintenance.
[0038] These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
[0040] FIG. 1 is a frontal isometric view of a typical motorized, riding trowel equipped with my new CVT gearing system, with portions thereof shown in section or broken away for clarity or omitted for brevity;
[0041] FIG. 2 is a rear isometric view of the concrete finishing trowel of FIG. 1 , equipped with my new CVT gearing system, with portions thereof shown in section or broken away for clarity or omitted for brevity;
[0042] FIG. 3 is an enlarged, fragmentary, left frontal isometric view of the preferred CVT power module, with portions thereof shown in section or broken away for clarity or omitted for brevity;
[0043] FIG. 4 is an enlarged, fragmentary, top isometric view of the preferred CVT power module, with portions thereof shown in section or broken away for clarity or omitted for brevity;
[0044] FIG. 5 is an enlarged, fragmentary, right frontal isometric view of the preferred CVT power module, with portions thereof shown in section or broken away for clarity or omitted for brevity;
[0045] FIG. 6 is an enlarged, fragmentary, rear isometric view of the preferred CVT power module, with portions thereof shown in section or broken away for clarity or omitted for brevity;
[0046] FIGS. 7 and 8 are exploded isometric assembly views, with portions thereof shown in section or broken away for clarity or omitted for brevity;
[0047] FIG. 9 is a fragmentary, frontal exploded isometric and diagrammatic view of an alternative embodiment of a CVT trowel;
[0048] FIG. 10 is a fragmentary, rear exploded isometric and diagrammatic view of an alternative embodiment of a CVT trowel;
[0049] FIG. 11 is a fragmentary rear left isometric view of the trowel of FIGS. 8 and 9 ; and,
[0050] FIG. 12 is a fragmentary front right isometric view of the trowel of FIGS. 8-10 .
DETAILED DESCRIPTION
[0051] The subject matter of this patent is related to one or more of the following U.S. Pat. Nos. D323,510 issued January 1992; U.S. Pat. No. 3,936,212 issued February 1976; U.S. Pat. No. 4,046,484 issued Sep. 6, 1977; U.S. Pat. No. 4,312,603 issued Jan. 26, 1982; U.S. Pat. No. 4,556,339 issued Dec. 3, 1985; U.S. Pat. No. 4,676,691 issued Jun. 10, 1987; U.S. Pat. No. 4,710,055 issued Dec. 1, 1987, U.S. Pat. No. 5,108,220 issued Apr. 28, 1992; U.S. Pat. No. 5,238,323 issued Aug. 24, 1993; U.S. Pat. No. 5,405,216 issued Apr. 11, 1995; U.S. Pat. No. 5,480,257 issued Jan. 2, 1996; U.S. Pat. No. 5,480,258 issued Jan. 2, 1996; U.S. Pat. No. 5,613,801 issued Mar. 25, 1997; U.S. Pat. No. 5,658,089 issued Aug. 19, 1997; U.S. Pat. No. 5,685,667 issued Nov. 11, 1997; U.S. Pat. No. 5,803,658 issued Sep. 8, 1998; U.S. Pat. No. 5,934,823 issued Aug. 10, 1999; U.S. Pat. No. 5,967,696 issued Oct. 19, 1999, U.S. Pat. No. 5,988,938 issued Nov. 23, 1999; and, U.S. Pat. No. 6,019,545 issued Feb. 1, 2000. For purposes of disclosure, and compliance with enablement and disclosure requirements of 35 USC Sec. 112 et. Seq., the foregoing patents are hereby incorporated by reference as if fully set forth herein.
[0052] The subject matter of this patent is also related to one or more of the following other references: “Hi-Lo Variable Speed Pulley Drives” brochure by Hi-Lo Manufacturing Co. Prtd. November 1994; “TS 78 Multi-Lap Ride-On Power Trowel” Spec Sheet by Bartell Powell Products; Bartell “Power Trowels” Brochure “Speed Selector Inc.'s “Variable Speed Drives & Accessories” Brochure form 910-1-9; For purposes of disclosure, and compliance with 35 USC Sec. 112, the foregoing references are hereby incorporated by reference as if fully set forth herein
[0053] FIG. 1 shows a typical dual rotor riding trowel 20 incorporating my new CVT transmission module variable gearing system. Common structural details relating to riding trowel motors, rotors, steering, rotor tilting, etc. are explained in detail in the above-cited references. It should be appreciated that trowel 20 may comprise either modern hydraulic steering, or it may employ the older manual steering arrangements such as that illustrated in U.S. Pat. No. 5,108,220. The drive engine may be diesel, gasoline, or gas powered. A variety of other differences between various riding trowels known in the art exist as well, but few of these are relevant to the employment of my CVT module.
[0054] The riding trowel 20 comprises a drive engine 22 for powering downwardly projecting, bladed rotors 24 that frictionally contact the concrete surface 23 below. The multiple, radially spaced apart blades 26 projecting from central hubs 28 are driven by gear boxes 30 to treat concrete. Engine 22 is interconnected with the gear boxes 30 via a CVT module generally designated by the reference numeral 29 . The steering system may include a plurality of both manual and hydraulic linkages and actuators. By tilting the rotors appropriately, directional steering forces are developed. The operator's seat 34 may be mounted above the motor 22 proximate suitable steering handles and controls (not shown). Seat 34 rests upon a subframe 36 supported upon the trowel main frame 40 .
[0055] U.S. Pat. No. 5,967,696 entitled “Riding Trowel with Variable Ratio Transmission”, issued Oct. 19, 1999 discloses a riding trowel with a CVT pulley system for establishing continuously variable gear ratios. In this device the amount of power that is transferred from the engine to the gearboxes results in excessive torque. The CVT belt breaks with too much torque with larger, modern engines. To operate efficiently the CVT clutch needs to run at a faster RPM. By speeding up the CVT pulley system torque is reduced, and belt pressure or tension is reduced. This results in longer belt life. However, the gearbox shafts must run at a reduced speed. Thus the instant torque converting arrangement uses another pulley, driven by the CVT, to reduce speed and increase torque to the gearbox driveshaft. The pulley and shaft arrangement is disposed in modular form, preferably beneath the operator seat, proximate the lower gearboxes, between the twin rotors.
[0056] With joint reference now directed to FIGS. 3-8 , the CVT module 29 is preferably mounted atop a rigid plate 44 that is configured to suitably attach atop the trowel main frame 40 . The power input end of the CVT module has been generally designated by the reference numeral 46 in FIGS. 4 , 5 , and 7 . The CVT module is positioned proximate the output end of the engine 22 , the power output flywheel of which has been designated by the reference numeral 50 in FIG. 7 . The PTO shaft 51 (i.e. FIG. 8 ) emanating from the flywheel 50 of the engine 22 drives the CVT module. Portions of the engine outer wall 52 are seen in FIGS. 3-8 . Engine wall 52 supports a pulley idler plate 54 used by the first or input stage of the CVT module.
[0057] The power input stage of the CVT unit (i.e., the first stage) comprises a pulley 60 that is splined to PTO shaft 51 . A first belt 62 entrained over pulley 60 is coupled to a reduced diameter pulley 64 that is positioned above pulley 60 . Pulley 64 thus rotates faster than PTO 51 . Pulley 64 is splined to a jackshaft 66 that penetrates it and terminates through a bushing 68 in a roller bearing 69 attached to plate 54 proximate the engine. Jackshaft 66 rotates at a higher speed and lower torque than the engine shaft 51 .
[0058] Jackshaft 66 reaches the second stage 67 ( FIG. 3 ) of the CVT module through a bearing 70 affixed to a support plate 72 mounted atop a vertically extending, intermediate plate 74 that is secured to horizontal plate 44 . Jackshaft 66 terminates within and is splined to a variable drive CVT pulley assembly 84 in CVT module second stage 67 . Pulley 84 can change its effective diameter, varying the speed and torque transmitted to lower pulley 88 by a second or CVT belt 89 . CVT pulley 84 will be driven by jackshaft 66 at a higher speed than the engine shaft 51 , therefore operating at a lower torque. A suitable CVT unit is available from CV Tech Company, Drummondville Quebec Canada. The CVT unit comprises a first and preferably upper pulley 85 with cooperating, conical halves 87 A and 87 B that are axially spaced apart a distance that establishes the belt gear ratio.
[0059] A second jackshaft 92 positioned below jackshaft 66 is splined through lower CVT pulley 88 . The CVT belt 89 extends to lower CVT pulley 88 from the upper CVT pulley. Jackshaft 92 extends from a roller bearing 95 that is mounted to a vertically oriented plate 97 that is secured to plate 44 near its leftward extreme. Jackshaft 92 extends through a bushing 99 and through intermediate plate 74 to the third stage of the CVT module that has generally been designated by the reference numeral 100 ( FIG. 8 ).
[0060] Referring now to FIGS. 5-8 , jackshaft 92 terminates within stage 100 through bearing 102 in a third pulley 104 that is supported by bearing 102 and intermediate plate 74 . A third belt 108 entrained over pulley 104 extends through and beneath plate 44 through an orifice 109 ( FIG. 5 ). Belt 108 reaches a larger diameter, fourth pulley comprising lower gearbox drive pulley 111 that is coupled to the gearbox drive shaft 113 . Gearbox drive shaft 113 is supported by a pair of spaced-apart bearings 116 ( FIGS. 6 ), 118 and 121 .
[0061] In short, the Allen power transmission system takes the power of the engine, which is supplied at a particular rotating speed and torque, converts it to a higher speed and lower torque which is more suitable for the CVT, then converts back to a lower speed and higher torque which is necessary for the proper speed of the gearboxes and rotors, and maximal efficiency of the trowel.
[0062] Turning to FIGS. 9-12 , and alternative embodiment of a module suitable for trowel 20 ( FIG. 1 ) has been designated by the reference numeral 29 B. This embodiment is advantageous when servicing the trowel. CVT power is delivered into the module 29 B from the side opposite that employed with module 29 .
[0063] The alternative CVT module 29 B is mounted similarly to embodiment 29 discussed above. The power input end of the CVT module 29 B has been generally designated by the reference numeral 46 B. The power output flywheel 50 B ( FIG. 10 ) drives PTO shaft 51 B that is coaxial with flywheel 50 B. Portions of the engine outer wall 52 B are fragmented as in FIG. 10 . Engine-driven shaft 51 B penetrates a bearing 201 and U-joint assembly 206 and is anchored in thrust bearing 202 and passes through pillow block 203 . Shaft 51 B penetrates taper lock bushing 204 that is coaxially centered within a first pulley 60 B that drives a lower diameter second pulley 64 B via entrained belt 62 B. Pulley 60 B is thus driven by PTO shaft 51 B. Pulley 64 B thus rotates faster than PTO shaft 51 B. Pulley 64 B is splined to a first jackshaft 66 B that penetrates it and terminates through a bushing 69 B 54 proximate the engine. Jackshaft 66 B rotates at a higher speed and lower torque than the engine shaft 51 B.
[0064] Jackshaft 66 reaches the second stage 67 B ( FIG. 10 ) of the CVT module through a bearing 70 B and terminates within and is splined to a variable drive CVT pulley assembly 84 B in second stage 67 B. Pulley assembly 84 B can change its effective diameter, varying the speed and torque transmitted to lower CVT pulley 88 B by a second or CVT belt 89 B. CVT pulley 84 B will be driven by jackshaft 66 B at a higher speed than the engine shaft 51 B, therefore operating at a lower torque. The CVT unit 84 B comprises a first and preferably upper CVT pulley 85 B with cooperating, conical halves 87 C and 87 D that are axially spaced apart a distance that establishes the belt gear ratio.
[0065] Preferably a second jackshaft 92 B is positioned below jackshaft 66 B and is splined through lower CVT pulley 88 B. The CVT belt 89 B extends to lower CVT pulley 88 from the upper CVT pulley. Jackshaft 92 B extends from a roller bearing 95 B and extends through a bushing 99 B to the third stage of the CVT module that has generally been designated by the reference numeral 100 B ( FIG. 11 ).
[0066] Referring now to FIGS. 10-12 , jackshaft 92 B terminates within stage 100 B through bearing 102 B and runs to a third pulley 104 B. A third belt 108 B entrained over pulley 104 B drives a larger diameter, fourth pulley comprising lower gearbox drive pulley 111 B that is coupled to the gearbox drive shaft 113 B. Gearbox drive shaft 113 B is supported by a pair of spaced-apart bearings 116 B ( FIGS. 10 , 11 ), and 118 B. The rotors 24 B are gearbox driven by the gearbox shafts 113 B.
[0067] From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
[0068] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations.
[0069] As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
|
A power riding trowel for finishing concrete comprising rotors turned by gearboxes driven by gearbox driveshaft's linked to the moor output by CVT gear ratio control. The motor output shaft drives a first jackshaft driven at a higher speed than the motor RPM. A CVT pulley assembly comprising first and second CVT pulleys and a CVT belt entrained between them has a first CVT pulley driven by the first jackshaft. A second jackshaft splined to the second CVT pulley drives the gearbox driveshaft at a speed lower than said second jackshaft to operate the rotor means at a proper speed and torque.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. provisional application serial No. 60/212,437 filed on Jun. 16, 2000, incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to passive energy dissipation systems in seismic applications, and more particularly to a method and apparatus for amplifying structural displacements for the driving of passive energy dampers.
2. Description of the Background Art
The use of damping devices on a structure to improve performance under shock, wind stress, vibration and so forth, is well known. Damping devices are typically connected to a rigid structure to receive the energy from the mechanical displacements to which the flexible building structure is subjected. The building is often referred to as a gravity frame and the rigid structure is often referred to as a reaction frame. A conventional damper for use in civil structures may be implemented with a large bore damper acting at very low pressure to minimize the rise time effects. However, this solution is often inefficient or impractical in that the damper can be difficult to package due to its large envelope, coupled with a high cost.
The use of less compressible fluid in the damper can reduce the size of a given damper yet these low compressibility fluids are not always practical as they are often toxic, flammable, or have less than favorable temperature characteristics or longevity.
Another attempt at improving the practicality of these seismic isolator makes use of a mechanism that combines a substantially braced column with a horizontal driving arm connected to the column and upper floor with hinge pins. An example of this mechanism being characterized by the “DREAMY” system described in the paper by Taylor, Douglas P. et al., Development and Testing of an Improved Fluid Damper Configuration for Structures Having High Rigidity, Taylor Devices, Inc., that can be found at www.taylordevices.com/techpaper2000.htm. In this configuration, vertically oriented dampers are connected at each end of the driving arm between the driver arm and the lower floor. Use of a lever in this manner increases the effective damper stroke, however, it may not be suitable for use in buildings or bridges because the entire mechanism is required to be extremely rigid to prevent the mechanism from flexing on the same level as the rise deflection of a direct acting damper, thus gaining no design improvement. In addition, utilizing a rigid mechanism necessitates hinge points that have very tight tolerances, while the mechanical links need to be large and heavy to prevent flexing under load. It will be appreciated that the external pin of the lever has to be free to move vertically to prevent the system from being locked in position. Furthermore, the close-fitting hinge points which allow in-plane response must not bind in the out-of-plane direction, and this requirement can readily drive up implementation costs.
Toggle braces have been developed to address certain limitations with lever-type damping mechanisms. Taylor et al., as well as U.S. Pat. No. 5,934,028 describe an approach that uses a toggle as a diagonal brace, with one end of the damper installed proximate the toggle pivot, and the opposite end attached to the building frame. With this approach, a relatively small lateral deflection in the building frame will cause a much larger deflection at the damper, due to the toggle mechanism multiplying deflections at the damper mounting point.
Therefore a need exists for an apparatus and method of increasing the amount of displacement energy which may be dissipated within a damper assembly of a given size, while not increasing implementation cost or reliability. The present invention satisfies those needs, as well as others, and overcomes the deficiencies with previously developed solutions.
BRIEF SUMMARY OF THE INVENTION
The present invention generally comprises a displacement amplification mechanism which is capable of increasing the seismic energy dissipation of buildings and other similar flexible civil structures which are subject to displacement. Embodiments are described, by way of example, which utilize simple lever systems with arms of different lengths or with two concentric connected gears with different radius pinned at the center. The displacement amplifying apparatus of the invention is configured for use within a seismic isolator configured for attachment between a rigid structure and a flexible structure to dissipate seismic energy. It will be appreciated that the flexible structure, such as a civil structure, is often referred to as a gravity frame which under seismic, wind, vibration or other loading conditions becomes physically displaced and distorted. To provide seismic isolation, the energy from the movement of the gravity frame is dissipated in relation to a rigid reaction frame which typically comprises a rigid structure, such as an “A”-frame structure beneath the gravity frame. The reaction frame is typically not subject to the same inter story displacement forces as the gravity frame, but is utilized to extend a rigid base against which the energy may be dissipated. Seismic isolation is provided by the present invention by registering the motion associated with said inter story displacement which is amplified by the displacement amplifying apparatus whose output is received by a damping assembly. The inter story displacement applied to the damper will be amplified by the ratio of the length of the longer arm of the pivoting lever to that of the shorter arm, or by the ratio of diameter of the larger gear to the diameter of the smaller gear. In this way, the effective damper stroke is increased while, at the same time, the required amount of applied force at the damper mounting points is reduced. The invention can be used to amplify the relative inter story displacement that occurs during an earthquake in civil structures, and the resultant amplified displacement can then be used to dissipate energy by means of energy displacement devices such as a fluid viscous dampers (hydraulic dampers), friction dampers, viscous elastic dampers, and so forth.
In addition to amplifying structural displacements, the invention can provide altering the direction of the displacement, which can be beneficial in many situations, such as for meeting selected design constraints or in seismically retrofitting bridges. Furthermore, the invention allows for the use of viscous fluid dampers where the exponent of the damping coefficient is less than one, wherein damping efficiency is increased and more energy may be dissipated.
Additionally, damper beams could be constructed as integral units containing girders, displacement amplification devices according to the present invention, and dampers. These damper beams can be constructed and tested prior to installation into the structure. Further, “super dampers” can be constructed using a plurality of displacement amplification devices integrated with one or more dampers according to the invention for significantly improving the energy dissipation capacity of a small damper. Utilization of a plurality of “super-damper” devices rather than a few high-capacity dampers can provide cost-effective improvements of the seismic response of a structure. It will be appreciated that lever type and geared type amplification mechanisms may be mixed or interchanged to provide the desired seismic isolation. In accordance with a further aspect of the invention, a “turbo damper” can be constructed where, instead of amplifying the displacement and transferring the amplified displacement to a damper, the displacement is converted into rotational energy. The “turbo damper” is a rotating damper that integrates the functions of the mechanical displacement amplifier and the energy damper. The motion received by the “turbo damper” is converted to a rapid rotation of a propeller retained within a housing filled with viscous fluid.
Conventional seismic isolators such as the DREAMY system require the utilization of large components and are subject to possible problems with out-of-phase motion. A problem that is not present in the DREAMY system but exists in other systems is that the external pin of the lever has to be free to move vertically to prevent the system from being locked in position. In contrast, the present invention allows for the use of very short lever arms which are more rigid from a flexural point of view. Out of plane deformation can be solved by employing shear key plates. The last problem of allowing the vertical movement of the pin is solved within the present invention by utilizing flexible coupling point whose motion is constrained, this is exemplified by utilizing an elongated hole in the lever plate into which a coupling pin is retained. This pin-lever connection has the added benefit of allowing relative movement in the out-of-plane direction. The amount of movement being allowed being controlled by the configuration of the shear key plates. These features allow the present displacement amplification apparatus to be beneficially employed for dissipating seismic deformations and wind induced vibrations within large buildings and other structures.
An object of the invention is to increase energy dissipation within seismic isolators for use within civil structures and other large flexible structures.
Another object of the invention is to amplify the displacement of gravity frames in relation to a reaction frame whereby the damper assembly can be made more efficient and cost effective.
Another object of the invention is to provide a displacement amplification apparatus for use with gravity frames slidably engaged over an “A”-shaped brace of the reaction frame.
Another object of the invention is to provide a displacement amplification apparatus for use with gravity frames having a reaction frame that is not located proximal a portion of the gravity frame which is subject to displacement.
Another object of the invention is to provide a displacement amplifying apparatus that is capable of redirecting the displacement energy being dissipated. Another object of the invention is to provide a displacement amplifying apparatus that is capable of directing the amplified displacement of the civil structure to dampers attached at any of a number of locations, including the gravity frame, the reaction frame, or the base level.
Another object of the invention is to provide a displacement amplifying apparatus that is capable of directing the amplified displacement of the civil structure to dampers which are integrated within structural building elements.
Another object of the invention is to provide a displacement amplifying apparatus combined with a damper assembly, such that displacement forces are amplified and damped within a seismic isolator that has a lowered component count.
Another object of the invention is to provide a displacement amplifying apparatus for use in a seismic isolator which is both reliable and easily manufactured.
Further objects and advantages of the invention will be brought out in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood by reference to the following drawings which are for illustrative purposes only, and where like reference numbers denote like parts:
FIG. 1 is side schematic view of an embodiment of a lever-style displacement amplification apparatus according to the present invention installed in a gravity frame shown within a building.
FIG. 2 is a detailed partial view of the displacement amplification apparatus of FIG. 1 shown in the context of the beam portion of the building frame.
FIG. 3 is a side schematic view of the structure shown in FIG. 1, shown undergoing lateral deformation.
FIG. 4 is a detailed partial view of the displacement amplification apparatus of FIG. 1, shown in the context of the beam portion of the building frame in response to lateral displacement.
FIG. 5 is a side schematic view of an embodiment of a gear-style displacement amplification apparatus according to an embodiment of the present invention shown installed in a building frame.
FIG. 6 is a detailed partial cutaway view of the displacement amplification apparatus of FIG. 5 .
FIG. 7 is a perspective view of an alternative embodiment of the gear-style displacement amplification apparatus shown in FIG. 6 .
FIG. 8 is a diagram depicting the response of a fluid viscous damper undergoing cycling load without a displacement amplification apparatus according to the present invention.
FIG. 9 is a diagram depicting the response of a fluid viscous damper undergoing cycling load with a displacement amplification apparatus according to the present invention.
FIG. 10 is a partial cutaway view of an embodiment of a gear-style displacement amplification apparatus according to the present invention with angled gear tracks.
FIG. 11 is a side schematic view of the gear-style displacement amplification apparatus of FIG. 10 shown installed in a building structure with a cross-brace.
FIG. 12 is a side schematic view of a damper beam employing the gear-style displacement amplification apparatus shown in FIG. 6 .
FIG. 13 is a side schematic view of the damper beam of FIG. 12 shown within a building frame.
FIG. 14 is a top plan schematic view of a super-damper according to an embodiment of the present invention.
FIG. 15 is a perspective view of a turbo-damper according to an embodiment of the present invention.
FIG. 16 is an exploded view of gear and propeller mechanism employed in the turbo-damper shown in FIG. 15 .
FIG. 17 is a side schematic view of a multi-level building structure employing an alternative embodiment of the lever-style displacement amplification apparatus according to an embodiment of the present invention.
FIG. 18 is a partial detail view of the displacement amplification apparatus employed in FIG. 17 shown in the context of a beam undergoing lateral displacement.
FIG. 19 is a detailed partial perspective view of the displacement amplification apparatus employed in FIG. 17 .
FIG. 20 is a side schematic view of a lever-style displacement amplification apparatus according to an embodiment of the present invention, shown configured for use within a bridge having an expansion joint.
FIG. 21 is a side schematic view of the displacement amplification apparatus of FIG. 10 shown installed in a wood frame shear wall.
FIG. 22 is a top plan view of an alternative embodiment of a super-damper according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring more specifically to the drawings, for illustrative purposes the present invention is embodied in the apparatus generally shown and described in FIG. 1 through FIG. 22 . It will be appreciated that the apparatus may vary as to configuration and as to details of the parts, and that the method may vary as to the specific steps and sequence, without departing from the basic concepts as disclosed herein.
FIG. 1 schematically shows a seismic isolation apparatus incorporating the displacement amplification apparatus of the present invention to dissipate the energy from the lateral displacement of a gravity frame in relation to a reaction frame implemented as an “A”-shaped brace slidably engaged with the horizontal girder at mid-span with roller-bearings. The triangular structure comprises a pair of legs having proximal ends rigidly attached to the base level and distal ends fixedly joined to one another at a roller bearing assembly which supports the girder and provides for mounting of the displacement amplifying apparatus. The building frame (gravity frame) is shown having a pair of vertical columns 10 a , 10 b extending from support bases 12 a , 12 b at their lower ends to a horizontal girder 14 at their upper ends. It will be appreciated that this gravity frame structure, which is shown in its static or undeformed position in FIG. 1, forms no part of the invention but constitutes the working environment. Referring to FIG. 1 and FIG. 2, the invention comprises a displacement amplification system that is configured for attachment to the gravity frame structure thus described. In the embodiment of the invention shown in FIG. 1 and FIG. 2, an “A”-shaped brace 16 having a pair of legs 18 a , 18 b is rigidly attached to bases 12 a , 12 b at the lower ends of legs 18 a , 18 b . The upper end of brace 16 is positioned beneath girder 14 and is coupled to girder 14 by means of a lever 20 . One end of lever 20 is pivotally coupled to brace 16 with a coupling 22 a , and the other end of lever 20 is pivotally coupled with a coupling 22 b to piston rods 24 a , 24 b on fluid viscosity dampers 26 a , 26 b or the like. It should be appreciated that the pivoting lever may be implemented as members of various shapes including straight, curved, or other shapes having mounting points that are radially displaced from a pivot point and yet need not be collinear with the pivot. Note that the pivotal couplings 22 a , 22 b comprise a pin or the like that extends through a hole in lever 20 which is preferably elongated according to the amount of displacement expected. Use of an elongated hole in lever 20 is an important feature which allows for movement of brace 16 and/or girder 14 in relation to lever 20 . A rigid connection is not desired since the stresses that can be placed on the coupling points during deformation could cause shearing. Fluid viscosity dampers 26 a , 26 b are in turn coupled to vertical cross-members 28 a , 28 b in girder 14 . Lever 20 is also pivotally coupled to a bottom flange 30 of girder 14 with a roller bearing 32 or the like at a point along lever 20 that is offset from the longitudinal center of lever 20 . The result is that two arms 34 a , 34 b are created in lever 20 between coupling 32 and couplings 22 a , 24 b at the ends of the lever, respectively, with arm 34 a being necessarily shorter than arm 34 b for displacement amplification according to the invention.
Referring now to FIG. 3 and FIG. 4, in the event of lateral deformation of the gravity frame, columns 10 a , 10 b , girder 14 will move laterally and lever 20 will rotate about coupling 32 . In the example shown in FIG. 4, the amount of lateral displacement in the relative displacement direction 36 is denoted by “a”. Lever 20 will amplify the inter story displacement in relation with the reaction frame so that the displacement applied to dampers 26 a , 26 b will be the inter story displacement multiplied by the ratio of the length of arm 34 b to the length of arm 34 a . In other words
b=βa
α=L 2 /L 1
where b=displacement applied to the pistons of the dampers, a=inter story displacement, L1 length of shorter lever arm, and L2=length of longer lever arm. The effective damper stroke is increased while, at the same time, the required amount of applied force F at the damper mounting points 28 a , 28 b is reduced. In FIG. 4, for α=2, the amount of force required at the damper mounting points is reduced to F/4.
While a displacement amplification system according to the invention can be implemented using a simple lever system as described above, it is not limited to use of a lever system. For example, referring to FIG. 5 and FIG. 6, the invention can be embodied in a displacement amplifying apparatus that utilizes a gearset having gears of different diameters that amplify motion received by a small gear to an output driven by a larger gear which is substantially concentric with said small gear. It will be appreciated that the mechanical displacement applied to the damper is amplified by the ratio of the diameter of the larger output gear in relation to the diameter of a smaller input gear. A displacement amplification device 36 is illustrated that employs two concentric connected gears 38 a , 38 b of differing radius which are fixedly connected at their centers with a pin 40 or the like. The gear assembly is in turn rotatably coupled to a housing 42 using such as pin 40 extending into a bearing in housing 42 . A lower gear track 44 a provides a linear coupling member which is joined to brace 16 and an upper gear track 44 b provides a another linear coupling member which is coupled to pistons 24 a , 24 b of dampers 26 a , 26 b . The gear tracks can be guided by, and move in relation to, a roller R that also resists the radial force developed by the gear system. Dampers 26 a , 26 b , as well as housing 42 are mounted beneath girder 14 as shown. Here, inter story displacement is amplified by the ratio of the diameter of the larger gear 38 b to the diameter of the smaller gear 38 a . FIG. 7 shows an alternative embodiment of this geared displacement amplification device where connecting rods 46 a , 46 b are coupled to the gear tracks 44 a , 44 b and slide within supports 48 a , 48 b attached to housing 42 .
The operational theory behind the displacement amplification system can be explained by applying a cycling load to two different cases using a linear fluid viscous damper and comparing the amounts of energy dissipated. Referring to FIG. 8, in the first case, a fluid viscous damper with a damping coefficient C=Co is used with no displacement amplification device. Referring to FIG. 9, in the second case, a fluid viscous damper with a damping coefficient C=Co/4 and a displacement amplification device with an amplification factor β=2 is used. The same load cycle is applied to both systems. The frequency of the load applied to the dampers in both systems will be the same, but the displacement and velocity applied to the damper in the second system is doubled. The energy displaced will also be the same for the two systems.
For the first case,
E D =πC 0 ωu 0 2 .
and for the second case,
E D =πC 0 /4ω(2 u 0 ) 2 =πC 0 ωu 0 2 .
This means that, if linear fluid viscosity dampers are used with a displacement amplification device with an amplification factor of two, only a damper with ¼ of the original damping coefficient needs to be utilized to produce the same effect.
Referring now to FIG. 10 and FIG. 11, not only can the invention be used to amplify the displacement but it can be used to change the direction of the displacement. These drawings figures show an alternative embodiment 50 of a geared displacement amplification system where, instead of tracks 44 a , 44 b being substantially parallel to each other as in FIG. 5 through FIG. 7, the tracks are set at a relative angle. The displacement amplification device 50 is placed within reaction frame that is substantially displaced from the gravity frame at the foot of the frame in once corner. The motion of the gravity frame is conveyed between the gravity frame and the reaction frame by a diagonal support member, such as a cross-brace, which has a proximal end configured for attachment to the mechanical displacement amplifying means, and a distal end configured to attach to the structure. One end of a diagonal cross-brace 52 is connected to track 44 a with the smaller gear 38 a . The other end of cross-brace 52 is coupled to a bottom flange 54 on girder 14 at the upper corner of the frame. Track 44 b with the larger gear is coupled to a damper 56 that in turn is connected to a stationary base 58 . This configuration changes the inter story drift 60 from one direction to the opposite direction as shown in the drawing. This can be helpful in the case where there are design constraints or in the seismic retrofit of bridges. Also, fluid viscous dampers where the exponent of the damping coefficient is less than one can be used. Such dampers are efficient and, therefore, more energy can be dissipated.
Referring to FIG. 12, the invention can also be embodied as a damper beam 62 that is constructed and tested prior to installation into the structure. Damper beam 62 would be an integral unit comprising girder 14 , displacement amplification device 36 , and dampers 26 a , 26 b . An example of how damper beam 62 would be installed is shown in FIG. 13 .
A displacement amplification device according to the invention can be embodied in various other ways as well. For example, FIG. 14 shows a form of rotating “super damper” that is very sensitive to the applied displacement. This rotating damper apparatus integrates the mechanical displacement amplifying means with a damper. The motion input to the rotating damper is converted to a rapid rotation of a propeller retained within a housing filled with viscous fluid. Multiple independent gear-driven propellers may be utilized, which may are preferably configured for coupling to a linear coupling member having multiple pinions. Configuring the multiple gear-driven propellers for counter-rotation in close proximity to one another within said fluid filled housing greatly increases the rotational damping effect. In this embodiment the rotating damper 66 comprises a pair of displacement amplification devices 36 a , 36 b having connecting rods as shown in FIG. 7 have been integrated into a single unit 64 with a pair of dampers 26 a , 26 b . By employing a configuration as shown, the dissipation capacity of small dampers can be greatly improved. Also, a plurality of “super-damper” devices rather than a few dampers with high capacity can achieve a cost-effective improvement of the seismic response of a structure.
Furthermore, it should be appreciated that FIG. 14 represents a single method of integrating a pair of displacement amplification devices and dampers; other configurations are contemplated as well. In addition, the size and type of the gear mechanisms and size of the pin connections can vary depending on the size and type of dampers. Furthermore, the geared amplification mechanism could be replaced with a lever-type mechanism of the type described in FIG. 1 and FIG. 2 . In any such configuration, however, a possible practical limitation can be the fact that, in order to transfer the relative large forces developed by the dampers, the gears must be sufficiently strong that only small dampers can be used. However, since the maximum forces developed by the particular dampers used are known, the gear mechanisms can be designed to be reliable and effective.
Referring now to FIG. 15 and FIG. 16, a “turbo damper” 66 is shown which employs a rack-pinion system. In this embodiment, instead of amplifying the displacement and transferring the amplified displacement to a damper, the displacement is amplified and converted into rotational energy by turbo damper 66 . Turbo damper 66 includes a pair of propellers 68 a , 68 b having corresponding gears or pinions 70 a , 70 b . By connecting the pinions to the propellers, rotation of the pinions is transferred to the larger diameter propellers thereby resulting in displacement amplification. The propellers are rotationally coupled at their centers so that they can rotate in opposite directions. A pair of tracks 72 a , 72 b and corresponding connecting rods 74 a , 74 are associated with propellers 68 a , 68 b , respectively. The exposed ends of the connecting rods are joined by coupling 76 for connection to the structure. As can be seen, the propellers are assembled in such a way that the propeller blades 78 a , 78 b , which are preferably flat plates or paddles, will rotate in opposite directs when a force is applied to coupling 76 . These components are carried by a housing 80 that is filled with a viscous fluid that engulfs propeller blade 78 a , 78 b and acts as a damper. When a displacement force is applied to coupling 76 , the propellers rotate and the blades start moving back and forth in the fluid, thereby producing viscous forces and heat. Because the blades rotate in opposite directions, the fluid inside the device is device is forced to move against the blades of the opposite set, thereby producing turbulence and increasing the ability to dissipate energy. Since the device can be made in such a way that the external radius of the propeller is much larger than the radius of the pinions, the velocity to which the blades move inside the fluid can be several times the velocity applied to the devices. The characteristics of this damper, such as the normal force and the damping coefficient, can be controlled by several parameters, such as the diametral pitch of the pinions, the viscosity of the fluid, and the geometry, dimensions and relative orientation of the rotating blades.
FIG. 17 through FIG. 19 depict implementations of the lever type displacement amplification system according to the invention that are particularly suited for seismic and wind applications of stiff buildings. These configurations are based on the same principles described in connection with the configurations shown in FIG. 1 through FIG. 4 and further illustrate the advantages of the present invention compared to conventional approaches. In these embodiments, the dampers are relocated from beam 14 to legs 18 a , 18 b of brace 16 . As a result, instead of lever 20 being a linear lever as shown in FIG. 1 through FIG. 4, lever 20 is angled to accommodate the placement of the dampers. Shear key plates are also used to allow for slight out of plane motion.
For example, FIG. 17 depicts a multi-story building structure where two levels 80 a , 80 b are shown, each level being differentiated by beam 14 that supports a concrete slab 82 . The upper portions of legs 18 a , 18 b of brace 16 are rigidly connected to a steel plate 84 which is not attached to beam 14 but which abuts or is placed slightly below beam 14 by an acceptable amount of vertical displacement. Legs 18 a , 18 b would typically be conventional double “C” or “U” braces. In upper level 80 a , damper 26 a would be installed in the front side of leg 18 a , and be coupled at its base to cross-member 84 using a pin 88 and clevis 90 . The piston would then be coupled to the long arm of lever 20 using pivotal coupling 22 b . Note that there is no need to elongate the corresponding hole in lever 20 in this configuration. Lever 20 is pivotally coupled to plate 84 at its bend or fulcrum point using coupling 32 . The other end of lever 20 , which includes an elongated hole 94 , is coupled to a shear key plate 92 using pin 96 . Shear key plate is in turn rigidly attached to beam 14 . The entire configuration described above is duplicated on the back side of leg 18 a as depicted in FIG. 19 .
FIG. 17 also shows how additional dampers could be incorporated into the system if desired. As can be seen with respect to lower level 80 b , both legs of brace 16 are fitted with dampers. For example, leg 18 b would include a pair of dampers 26 c and 26 d (not shown) and associated lever mechanisms.
FIG. 18 schematically depicts movement in the direction 36 showing how the beam and shear key plates will move in relation to plate 84 and brace 16 , and the relative movement of the levers and dampers.
Referring more particularly to FIG. 19, this configuration has many practical advantages. First, coupling the lever to the shear key plate beam using a pin extending through an elongated hole allows for relative vertical movement. Second, movement in the out of plane direction 98 is limited to a small space between the two shear key plates 92 a , 92 b and plate 84 which is sandwiched between the two shear key plates. For example, using such shear key plates will allow the frame to move in the out of plane direction with respect to brace system only very little (e.g., 0.5 in). Third, lever connection using a pin extending through an elongated hole also allows for relative movement in the out-of-plane direction (at least for the small amount allow by the shear key plates). These features allow the system to be used to reduce seismic deformations and wind induced vibrations of tall and rigid buildings.
FIG. 20 depicts the lever system of the present invention applied to a bridge application where a joint of a bridge with the damper and lever system is schematically shown. The joint of the bridge is basically a cut in the structure to allow movement such induced by shrinkage, creep deformations and temperature changes. To fill the gap and allow the traffic to over the surface 100 of the bridge, an expansion joint 102 is used between the cut sections 104 a , 104 b . However, these joints are quite sophisticated and expensive. On the other hand, by using the present invention, a damper 106 coupled to a lever 108 and a bearing 110 made from neoprene or the like can be used to reduce the relative displacements that can occur during an earthquake in order to reduce the size of the expansion joints and reduce possible damage.
FIG. 21 depicts an implementation of the gear type displacement amplification system according to the present invention which is similar to that shown in FIG. 10 and FIG. 11 . Here, however, the invention is shown in the context of a wood frame building for which the gear type mechanism 50 is particular well suited. One of the potential limitations of the gear type system is the size of the forces that can be transferred without breaking the gears. However, in the case of wood frame buildings, the forces involved during an earthquake are much smaller since the material is much lighter. The example shown in FIG. 21 is of a shear wall section having a plurality of studs 112 , a double top plate 114 , a bottom plate 116 , and plywood sheeting 118 . In this configuration, cross-brace 52 would typically be a steel brace, square tube, 2×2 wood brace or the like. Otherwise, the configuration would be the same as shown in FIG. 10 and FIG. 11 .
Referring now to FIG. 22 an alternative embodiment of the “super damper” of FIG. 14 is illustrated. In this embodiment, a pair of gear assemblies 120 a , 120 b , each of which would comprise a smaller diameter gear 36 a , and larger diameter gear 36 b , would be rotatably coupled to a steel plate 122 used as a base. A moveable track assembly 124 would be in turn coupled to the piston of a damper 126 and the other end of the damper would be connected to a steel plate 128 that is attached to base 122 .
As can be seen, therefore, the invention can be implemented in various structures subject to lateral loads, such as earthquake ground motion, or wind load, and can be used in new structures as well as for seismic retrofitting of existing buildings or bridges. The invention is capable of drastically reducing the size of the dampers required to dissipate the energy. In additional, several small dampers can be used instead of large size dampers, providing better results and cost effectiveness. The overall response of structures to seismic events can be improved, thus reducing damage and possible loss of life. Additionally, a considerable amount of money can be saved in the construction of new seismic resistant structures or in retrofitting existing buildings or bridges. The amplifying of displacement can also be very useful for wood frame or masonry buildings wherein even the small relative displacement expected in to the elastic range can be used to dissipate a considerable amount of energy. In these applications, the major limitation on the implementation of passive energy systems has been the fact that the small relative displacements were generally insufficient to activate the passive energy systems. This problem is solved with a displacement amplification system according to the present invention.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of this invention should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”
|
An apparatus and method of dissipating inter floor seismic energy within buildings and other large structures which are subject mechanical deformation in response to seismic activity, wind shear, vibration, and so forth. The present invention provides displacement amplification methods and apparatus which increase the dissipation of seismic energy that is coupled from the building under deformation to a seismic damper. By way of example, the displacement amplifier is exemplified in a number of embodiments that utilize mechanical lever arms, gear sets, and combination amplifier/dampers to amplify energy dissipation.
| 4
|
BACKGROUND OF THE INVENTION
This invention relates to a speed regulator for fuel injection pumps of internal combustion engines. The present invention is concerned, more particularly, with such a speed regulator which includes an intermediate lever pivotable about an axis defined by a shaft. Both the shaft and the intermediate lever are coupled with a flow quantity adjustment member of the injection pump and are acted on by a speed signalling device, with a speed dependent force, against the arbitrarily variable force of a main control spring and the force of starting spring.
An injection pump of the above-mentioned type is already known which includes a centrifugal force governor which acts against a main control spring of variable biasing, thereby adjusting the position of a regulating shaft. The displacement of the sleeve of the centrifugal force governor is thereby transmitted by a centrally located intermediate lever directly onto the regulating shaft and by a second lever which is rigidly connected to the intermediate lever onto a leaf spring which is held on an angled lever acted on by the main control spring and which is deformable on this angled lever as far as the position of an adjustable stop. The leaf spring thus cooperates with the main control spring against the positioning movement of the centrifugal force governor. As the positioning forces increase, the leaf spring is first deformed as far as its stop and thereafter the main control spring is deformed. Thus, the leaf spring which, during normal operation, constantly rests against its stop, enables a starting excess to be obtained which cuts off automatically after starting.
A fuel injection pump is also known which includes a centrifugal force governor which acts, with speed dependent force, on an intermediate lever coupled to the flow quantity adjustment member of the injection pump against the force of a main control spring and starting spring. In this case the main control spring is in the form of a tension spring and is secured to a drag lever which is pivotable about the same axis as the intermediate lever. The starting spring is also in the form of a tension spring and is secured to the outer end of the intermediate lever. Both springs have an adjustable lever as their second adjustment point and they can be adjusted in common via this adjustable lever. As the speed increases, the intermediate lever is moved by the centrifugal force governor against the force of the starting spring and then comes to rest against the drag lever which it lifts from a full load stop as the speed increases against the force of a main control spring, as a control measure.
The two above-mentioned types of speed regulators for injection pumps have the distinct disadvantage of not enabling the full load injection quantity to be adjusted according to the speed.
SUMMARY OF THE INVENTION
The principal object of the present invention is to provide a speed regulator of the type described initially which retains minimum dimensions, particularly in the operating direction of the speed signalling device, with which a starting excess is obtained which is automatically reduced to the normal injection quantity as the speed increases and which is combined with an adjustment device which, as the speed continues to increase after the starting quantity has been reduced, produces an increase in the quantity of fuel injected in the form of a negative adjustment.
The foregoing object, as well as others which are to become apparent from the text below, is achieved in that the speed signalling device acts on a one-armed adjustment lever which is pivotably attached to the intermediate lever and acted on by the starting spring. The adjustment lever includes at its end an adjustment capsule which cooperates with a one-armed drag lever pivotable about the axis of the intermediate lever as far as an adjustable stop, the main control spring engaging on this drag lever. The adjustment lever also includes a stop projecting the direction of the drag lever between the engagement point of the speed signalling member and the attachment point on the intermediate lever. Another feature according to the invention consists in that the starting spring is in the form of a pressure spring and is disposed in series with the main control spring between the adjustment lever and the drag lever. When a double lever arrangement is provided for producing a starting excess the possibility of the intermediate lever being displaced independently of the drag lever acted on by the main control spring is advantageously exploited. By coordinating the attachment of the adjustment lever, its stop, the adjustment capsule and the engagement point of the speed signalling member, the movement of the intermediate lever in the direction of the drag lever caused by the speed signalling member is reversed by the compression of the adjustment capsule, from the time when the stop of the adjustment lever rests against the drag lever and thus the initial adjustment in terms of reducing the injection quantity is reversed after cutting off the starting excess. The length of the travel stroke of the adjustment capsule determines the extent of the possible adjustment With this arrangement, even if an adjustment lever is not provided, the necessary space for housing a starting spring between the intermediate lever and the drag lever is used and thus there is no need to increase the working capacity of the centrifugal force governor in respect thereof.
Another feature of the invention consists in that the intermediate lever, the drag lever and the adjustment lever are pivotable in the same plane and in that the adjustment lever is disposed between the drag lever and the intermediate lever and the intermediate lever has, in its central region, a recess through which passes an adjustment sleeve of the speed signalling device and the adjustment capsule. As a result of this arrangement, the space requirement in the working direction of the speed signalling device remains minimal and furthermore, the three levers can be disposed very close to each other as a result of the fact that the adjustment lever can partially pass through the recess in the intermediate lever. Thus, a compact arrangement having a high operating capacity is obtained.
BRIEF DESCRIPTION OF THE DRAWING
The sole figure of drawing is a cross-sectional, front elevational view of a speed regulator according to the present invention in combination with a fuel injection pump and fuel supply, the latter being shown schematically.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawing, an illustrative embodiment of a speed regulator according to the present invention includes a housing 1 of a fuel injection pump having a pump piston 3 which is displaceable in a simultaneous reciprocating and rotating movement by conventional instrumentalities (not shown) against the force of a conventional restoring spring (not shown). The working chamber 4 of the pump is supplied with fuel from a suction chamber 7 via a longitudinal groove 5 disposed in the surface of the piston 3 and via a channel 6 disposed in the housing 1 for as long as the piston 3 makes its intake stroke and takes its lower dead center position. As soon as the channel 6 has been closed after commencing the compression stroke and after a corresponding rotation of the piston, the fuel in the pump working chamber 4 is conveyed along a longitudinal channel 8 provided in the piston 3. From the longitudinal channel 8 the fuel is supplied via a branching radial bore 9 and a longitudinal distribution groove 10 disposed in the surface of the piston to one of the pressure lines 11. The pressure lines 11 are distributed at the perimeter of the cylinder bore 2 in correspondence with the number of cylinders (not shown) to be supplied. Each of the pressure lines 11 runs via a respective check valve 12 opening in the flow direction to the injection valves (not represented) of the individual cylinders of the internal combustion engine supplied by this injection pump.
The suction chamber 7 is supplied with fuel via a pump 13 from a fuel storage container 14. The pressure in the section chamber 7 is controlled, in a manner known per se, by a pressure control valve 15 disposed in parallel to the fuel pump 13.
Cylindrical slide 16 surrounds and is displaceable on the piston 3. This slide 16 regulates a radial bore 17 which communicates with the longitudinal channel 8 during the compression stroke of the piston 3 and thus provides direct communication between the working chamber 4 and the pump suction chamber 7 and thus, from this regulation point on, the remaining fuel delivered by the piston 3 is not supplied to the pressure lines 11, rather, the fuel flows into the suction chamber 7. Thus, depending on the position of the slide 16, connection is made sooner or later to the pump suction chamber 7 and the fuel injection is interrupted. The farther the slide 16 is pushed in the direction of the upper dead center point of the piston 3, the greater the quantity of fuel which is supplied by the piston 3 to the pressure lines 11.
The slide 16 is displaced by an intermediate lever 18 which is pivotable about an axis defined by a shaft 19. The shaft 19 is disposed in the pump housing 1 and can be rotated, by way of an eccentric element, to adjust the pump. A head 20 which engages in a recess 21 in the slide 16 is attached to a lever arm of the intermediate lever 18 to move the slide 16. A bearing 23 with an axis defining shaft 24 is provided at the outer end of the other lever arm of the intermediate lever 18. An adjustment lever 25 which is in the same plane as the intermediate lever 18 is pivotable about the axis defined by the shaft 24. The adjustment lever 25 extends in the direction of the axis defined by the shaft 19 and thus shares a hinged overlapping relationship with the intermediate lever 18. Viewed from the pump piston 3 drive side, the adjustment lever 25 is disposed on the other side of the intermediate lever 25.
A one-armed drag lever 27 is also pivotable about the axis defined by the shaft 19 independently of the intermediate lever 18. The main position of the drag lever 27 is in overlapping relationship with the intermediate lever 18 such that the adjustment lever 25 is disposed between the intermediate lever 18 and the drag lever 27. The drag lever 27 includes a shoulder and near its free end is a bore 28 through which a bolt 29 is guided. Viewed from the pump piston 3 drive side, this bolt 29 includes a head 30 on the other side of the drag lever 27. An idling spring 31 is disposed between the head 30 and the drag lever 27. A main control spring 32 in the form of a tension spring is connected to the other end of the bolt 29. The main control spriing 32 is secured to an arbitrarily adjustable lever 33 at its other end. The lever 33 is used to adjust the biasing of the main control spring 32 and also to adjust the load. As a result of the biasing of the main control spring 32 the drag lever 27 is pressed by its free end against an adjustable stop 35.
Adjacent to its axis defined by shaft 24, the adjustment lever 25 includes a stop 37 projecting in the direction of the drag lever 27. In the direction of the axis defined by the shaft 19, the adjustment lever 25 includes a semi-spherical lug 38 projecting in the direction of the intermediate lever 18 and on which the adjustment sleeve 39 of a centrifugal governor 40 engages. The intermediate lever 18 includes a recess 41 in its central region through which the sleeve 39 of the centrifugal force governor 40 can pass. The centrifugal force governor 40 is driven by conventional gearing (not shown) according to the speed of the pump piston 3 and is provided with a carrier 42 having compartments in which centrifugal weights 43 are disposed. The centrifugal weights engage with nose-shaped parts 44 on the lower edge of the adjustment sleeve 39 which is displaced in the longitudinal axial direction on a shaft 45 of the centrifugal governor 40. When the sleeve 39 rests aagainst the semi-spherical element 38, it is possible to transmit the adjustment movement of the centrifugal governor 40, with the least amount of friction and momentum.
A starting spring in the form of a coiled compression spring 46, is disposed on the other side of the adjustment lever 25 opposite to the engagement point of the centrifugal force governor 40 between the adjustment lever 25 and the drag lever 27. The compression spring 46 tends to press the adjustment lever 25 onto the sleeve 39 of the centrifugal force governor 40 and is supported on the drag lever 27 which is held against the stop 35 by the main control spring 32.
Compression spring 46 which acts as a starting spring and accordingly must be yielding is guided by a pin 47 rigidly connected to the drag lever 27. At the end of the adjustment lever 25, an adjustment capsule 49 is disposed adjacent to the contact point of the compression spring 46 in the direction of the axis defined by the shaft 19. This adjustment capsule 49 includes, in a manner known per se, a supporting carrier member 50 which is vertically and rigidly set in the adjustment lever 25, and of a bolt 51 which is displaceable in this carrier member 50 against a compression spring 52. The capsule 49 may also be adjustably connected to the adjustment lever 25, for example, by way of a screw thread. The bolt 51, which is displaceable in the direction of the drag lever 27, includes at its end adjacent to the drag lever 27 a head 53 which, in the normal position, projects beyond the edge of the capsule 49 and is guided in the capsule 49. The other end of the bolt 51 penetrates the bottom of the capsule 49 in a bore and, on the other side thereof, has a stop 57 consisting of a retaining ring and one or more disks 56. The compression spring 52, which is supported internally on the bottom of the capsule 50 and on the head 53 of the bolt 51, tends to hold the bolt 51 against its stop 57. The adjustment capsule 49 is located in the region of the recess 41 disposed opposite the intermediate lever 18, and, for this reason, it can pass through this recess 41 together with the adjustment lever 25 under the action of the compression spring 46. As a result of this arrangement, the three levers 18, 25 and 27 are closely disposed one above the other and thus the overall arrangement is extremely compact in spite of its adjustment possibilities and it only requires a small amount of space. By selecting the compression spring 52, the stroke of the bolt 51 and the strength of the disk or disks 56 in front of the stop 57, the adjustment features can be adjusted according to the actual requirements.
The above-described arrangement operates as described in some detail below.
In the starting position, which is indicated, the drag lever 27 abuts against its full load adjustable stop 35 under the action of the main control spring 32. The adjustment lever 25 is simultaneously pressed onto the front side of the sleeve 39 of the centrifugal force governor 40 under the action of the compression spring 46, which is a starting spring. As a result, the intermediate lever 18 is removed from the drag lever 27 which causes a displacement of the slide 16 as a result of this pivoting movement into the upper starting position. The centrifugal weights 43 of the centrifugal force governor 40 are still in the starting position at this point. When the internal combustion engine starts up the injection pump is simultaneously driven which causes the centrifugal force governor 40 to rotate with increasing speed. As a result of the centrifugal forces which are produced, the centrifugal weights 43 are deflected outwardly and raise the sleeve 39 of the centrifugal force governor 40 with the nose-shaped parts 44 of the weights 43. This movement causes the simultaneous compression of the compression spring 46 and a displacement of the adjustment lever 25 in the direction of the drag lever 27. After the adjustment lever 25 with its stop 37, and with the head 53 of the adjustment capsule 49 has reached the drag lever 27, the cylindrical slide 16 is pushed downwardly by the intermediate lever 18 which is pivoted by the adjustment lever 25. At this point, the starting excess is cut off. As the speed of the engine increases, the drag lever 27 is not deflected against the force of the main control spring 32, but the compression spring 52 is compressed in the adjustment capsule 49. As a result, the adjustment lever 25 is pivoted about its stop 37 which is in contact with the drag lever 27 until the head 53 of the adjustment capsule 49 is completely inserted in the adjustment capsule 49 and the adjustment capsule 49 is firmly lodged on the drag lever 27. As a result of this pivoting movement, the intermediate lever 18 is moved in the opposite direction to that of the original operation for cutting off the starting excess and the cylindrical slide 16 is again moved to a certain extent in an upward direction and increases the quantity of fuel being injected. The drag lever 27 is only moved from its stop 35 against the force of the main control spring 32 through the action of increasing speed forces when the speed increases or when the final speed is reached. The other levers 18 and 25 are also moved simultaneously with the pivoting movement of the drag lever 27 and thus the sliding cylindrical slide 16 is again pushed downwardly and reduces the quantity of fuel being injected. The idling spring 31 will then commence to operate in a manner known per se according to the load on the internal combustion engine.
A compression spring biased between the adjustment lever 25 and a fixed point in the housing 1 can obviously be used in place of the compressing spring 46 which is disposed between the drag lever 27 and the adjustment lever 25. The attachment point of this spring on the housing 1 may also be made adjustable in a manner known per se.
The foregoing description and accompanying drawing illustration relate to an illustrative embodiment of a speed regulator and are set out by way of example, not by way of limitation. It is to be appreciated that numerous other embodiments and variants are possible within the spirit and scope of the invention, the scope being defined as the appended claims.
|
A speed regulating device for fuel injection pumps of internal combustion engines includes an intermediate lever pivotable about an axis defined by a shaft which is coupled to a fuel quantity adjustment member of the injection pump. The shaft is acted on by a speed signalling device with speed dependent force against the arbitrarily variable force of a main control spring and the force of a starting spring. A speed signalling device acts on a one-armed adjustment lever, which is pivotably attached to the intermediate lever. The adjustment lever is acted on by the starting spring, and includes an adjustment capsule at its end. This adjustment capsule cooperates with a one-armed drag lever, pivotable, about the same axis defined by the shaft about which the intermediate lever pivots, as far as an adjustable stop. The drag lever is acted on by the main control spring. The adjustment lever includes a stop projecting in the direction of the drag lever between the point of contact of the speed signalling device and the attachment point on the intermediate lever.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of International application No. PCT/CN2015/074434, filed Mar. 18, 2015 which claims the benefits of priority of CN application No. 201420316795.2 filed on Jun. 13, 2014 and No. 201520076344.0 filed on Feb. 3, 2015, the content of which are incorporated herein by reference.
BACKGROUND
[0002] Technical Field
[0003] The present disclosure relates to a textile. More particularly, the present disclosure relates to a textile with elasticity that has superior elastic and ventilation property.
[0004] Description of Related Art
[0005] Since the textile machine was invented, textile industry has made remarkable progress. In addition to the development of chemical technology that makes the materials used in textile industry more selective, there is a significant aspect that the different textile structures create special effects for products. In these reasons, the main topic of textile products is not how to keep warm but superior elastic, ventilation property and comfort.
[0006] Conventional textile products are usually blended with elastic cottons, such as Lycra and Rayon to make products flexible. However, these materials must be designed as multi-slit to absorb moisture and sweat because they are polymer which is not applicable for the above function. The defect makes these materials unsuitable for clothes in sultry weather.
[0007] Some textile products could make up the disadvantage, for example, Non-woven fabric possesses better comfort, elastic and ventilation property, but it is not tough as common woven fabric so would be destroyed easily cause in snag or tear. Besides, Non-woven fabric is restricted in washing and maintenance so is unsuitable for products that are precious or in need of durability.
SUMMARY
[0008] In view of this, the present disclosure provides a textile with elasticity using elastic fabrics and special weave structure to be elastic, good in ventilation property and comfort and durable in use.
[0009] According to an embodiment of the present disclosure, a textile with elasticity includes a basic cloth and a warp yarn layer. The basic cloth includes a plurality of yarns fixed and parallel to each other. The warp yarn layer includes a plurality of elastic warp yarns and a plurality of twines, wherein the elastic warp yarns are parallel to each other and located on the yarns. The elastic warp yarns and the yarns are crisscross. Each of the twines wraps along each of the elastic warp yarns and fixes the elastic warp yarns and the yarns.
[0010] In one example, a diameter of each elastic warp yarn can be 0.05 cm to 0.1 cm, and a distance between any two of the elastic warp yarns 310 which are adjacent to each other can be 0.2 cm to 0.5 cm.
[0011] According to another embodiment of the present disclosure, a textile with elasticity applied to a shoe includes two elastic cloths, one of the elastic cloths is disposed on a toe part of a vamp of the shoe, and the other elastic cloth is disposed on an ankle part of the vamp of the shoe. Each of the elastic cloths includes a basic cloth and a plurality of elastic warp yarns. Each of the basic cloths includes a plurality of yarns interwoven with each other. The elastic warp yarns are parallel to each other and picoted on the basic cloth.
[0012] In one example, each of the yarns can be interwoven with the elastic warp yarns longitudinally or transversely. A diameter of each of the elastic warp yarns can be 0.05 cm to 0.1 cm, and a distance between any two of the elastic warp yarns which are adjacent to each other can be 0.2 cm to 0.5 cm. The textile with elasticity can further include a supported fabric which can be sawed on the elastic cloth for connecting and supporting each of the elastic cloths. The yarns of the elastic cloth can be elastic.
[0013] According to still another embodiment of the present disclosure, a textile with elasticity applied to a protective equipment includes two elastic cloths. Each of the elastic cloths includes a basic cloth and a plurality of elastic warp yarns. Each of the basic cloths includes a plurality of yarns interwoven with each other. The elastic warp yarns are parallel to each other and picoted on the basic cloth.
[0014] In one example, each of the yarns can be interwoven with the elastic warp yarns longitudinally or transversely. A diameter of each of the elastic warp yarns can be 0.05 cm to 0.1 cm, and a distance between any two of the elastic warp yarns which are adjacent to each other can be 0.2 cm to 0.5 cm. The textile with elasticity can further include a supported fabric which can be sawed on the elastic cloth for connecting and supporting each of the elastic cloths. The yarns of the elastic cloth can be elastic.
[0015] Therefore, the textile with elasticity of the present disclosure can improve elasticity of shoes or protective equipments by using the elastic warp yarns. Moreover, the crisscross structure formed of elastic warp yarns and yarns can also improve the ventilation property of the textile with elasticity conspicuously since the ventilation area of the textile with elasticity is increased. The advantage makes wearer comfort when wearing the shoes or protective equipments.
[0016] According to yet another embodiment of the present disclosure, a textile with elasticity includes a first weft unit, a second weft unit, a third weft unit, a fourth weft unit and a warp yarn layer. The first weft unit includes a plurality of first elastic weft yarns that are adjacent and parallel to each other. The second weft unit includes a plurality of second elastic weft yarns that are adjacent and parallel to each other. The third weft unit includes a plurality of third elastic weft yarns that are adjacent and parallel to each other. The fourth weft unit includes a plurality of fourth elastic weft yarns that are adjacent and parallel to each other. Each of the first elastic weft yarns, each of the second elastic weft yarns, each of the third elastic weft yarns and each of the four elastic weft yarns are interwoven by a main yarn and at least one covering yarn respectively, wherein the main yarn can be elastic fabric and the covering yarn can be cottony. Each of the main yarns is helically wrapped by the covering yarns so the first elastic weft yarns, the second elastic weft yarns, the third elastic weft yarns and the four elastic weft yarns can have better tactile feelings. The first weft unit and the second weft unit are disposed on the same plane and separated by a distance. Each of the first elastic weft yarns is adjacent to each other and woven to and fro as continuous S-shaped by a fabric, and so is each of the second elastic weft yarns. Moreover, the first weft unit and the second elastic weft unit can be distributed alternately. The third weft unit and the fourth weft unit are disposed on the other same plane and separated in parallel with the first weft unit and the second weft unit by a gap. The third weft unit and the fourth weft unit are corresponded to the first weft unit and the second weft unit respectively. The third weft unit and the fourth weft unit are separated by the distance, too. The third elastic weft yarns and the fourth elastic weft yarns are woven to and fro as continuous S-shaped, thus one of the first elastic weft yarns is corresponded to one of the third elastic weft yarns, and one of the second elastic weft yarns is corresponded to one of the fourth elastic weft yarns. It's noted that the third elastic weft yarns and the fourth elastic weft yarns are woven by the same fabric. The warp yarn layer includes a plurality of elastic warp yarns that are longitudinally disposed within the gap. Each of the elastic warp yarns includes a twine tying one of the elastic warp yarns as a center for binding the first weft unit, the second weft unit, the third weft unit and the fourth weft unit to keep the distance. When each of the twine ties the mentioned units, a plurality of slip knots are created to keep the distance, so that the distance won't be disappear during weaving process. The elastic warp yarns can be elastic fabrics.
[0017] With the disclosure of the embodiment, the textile with elasticity can have better ventilation property because of the distance between the first weft unit, the second weft unit, the third weft unit and the fourth weft unit creates many and wide ventilation areas. With the weft units and warp yarn layer that are elastic and interwoven with each other, the textile with elasticity could make better flexibility in multi-direction so suitable to apply to sportswear and sports shoes which are demanded for high durability, high flexibility and better performance in heat dissipation. Moreover, the covering yarns cover on the each of the weft units are absorbent, the feature makes the textile with elasticity comfortable for wearers.
[0018] According to further another embodiment of the present disclosure, a textile with elasticity includes a first weft unit, a second weft unit, a plurality of elastic warp yarns and a plurality of twines. The first weft unit includes a plurality of first elastic weft yarns that are adjacent and parallel to each other. The second weft unit includes a plurality of second elastic weft yarns that are adjacent and parallel to each other. Each of the first elastic weft yarns and each of the second elastic weft yarns are interwoven by a main yarn and at least one covering yarn respectively, wherein the main yarn can be elastic fabric. The first weft unit and the second weft unit are disposed on the same plane and separated by a distance. Each of the first elastic weft yarns is adjacent to each other and woven to and fro as continuous S-shaped by a fabric respectively, and so is each of the second elastic weft yarns. Moreover, the first weft yarns and the second elastic weft yarns can be distributed alternately. The elastic warp yarns are longitudinally disposed on one side of the first elastic weft yarns and the second elastic weft yarns. Each of the twines ties the corresponded elastic warp yarn as a center for binding the first weft unit and the second weft unit to keep the distance. When each of the twine ties the mentioned units, a plurality of slip knots are created to keep the distance, so that the distance won't be disappear during weaving process. The elastic warp yarns can be elastic fabrics. Because the twines ties the weft yarns disposed on the two side of the textile with elasticity at a time, the third weft unit and the fourth weft unit can be removed. That is, the textile with elasticity can just include the first weft unit, the second weft unit and the warp yarn layer, so the cost for material of the textile with elasticity can be reduce.
[0019] Furthermore, the textile with elasticity with single layer is more appropriate for weaving on other products.
[0020] According to still further another embodiment of the present disclosure, a textile with elasticity includes a first weft unit, a second weft unit, a third weft unit and a warp yarn layer. The first weft unit includes a plurality of first elastic weft yarns that are adjacent and parallel to each other. The second weft unit includes a plurality of second elastic weft yarns that are adjacent and parallel to each other, and the first weft unit and the second weft unit are disposed on the same plane and separated by a distance. The third weft unit includes a plurality of third elastic weft yarns that are adjacent and parallel to each other. Each of the first elastic weft yarns, each of the second elastic weft yarns and each of the third elastic weft yarns are interwoven by a main yarn and at least one covering yarn respectively, wherein the main yarn can be elastic fabric and the covering yarn can be cottony. Each of the main yarns is helically wrapped by the covering yarns so the first elastic weft yarns, the second elastic weft yarns, the third elastic weft yarns and the four elastic weft yarns can have better tactile feelings. The first elastic weft yarns and the second elastic weft yarns are woven to and fro as continuous S-shaped by a fabric respectively. The third elastic weft yarns are woven to and fro as continuous S-shaped. The third weft unit is disposed on the other plane and parallel to the first weft unit and the second weft unit as a gap. The warp yarn layer includes a plurality of elastic warp yarns that are longitudinally disposed within the gap. Each of the elastic warp yarns includes a twine tying one of the elastic warp yarns as a center for binding the first weft unit and the second weft unit to keep the distance. When each of the twine ties the mentioned units, a plurality of slip knots are created to keep the distance, so that the distance won't be disappear during weaving process. The twines tie the third weft unit in the opposite side of the first weft unit and the second weft unit. Each of the twines ties at least one of the third elastic weft yarns within the distance. The elastic warp yarns can be elastic fabrics.
[0021] In the mentioned embodiment, the third weft unit can be dislocated with the first weft unit and the second weft unit, namely the third weft unit can be wrapped in the distance between the first weft unit and the second weft unit. By changing a number of the third elastic weft yarns within the distance, the ventilation property or the transparency of the textile with elasticity can be adjusted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 shows an end schematic view of a textile with elasticity according to one embodiment of the present disclosure;
[0023] FIG. 2 shows a plane schematic view of the textile with elasticity of FIG. 1 ;
[0024] FIG. 3 shows a section of three dimensional view of the textile with elasticity of FIG. 1 ;
[0025] FIG. 4A shows a weaving schematic view of the textile with elasticity of FIG. 1 ;
[0026] FIG. 4B shows a weaving schematic view of the textile with elasticity of FIG. 1 ;
[0027] FIG. 5A shows an application schematic view of a textile with elasticity according to another embodiment of the present disclosure;
[0028] FIG. 5B shows an application schematic view of a textile with elasticity according to still another embodiment of the present disclosure;
[0029] FIG. 6 shows a three dimensional view of a textile with elasticity according to yet another embodiment of the present disclosure;
[0030] FIG. 7 shows a front side view of the textile with elasticity of FIG. 6 ;
[0031] FIG. 8 shows a rear side view of the textile with elasticity of FIG. 6 ;
[0032] FIG. 9 shows a construction schematic view of the first elastic weft yarn of the textile with elasticity of FIG. 6 ;
[0033] FIG. 10 shows a side view of the textile with elasticity of FIG. 6 ;
[0034] FIG. 11A shows a front side view of an enlarged portion 3 of the elastic warp yarn of the textile with elasticity of FIG. 6 ;
[0035] FIG. 11B shows a rear side view of the enlarged portion 3 of the elastic warp yarn of the textile with elasticity of FIG. 6 ;
[0036] FIG. 12 shows a three dimensional view of a textile with elasticity according to still another embodiment of the present disclosure; and
[0037] FIG. 13 is a schematic view of a distance being complemented of the textile with elasticity of FIG. 12 .
DETAILED DESCRIPTION
[0038] FIG. 1 shows an end schematic view of a textile with elasticity 100 according to one embodiment of the present disclosure. FIG. 2 shows a plane schematic view of the textile with elasticity 100 of FIG. 1 . FIG. 3 shows a section of three dimensional view of the textile with elasticity 100 of FIG. 1 .
[0039] In FIG. 1 , FIG. 2 and FIG. 3 , the textile with elasticity 100 includes a basic cloth 200 and a warp yarn layer 300 .
[0040] In said figures, the basic cloth 200 includes a plurality of yarns 201 which can be elastic. The yarns 201 are divided into two groups with different orientations, and the yarns 201 in each group are fixed and parallel to each other. The warp yarn layer 300 includes a plurality of elastic warp yarns 310 and a plurality of twines 320 . The elastic warp yarns 310 are parallel to each other and located on the basic cloth 200 , and each of the elastic warp yarns 310 and each of the yarns 201 of the basic cloth 200 are crisscross. Each of the twines 320 of the warp yarn layer 300 wraps along each of the elastic warp yarns 310 and fixes one of the elastic warp yarns 310 and the yarns 201 of the basic cloth 200 .
[0041] To enhance the flexibility of the textile with elasticity 100 , the material for the twines 320 can be made of elastic material as the yarns 201 . To make the textile with elasticity 100 aesthetic and tough, a diameter of each elastic warp yarn 310 can be 0.05 cm to 0.1 cm, and a distance between any two of the elastic warp yarns 310 which are adjacent to each other can be 0.2 cm to 0.5 cm.
[0042] FIG. 4A and FIG. 4B show two weaving schematic views of the textile with elasticity 100 of FIG. 1 . In FIG. 4A , each of yarns 201 can be weaved as 8-shaped, but the weaving distance would not be restricted herein. In FIG. 4B , the distributions of the yarns 201 and the elastic warp yarns 310 are shown, but the weaving way would not be restricted herein. The yarns 201 can distributed more densely than the elastic warp yarn 310 , so that the elastic warp yarn 310 can protrude from the textile with elasticity 100 to make better looks.
[0043] FIG. 5A shows an application schematic view of a textile with elasticity 100 according to another embodiment of the present disclosure. In FIG. 5A , a textile with elasticity 100 is applied to a vamp of a shoe, the textile with elasticity 100 includes two elastic cloths 400 , and each of the elastic cloths 400 includes a basic cloth 200 and a plurality of elastic warp yarns 310 . The two elastic cloths 400 are disposed on a toe part and an ankle part of the vamp of the shoe corresponding to the toe and the ankle of the foot of human body, respectively.
[0044] Each of the basic cloths 200 includes a plurality of yarns 201 interwoven with each other. The elastic warp yarns 310 are parallel to each other and picoted on the basic cloth 200 . The mentioned “picoted” means the elastic warp yarns 310 are disposed on a surface of the basic cloth 200 . In FIG. 4A and FIG. 4B , the elastic warp yarns 310 can be fixed and protrude from the basic cloths 200 . (To show the weave structures of the elastic warp yarns 310 and the basic cloth 200 dearly, the basic cloths 200 at the under layers are hidden in FIG. 4A and FIG. 4B .) The weave structures in FIG. 4A and FIG. 4B are for example, so the embodiment about “picoted” can be other possible weave structures and not restricted herein.
[0045] The textile with elasticity 100 can further include two supported fabric 500 which can be sawed on the elastic cloths 400 for connecting and supporting each of the elastic cloths 400 . Each of the supported fabrics 500 can be disposed on areas of toe, heel or shoelace of the vamp of the shoe corresponding to human body.
[0046] Each of the yarns 201 can be elastic and can be interwoven with the elastic warp yarns 310 longitudinally or transversely. Moreover, a diameter of each of the elastic warp yarns 310 can be 0.05 cm to 0.1 cm, and a distance between any two of the elastic warp yarns 310 which are adjacent to each other can be 0.2 cm to 0.5 cm.
[0047] FIG. 5B shows an application schematic view of a textile with elasticity 100 according to still another embodiment of the present disclosure. In FIG. 5B , a textile with elasticity 100 is applied to a protective equipment for increasing elasticity and beautifying the looks for weaving products.
[0048] The textile with elasticity 100 includes two elastic cloths 400 , and each of the elastic cloths 400 further includes a basic cloth 200 and a plurality of elastic warp yarns 310 . Each of the basic cloths 200 includes a plurality of yarns 201 interwoven with each other. The elastic warp yarns 310 are parallel to each other and picoted on the basic cloth 200 . The definition of “picoted” is the same as the aforementioned statement, and will not be stated again herein.
[0049] The textile with elasticity 100 can further include a supported fabric 500 which can be sawed on the elastic cloth 400 for connecting and supporting each of the elastic cloths 400 .
[0050] Each of the yarns 201 can be elastic and can be interwoven with the elastic warp yarns 310 longitudinally or transversely. Moreover, a diameter of each of the elastic warp yarns 310 can be 0.05 cm to 0.1 cm, and a distance between any two of the elastic warp yarns 310 which are adjacent to each other can be 0.2 cm to 0.5 cm.
[0051] FIG. 6 shows a three dimensional view of a textile with elasticity 100 according to yet another embodiment of the present disclosure. In FIG. 6 , a textile with elasticity 100 includes a first weft unit 210 , a second weft unit 220 , a third weft unit 230 , a fourth weft unit 240 and a warp yarn layer 300 .
[0052] The first weft unit 210 and the second weft unit 220 are separated by a distance D, and the third weft unit 230 and the fourth weft unit 240 are separated by the distance D, too. Moreover, the first weft unit 210 and the second weft unit 220 are at the front side of the textile with elasticity 100 , and the third weft unit 230 and the fourth weft unit 240 are at the rear side of the textile with elasticity 100 . The warp yarn layer 300 is disposed between the front side and the rear side of the textile with elasticity 100 .
[0053] FIG. 7 shows a front side view of the textile with elasticity 100 of FIG. 6 . In FIG. 7 , the first weft unit 210 includes a plurality of first elastic weft yarns 211 , and the second weft unit 220 includes a plurality of second elastic weft yarns 221 . As shown in FIG. 7 , the first weft unit 210 including the first elastic weft yarns 211 and the second weft unit 220 including the second elastic weft yarns 221 are distributed alternately at the front side of the textile with elasticity 100 .
[0054] Please see the top of FIG. 7 , first elastic weft yarns 211 and the second elastic weft yarns 221 are woven to and fro as continuous S-shaped by a fabric respectively. For example shown in FIG. 7 , four of the first elastic weft yarns 211 and four of the second elastic weft yarns 221 are formed into a sub unit respectively, but the present disclosure will not be limited to the number of the first elastic weft yarns 211 or the second elastic weft yarns 221 herein. The first elastic weft yarn 211 and the second elastic weft yarn 221 adjacent to each other are separated by the distance D.
[0055] It's noted that not only the first elastic weft yarns 211 or the second elastic weft yarns 221 included in each sub unit can be connected up by single fabric, but each sub unit belong to the first weft unit 210 or the second weft unit 220 can be connected up by the same fabric.
[0056] The warp yarn layer 300 is disposed behind the first weft unit 210 and second weft unit 220 . The warp yarn layer 300 includes a plurality of elastic warp yarns 310 and a plurality of twines 320 . The elastic warp yarns 310 are crossed but not woven with the first elastic weft yarns 211 and the second elastic weft yarns 221 . Each of the elastic warp yarns 310 can be elastic fabric. Each of the elastic warp yarns 310 corresponds to a twine 320 tying one of the elastic warp yarns 310 as a center for binding the first weft unit 210 , the second weft unit 220 , the third weft unit 230 and the fourth weft unit 240 , so that the elastic warp yarn 310 can be fixed by the first elastic weft yarns 211 , the second elastic weft yarns 221 , the third elastic weft yarns 231 and the fourth elastic weft yarns 241 .
[0057] FIG. 8 shows a rear side view of the textile with elasticity 100 of FIG. 6 . As shown in FIG. 8 , the third weft unit 230 and the fourth weft unit 240 are at the rear side and corresponded to the first weft unit 210 and the second weft unit 220 respectively, and the third weft unit 230 and the fourth weft unit 240 are separated by the distance D, too. The difference between the front side and rear side of the textile with elasticity 100 is that the third elastic weft yarns 231 and the fourth elastic weft yarns 241 are woven continuously into continuous S-shaped by single fabric, the fabric connects up the third weft unit 230 and the fourth weft unit 240 at one edge of the textile with elasticity 100 .
[0058] The third weft unit 230 and the fourth weft unit 240 also can be woven as same as the front side of the textile with elasticity 100 . That is, the third weft unit 230 and the fourth weft unit 240 can be connected up at another edge of the textile with elasticity 100 . Therefore, the embodiment shown in FIG. 6 , FIG. 7 and FIG. 8 would not be a limitation of the present disclosure.
[0059] FIG. 9 shows a construction schematic view of the first elastic weft yarn 211 of the textile with elasticity 100 of FIG. 6 . According to the embodiment of FIG. 9 , each elastic weft yarn is made of two kinds of yarn materials. As shown in FIG. 9 , each of the first elastic weft yarns 211 includes a main yarn 211 a and two covering yarn 211 b . The main yarn 211 a can be elastic fabric and helically wrapped by the covering yarns 211 b.
[0060] The material or number of the covering yarns 211 b can be adjusted as long as features of the textile with elasticity 100 won't be affected, such as cotton yarn etc. which is conventional material. Moreover, the second elastic weft yarn 221 , the third elastic weft yarn 231 and the fourth elastic weft yarn 241 are as same material as the first elastic weft yarn 211 , and will not further stated herein.
[0061] FIG. 10 shows a side view of the textile with elasticity 100 of FIG. 6 . As shown in FIG. 10 , the first elastic weft yarn 211 and third elastic weft yarn 231 are disposed at two sides of the textile with elasticity 100 and separated by a gap G. Each of the elastic warp yarns 310 is longitudinally disposed within the gap G, and the twines 320 tie the elastic warp yarns 310 as a center for binding the first weft unit 210 , the second weft unit 220 , the third weft unit 230 and the fourth weft unit 240 then fix the elastic warp yarns 310 with the mentioned weft units.
[0062] In detail, the twine 320 ties the first elastic weft yarn 211 and third elastic weft yarn 231 or the second elastic weft yarn 221 and fourth elastic weft yarn 241 together, so that each of the elastic warp yarns 310 can be drawn out longitudinally without affecting the stability of the textile with elasticity 100 .
[0063] The main differences between the yet another embodiment in FIG. 6 and the first three embodiments in FIG. 1 to FIG. 5B are that the density of the twines 320 in each of the first three embodiments is steady, so that the basic cloth 200 and a warp yarn layer 300 can be woven by the consistent density; however, the density of the twines 320 is further adjusted in the yet another embodiment, thus the function of the textile with elasticity 100 would be varied.
[0064] FIG. 11A shows a front side view of an enlarged portion 3 of the elastic warp yarn 310 of the textile with elasticity 100 of FIG. 6 . FIG. 11B shows a rear side view of the enlarged portion 3 of the elastic warp yarn 310 of the textile with elasticity 100 of FIG. 6 . Please refer to FIG. 11A and FIG. 11B , as mentioned in FIG. 10 , the twine 320 ties two elastic weft yarns that are disposed at two sides of the textile with elasticity 100 at once.
[0065] In FIG. 11A , each of the twines 320 shuttles backwards and forwards through the first elastic weft yarns 211 of the first weft unit 210 (and through the second elastic weft yarns 221 of the second weft unit 220 ) repeatedly, but all of the elastic weft yarns are never tied at the distance D of the textile with elasticity 100 . In FIG. 11B , the twine 320 twirls to form a slip knot at the rear side of the textile with elasticity 100 for receiving the next entrance from the front side of the textile with elasticity 100 by itself.
[0066] Since the twine 320 at the distance D never weave with nor towed by any elastic weft yarn, the length of the distance D can be kept or adjusted by changing a number of the slip knots.
[0067] According to the yet another embodiment shown in FIG. 6 to FIG. 11B , because the twine 320 fixes the elastic warp yarn 310 within the gap G by tying two elastic weft yarns that dispose at the front side and the rear side of the textile with elasticity 100 , the weft units at one side of the textile with elasticity 100 can be fully removed. For example, the third weft unit 230 and the fourth weft unit 240 can be removed, and the first weft unit 210 , the second weft unit 220 and the warp yarn layer 300 are remained. In this state, the distance D can still be kept by slip knots because the elastic warp yarns 310 tied by the twine 320 are not drawn out. The embodiment is suitable for products which are needed in higher ventilation property and elasticity but contacting with skin of human body.
[0068] FIG. 12 shows a three dimensional view of a textile with elasticity 100 according to still another embodiment of the present disclosure. FIG. 13 is a schematic view of a distance D being complemented of the textile with elasticity 100 of FIG. 12 . Please refer to FIG. 12 and FIG. 13 , because the distance D is kept with the twine 320 , each of the weft units is independent. Therefore, the third weft unit 230 and the fourth weft unit 240 can move in parallel at the rear side of the textile with elasticity 100 .
[0069] In the still another embodiment, the distance D is occupied partially by the third weft unit 230 or the fourth weft unit 240 , so the width of the distance D can be change by adjusting the position of the mentioned weft units disposed at both side of the textile with elasticity 100 . Therefore, the proportion of exposure of the distance D also can be adjusted.
[0070] In FIG. 13 , the distance D is occupied mostly by the third weft unit 230 or the fourth weft unit 240 . In views of the embodiments disclosed in FIG. 12 and FIG. 13 , the color or material of the first elastic weft yarns 211 , the second elastic weft yarns 221 , the third elastic weft yarns 231 and the fourth elastic weft yarns 241 can be different since the mentioned weft units are independent, this feature makes mechanical properties and appearance variable. That is, each of the distances D between any two elastic weft yarns can be different, so the density of weave structure of the textile with elasticity 100 is variable, too.
[0071] According to the foregoing embodiments, the advantages of the present disclosure are described as follows. 1. The textile with elasticity provides better ventilation property for textile products by using elastic material and special weave structure, the features solve the problem that textile products can't take care of elasticity and ventilation. 2. The materials of the textile with elasticity are inexpensive, this advantage makes the textile with elasticity reduce the cost. 3. The weave structure of the textile with elasticity is stable for the reason each of the elastic warp yarns is tied by the twine independently. Even if some of the elastic warp yarns are drawn out, the textile with elasticity can still maintain the structural integrity. 4. Because of the distances are kept by the slip knots, each of the distances can be adjusted respectively for different requirements when applying to textile products. Moreover, number of the elastic weft yarns of the weft units can be changed flexibly for adjusting the elasticity of the textile with elasticity.
[0072] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present disclosure without departing from the scope or spirit of the present disclosure. In view of the foregoing, it is intended that the present disclosure cover modifications and variations of this present disclosure provided they fall within the scope of the following claims.
|
The invention disclosed a textile with elasticity. The textile with elasticity includes a plurality of elastic weft units and a plurality of elastic warp yarns of a warp yarn layer. These weft units include a plurality of weft yarns. The warp yarn layer penetrates through gaps formed by the weft units. The warp yarns and the weft yarns all have elasticity. The warp yarn has a twines, wherein each of the twines ties the warp yarn for binding these warp yarns located at the gap. Therefore, the textile with elasticity has good stretching ability and air permeability, and provides comfortable wearing feel by means of yarns wrapped on the weft yarns.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a carrier for supporting thereon a user's body, and more particularly to a bed or operation table capable of changing the posture of the user's body lying thereon.
2. Prior Art
A variety of beds, operating tables or other carriers for supporting patients thereon have been proposed. However, the known beds or operating tables have relatively complicated structures with restricted functions. A carrier of simple construction having a mechanism for changing the posture of the user's body has not yet been known.
OBJECTS AND SUMMARY OF THE INVENTION
A primary object of this invention is to provide a carrier for supporting thereon a user's body for changing the posture of the user's body into a desired condition where the user is lying on his side or in a supine or prone position.
A more specific object of this invention is to provide such a carrier operable to change the posture of the user, as desired, to prevent formation of bed sores and to promote metabolism of the patient without the need of lifting the patient's body into one's arms.
A further object of this invention is to provide such a carrier operable to change the posture of the user and/or to move the whole body of the user, as desired, to facilitate surgical operations, medical treatments, cleaning of the patient's body, exchange of clothes or sheets, and the bed making operation.
A still further object of this invention is to provide such a carrier provided with means for moving the user therefrom for bathing or other purposes.
The above and other objects of this invention will become apparent from the following detailed description.
The carrier for supporting a user's body and for changing the posture of the user, according to the present invention, comprises a first support means for carrying thereon the user's body substantially in a horizontal rest posture in the normal position; at least one second support means swingably mounted to either side of the first support means for supporting the user's body in such condition that the user is lying on his side and to receive the user's body from the first support means for supporting the user's body substantially in a horizontal rest posture in which the user is lying in a topsy-turvy posture; and drive means for pivoting the first and second support means to change the posture of the user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of a bed embodying the present invention, wherein certain parts are shown disassembled for simplification of illustration;
FIG. 2 is a fragmentary view showing the side elevation of the reclining means incorporated in the bed of FIG. 1;
FIGS. 3 to 6 are schematic illustrations showing the position change operations of the bed of FIG. 1;
FIG. 7 is a partial perspective view of an operating table embodying the present invention;
FIG. 8 is a partial perspective view of another type of bed embodying the present invention, wherein certain parts are shown disassembled for simplification of illustration;
FIGS. 9 to 12 are schematic illustrations showing the position change operations of the bed of FIG. 8;
FIGS. 13 to 17 are schematic illustrations showing the operations of transporting the patient for bathing while using the mechanism incorporated in the bed of FIG. 8.
DESCRIPTION OF PREFERRED EMBODIMENTS
The presently preferred embodiments of this invention will now be described with reference to the appended drawings.
FIGS. 1 to 6 show a bed embodying the carrier for supporting a patient according to this invention. Initially referring to FIG. 1, a bed embodying the invention is generally denoted by numeral 10. The bed 10 has a main frame 11 for supporting thereon a patient in the supine posture at the normal position, and a side frame 12 for supporting the patient in the prone posture as will be described in detail hereinafter. As seen from FIGS. 1 and 2, the main frame 11 includes a reclining frame 11a mounted by means of hinges 11b. The underside of the reclining frame 11a is engaged by an engagement member 13a of a screw-type jack 13 so that the reclining frame 11a may be inclined and fixed at a desired position when the patient desires to sit on the bed 10. As best seen in FIG. 2, the engagement member 13a is swingable about an axis 13b to change the angular position depending on the inclination of the reclining frame 11a. Although one reclining frame for reclining the back of the user is assembled in the main frame 11 in the illustrated embodiment, a reclining frame for raising the legs of the user may be assembled in the main frame in place of or in addition to the illustrated reclining frame 11a. When the main frame 11 is pivoted to change the posture of the patient as will be described hereinafter, the reclining frame 11a is returned back to the position shown in FIG. 1.
The main frame 11 is pivotally mounted at its one side to a pivot shaft 14 by means of hinges 15, and the side frame 12 is also pivotally mounted at its one side to the same pivot shaft 14 by means of hinges 16. A slide plate 17 is contained in the side frame 12 and capable of extension to widen the side frame 12, as desired, to increase the area of the side frame. A grasping bar 18 extends in the side frame 12 in the transverse direction so that the patient can grasp the bar 18 to hold his body by himself during posture changing operations. The grasping bar 18 is paired with another bar 18 extending similarly in the side frame 12 in the transverse direction, and these bars 18 have the free ends sheathed with cylinders 18a which are extensible transversely and a protection plate 19 is mounted between the paired bars 18. The protection plate 19 may be swung in the direction shown by the arrow A to ensure protective function (see FIG. 5).
A fixed plate or wall 20 stands vertically from the floor and positioned close to the end face of one side of the main frame 11. A pin 20a is mounted at a pertinent position of the fixed wall 20 and pivotally connected to the bottom extension 21a of the piston rod of a piston-cylinder unit 21 actuated by fluid pressure. The other end, i.e. the foreward extension 21b of the piston rod of the piston-cylinder unit 21 is pivotally connected to a fixed pin 12a fixed to the end plate of the side frame 12. The piston rod extensions 21a and/or 21b are extended and retracted by a not-shown actuator.
A fastener member 11c provided with a plurality of indents 11e for snugly engaging with set pins 12b protruding from the end plate of the side frame 12 is swingably attached to the end face of the main frame 11 so that the fastener member 11c is swung about an attachment pin 11d.
A main support mat 22 is securely placed on the main frame 11 and has waist pads 22a for holding the waist of the patient in situ. An opening 22b is formed through the mat 22 at the region surrounded by the pads 22a, and a discharge pipe 23 having an inlet port positioned beneath the opening 22b is disposed to deliver liquid and solid wastes to the outside. The main support mat 22 is further provided with shoulder pads 22c for securely holding the shoulders of the patient. A side support mat 24 is placed on the side frame 12. As shown in FIG. 1, flanges 12c extend inward from the end edges of the transverse end faces of the side frame 12 so that the side support mat 24 is slidingly contained below the flanges 12c to be in the extended position as necessity arises. The side support mat 24 is also provided with a slot 24a through which the patient reaches out his hand to seize the the grasping bar 18 during the posture change operation. An opening or concavity 24b is provided at a pertinent area of the mat 24 to prevent compressive force from being applied to the heart of the patient during and after the posture change operation.
Referring to FIGS. 3 to 5, the operation of changing the posture of the patient from the supine position to the prone position will now be described. At the initial step, the piston rod 21b is retracted by actuating the piston-cylinder unit 21, whereupon the side frame 12 is swung about the pivot shaft 14 from the position shown by the broken line to the position shown by the real line in FIG. 3 so that the side frame 12 overhangs the patient's body 25. At that position, the fastener member 11c is swung about an attachment pin 11d from the position shown by the broken line to the position shown by the real line so that one of the set pins 12b is engaged in one of the indents 11e. Although the side mat 24 is not extended in the illustrated operation example, the side mat 24 may be extended to prevent the patient's body from jutting out of the mat 24.
Thereafter, the piston rod 21b of the piston-cylinder unit 21 is extended, whereby the main frame and the side frame are tilted to move to the position as shown in FIG. 4 since the frames 11 and 12 are united together by means of the fastener member 11c so that the patient 25 is laid on his side. During this step of posture change operations, the patient 25 can reach his hand through the opening 24a of the side mat 24 to seize the grasping bar 18 for holding the position of his body.
Upon turning the patient into the prone position, the piston rod 21b is further extended, as shown in FIG. 5, to swing the side frame 12 to the horizontal position. The slide plate 17 and the cylinders 18a may be extended and the protection plate 19 may be swung in the direction as shown by the arrow A to an upstanding protective position, if necessary. If it is desired to hold the patient in this posture, the fastener member 11c is released from the side frame 12 by a nurse or helper and the main frame 11 is returned back to the position shown by the broken line in FIG. 5 manually or by chain or other driving means (not shown).
If it is desired to hold the patient in the position of lying on the side, the side frame 12 is set and fixed by the fastener member 11c at the position relative to the main frame 11 where the side frame extends perpendicular to the main frame at the initial step of the posture change operations, and then the piston-cylinder unit 21 is actuated to swing the joined main and side frames to the desired position as shown in FIG. 6. At this position, the major portion of the weight of the patient is carried by the side frame 12 while the shoulders and waist of the patient are held by the waist pads 22a -and the shoulder pads 22c so that the patient is held in the posture lying on his side.
FIG. 7 shows an operating table 100 embodying the carrier of the present invention. In FIG. 7, the same parts as those of the bed 10 shown in FIGS. 1 to 6 are denoted by reference numerals having the same number as used in FIGS. 1 to 6, with one hundred added thereto, and the duplicative descriptions thereof will be omitted. In the operating table shown in FIG. 7, two piston-cylinder units 121 and 130 each actuated by fluid pressure are used, contrary to the aforementioned bed 10. The piston rod 130a of the piston-cylinder unit 130 is pivotally connected to a pin 131 fixed to a main frame 111 which is pivotable about a pivot shaft 114. In position change operation, the piston-cylinder units 121 and 130 are actuated co-operatively to move the main frame 111 and the side frame 112 in a manner similar to that described with reference to FIGS. 3 to 6. A main frame plate 132 is attached to the main frame 111 such that the plate 132 may be folded downwards to allow closer access to the patient if necessity arises during the operation. A side frame plate 133 is attached to the side frame 112 similarly to allow the downward folding thereof for the same purpose. Two sets of plate support legs 134, one set for each of the plates 132 and 133, are slidingly mounted on the pivot shaft 114. As shown in FIG. 7, one set of support legs 134 for supporting thereon the side frame plate 133 is moved to both ends of the shaft 114 so that the support legs 134 do not obstruct such closer access when the side frame plate 133 is folded downward.
Meanwhile, the bed 10 shown in FIGS. 1 to 6 may be provided with two piston-cylinder units which are actuated by fluid pressure to operate the bed 10, similarly to the operating table 100 shown in FIG. 7.
Another embodiment of the carrier, according to the invention, is shown is FIGS. 8 to 12 and generally denoted by reference numeral 200. In FIGS. 8 to 12, the same parts as those of the bed 10 shown in FIGS. 1 to 6 are denoted by the reference numerals having the same number as used in FIGS. 1 to 6, with two hundred added thereto, and the duplicative descriptions thereof will be omitted. In the bed 200, a first side frame 212 is mounted at one side of a main frame 211 by means of hinges 251, and a second side frame 250 is mounted at the other side of the main frame 211 by means of hinges 252. The main frame 211 is mounted to two fixed plates or walls 220 upstanding vertically from the floor respectively through pivot shafts 253 and 254 so as to be pivotable thereabout. A gear 255 is mounted on the pivot shaft 253 and meshed with a chain 256 which is driven by a motor 257 provided with a reduction gear. Upon energization of the motor 257, the main frame 211 is pivoted in the clockwise or counter-clockwise direction about the pivot shafts 253 and 254.
A plate 258 is fixed to the main frame 211, and pivot pins 258a and 258b protrude from the plate 258. One end of a piston rod 221a of the piston-cylinder unit 221 is connected to the pin 258a, and the end of the other piston rod 221b of the piston-cylinder unit 221 is connected to a pivot pin 212a secured to the side frame 212. Similarly, one end of a piston rod 259a of the piston-cylinder unit 259 is connected to the pin 258b, and the end of the other piston rod 259b of the piston-cylinder unit 259 is connected to a pivot pin 250a secured to the side frame 250.
Although the slide plates 17, grasping bars 18, extensible sheath cylinders 18a and protection plates 19 are not shown in FIG. 8, the same or similar parts may be assembled in the side frames 212 and 250. Likewise, the main frame mat 22 and the side frame mat 24 may be used similarly as in the embodiment shown in FIG. 1.
The operation for changing the posture of a patient 225 from the supine position to the prone position will now be described with reference to FIGS. 9 to 11. In the initial condition shown in FIG. 9, the patient is in the supine posture. The side frame mat 24 of the side frame 250, onto which the patient is transferred, is extended and then the piston-cylinder unit 259 is actuated by fluid pressure to retract the piston rod 259b, whereby the side frame 250 is swung to overhang the patient's body 225. The other side frame 212 is also swung by retracting the piston rod 221b by the actuation of the piston-cylinder unit 221 to move to a position at which the side frame 212 upstands substantially perpendicular relative to the main frame 211 so that the side frame 212 does not hinder the pivotal movement of the entire structure. Thereafter, the motor 257 provided with the reduction gear is energized to swing the main frame 211 about the pivot shaft 253 in the counter-clockwise direction, i.e. the direction shown by the arrow B in FIG. 9, whereby the patient's body 225 is transferred onto the side frame 250 as shown in FIG. 10. Subsequently, while extending the piston rod 259b, the main frame 211 is swung about the pivot shaft 253 in the clockwise direction, i.e. the direction shown by the arrow C in FIG. 10, to the horizontal position as shown in FIG. 11 at which the patient 225 is lying in the prone posture on the side frame 250.
In the position shown in FIG. 12, the patient 225 is held in the posture of lying on his side. In this case, the side frames 250 and 212 are swung such that they extend substantially perpendicular to the plane of the main frame 211 so as to allow the weight of the patient 225 to be carried by one of the side frames 250 or 212 without excessive compressive force. Distinctive from the embodiment shown in FIGS. 1 to 6, since the embodiment shown in FIGS. 8 to 12 is provided with two side frames 212 and 250 at both sides of the main frame 211, the motor 257 provided with a reduction gear (see FIG. 8) is actuated to pivot the main frame 211 about the pivot shaft 253 in either of the clockwise or counter-clockwise direction. The patient can, thus, change the posture arbitrarily from one side to the other side if the patient is fatigued in one posture.
The bed 10 shown in FIGS. 1 to 6 and the bed 200 shown in FIGS. 8 to 12 may be used for allowing the patient to take a bath. The bathing operation will be described, for example, with the use of the bed 200 illustrated in FIGS. 8 to 12.
A bathing cage 260 is put on the patient 225 lying in the prone posture as shown in FIG. 11, and then the bed 200 is operated in the sequence reverse to the operation sequence as described with reference to FIGS. 9 and 10 for changing the posture into the prone position, whereby the patient 225 is laid in the bathing cage while lying in the supine position as shown in FIG. 13. One end 264a of a rope 264 suspended from a pulley 263 integrally mounted to a wheel 262, which runs along an overhead rail or track 261, is then connected to the cage 260 by a hook or other means. The other end 264b of the rope 264 is fixed to a fastener 250a fixedly secured to the side frame 250. Upon swinging the side frame 250 in the direction shown by the arrow D, the cage 260 is raised as shown in FIG. 14. The cage 260 is held in this raised position by fixing the hook 265 to a ring 264c secured intermediately of the rope 264.
Then a short rope 264e is removed from a hook 264d disposed intermediately of the rope 264 and one end of a long rope 266 is engaged by the hook 264d with the other end of the rope 266 being fixed to the fastener 250a, as shown in FIG. 15. The wheel 262 is then allowed to run along the rail 261 manually or any other means to move the cage 260 above a bath 267 placed at the side of the bed 200, as shown in FIG. 16. Then, the ring 264c is released from the hook 265 and the main frame 211 is swung in the direction shown by the arrow E in FIG. 16 about the pivot shaft 253 to lower the cage 260 into the bath 267 as shown in FIG. 17. After the completion of bathing, the patient is returned to the bed 200 following to the operation sequence reverse to that described above.
Incidentally, the cage 260 is moved by the rotational movement of the main frame 211 and the side frame 250 in the illustrated embodiment. One skilled in the art may modify the cage 260 associated with the movement of the reclining means 13, 13a and 11a.
Although the present invention has been described by referring to preferred embodiments thereof, it is not intended to limit the same only to the illustrated embodiments but to embrace all changes and modifications thereof which can be conceived without departing from the spirit of the invention. The scope of the present invention should be defined only by the appended claims.
|
A carrier is provided for changing the posture of a user. The carrier includes a first support frame for carrying thereon the user's body substantially in a horizontal rest posture at the normal position. The carrier also includes at least one second support frame swingably mounted to either side of the first support frame. The second support frame can support the user's body so that the user is lying on his side or can receive the user's body from the first support frame to make the user lie thereon in a topsy-turvy posture. The first and second support frames are swung in association so that the user is made to lie on his side or to lie in the topsy-turvy posture.
| 8
|
This application is a continuation of 08/859,310 filed May 20, 1997 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to non-animal polymer compositions suitable for film forming, particularly hard and soft capsules, comprising water soluble cellulose ethers, hydrocolloids and sequestering agents.
2. Description of Related Art
Capsules are widely used in the pharmaceutical industry as well as in the health food supplement market. The main usage thereof is as dosage form for solid, semi-solid, liquid, pellet or herbal preparations. A primary objection of these dosage forms is to have a good disintegration after being administered in order to enable an effective dissolution of the active substances in the appropriate digestive organ. Consequently, this disintegration characteristic has to remain stable over time when finished products are stored prior to use.
The traditional material for forming the capsule shell is gelatin, because it has the correct and quite ideal properties. Nevertheless, gelatin has some disadvantages which make it necessary to have other capsule shell materials available. A major unfavorable aspect is the animal origin of gelatin. Other disadvantages are the inconveniences of relatively high water content (10-17%) and the loss of elasticity with decreasing water content. Furthermore gelatin capsules are sensitive to heat and humidity which affects the usability of the product. In particular, soft gelatin capsules are known to aggregate under hot and humid conditions. Under dry conditions gelatin films may induce static charge build up affecting later processing.
As a gelatin substitute the use of water soluble film forming cellulose derivatives is widely described in the literature. Reports of capsules made from cellulose derivatives refer to poor disintegration in vivo especially when compared with gelatin. To overcome this drawback in EP0714656 it is suggested to use hydroxypropylmethylcellulose (HPMC) with a viscosity of 2.4 to 5.4 centistokes in 2% aqueous solution at 20° C. with carrageenan as gelling agent and calcium or potassium ions as co-gelling agent. However the very low viscosity of HPMC resulting from lower molecular weight chains induces higher film brittleness. Furthermore, the use of this composition results in an undesirable loss of transparency of the film. Attempts to improve transparency are disclosed in EP0592130 by exposing BPMC to UV radiation prior to capsule processing.
SUMMARY OF THE INVENTION
It has been found that a polymer film composition for capsules wherein the ratios of cellulose ethers, hydrocofloids and sequestering agents are 90 to 99.98% by weight of a cellulose ether or mixture of cellulose ethers with a water content of 2 to 10%, 0.01 to 5% by weight of a hydrocolloid or mixtures of hydrocofloids, and 0.01 to 5% by weight of a sequestering agent or agents do not have the mentioned disadvantages.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Suitable cellulose ethers for the present invention are alkyl and/or hydroxyalkyl substituted cellulose ether with 1 to 4 carbon atoms in the alkyl chains, preferably methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxyethylmethyl cellulose, hydroxyethylethyl cellulose, hydroxypropylmethyl cellulose or the like. Especially preferred is HBPMC. The amount of the cellulose ether or mixture of cellulose ethers is preferably 95 to 99.98% by weight. The viscosity of the cellulose ether or blend is 3 to 15 cps in 2% aqueous solution at 20° C., preferred 5 to 10, especially preferred 6 cps.
Suitable hydrocolloids include such items as synthetic gums which are capable of gelling without the addition of alkaline or alkaline earth metal ions. The preferred gum for this purpose is gellan gum. Such gum, particularly including gellan gum, may be combined in mixtures producing synergistic properties which mixtures may also include natural seaweeds, natural seed gums, natural plant exudates, natural fruit extracts, bio-synthetic gums, bio-synthetic processed starch or cellulosic materials. More specifically, the mixture may include alginates, agar gum, guar gum, locust bean gum (carob), carrageenan, tara gum, gum arabic, ghatti gum, Khaya grandifolia gum, tragacanth gum, karaya gum, pectin, arabian (araban), xanthan, gellan, starch, Konjac mannan, galactomannan, funoran, and other exocellular polysaccharides of which are preferred the exocellular polysaccharides, such as xanthan, acetan, gellan, welan, rhamsan, furcelleran, succinoglycan, scieroglycan, schizophyflan, tamarind gum, curdlan, pullulan, dextran. The amount of gum present is preferably 0.01 to 2% by weight and especially preferred 0.1 to 1.0%.
The preferred sequestering agents are ethylenediaminetetraacetic acid, acetic acid, boric acid, citric acid, gluconic acid, lactic acid, phosphoric acid, tartaric acid or salts thereof methaphosphates, dihydroxyethylglycine, lecithin or beta cyclodextrin and combinations thereof Especially preferred is ethylenediaminetetraacetic acid or salts thereof or citric acid or salts thereof The amount is preferably 0.01 to 3%, especially 0.1 to 2% by weight.
The sequestering mechanism can be adjusted by addition of either monovalent or divalent cations, such a Ca++, Mg++, K+, Na+, Li+, NH4+ or the like.
Capsules or films with the inventive polymer composition may be manufactured with conventional machines by the conventional processes like extrusion moulding, injection moulding, casting or dip moulding.
The capsules and films have a non-animal polymer composition, an improved dissolution behavior, an enhanced elasticity and show higher transparency. The enhanced elasticity makes the capsules more useful for inhalation products. Furthermore the capsules are not sensitive to formaldehyde, for e.g. from a contaminated fill and they have a better temperature stability compared to gelatin capsules, because a crosslinking at storage on elevated temperatures does not occur.
The inventive polymer composition may contain additionally acceptable plasticizers in a range from about 0 to 40% based upon the weight of the cellulose ether. Suitable plasticizers are polyethylene glycol, glycerol, sorbitol, sucrose, corn syrup, fructose, dioctyl-sodium sulfosuccinate, triethyl citrate, tributyl citrate, 1,2-propylenglycol, mono-, di- or triacetates of glycerol, natural gums or the like as well as mixtures thereof.
The inventive polymer composition may contain in a further aspect additionally pharmaceutically or food acceptable coloring agents in the range of from about 0 to about 10% based upon the weight of the cellulose ether. The coloring agents may be selected from azo-, quinophthalone-, triphenylmethane-, xanthene- or indigoid dyes, iron oxides or hydroxides, titanium dioxide or natural dyes or mixtures thereof. Examples are patent blue V, acid brilliant green BS, red 2G, azorubine, ponceau 4R, amaranth, D+C red 33, D+C red 22, D+C red 26, D+C red 28, D+C yellow 10-, yellow 2G, FD+C yellow 5, FD+C yellow 6, FD+C red 3, D+C red 40, FD+C blue 1, FD+C blue 2, FD+C green 3, brilliant black BN, carbon black, iron oxide black, iron oxide red, iron oxide yellow, titanium dioxide, riboflavin, carotenes, anthocyanines, turmeric, cochineal extract, clorophyllin, canthaxanthin, caramel, or betanin.
The shaped polymer composition of the invention or the final product thereof may be coated with a suitable coating agent like cellulose acetate phthalate, polyvinyl acetate phthalate, methacrylic acid polymers, hypromellose phthalate, hydroxypropylmethyl cellulose phthalate, hydroxyalkyl methyl cellulose phthalates or mixtures thereof to provide e.g. enteric properties.
The polymer composition of the invention may be used for the production of containers for providing unit dosage forms for example for agrochemicals, seeds, herbs, foodstuffs, dyestuffs, pharmaceuticals, flavoring agents and the like.
The improved elasticity of the inventive polymer composition makes it useful for the encapsulation of caplets in a capsule, especially in a tamper-proof form. The encapsulation of a caplet in a capsule is preferred processed by cold shrinking together capsule parts, which are filled with a caplet, which comprises the steps providing empty capsule parts, filling at least one of said capsule parts with one or more caplets, putting said capsule parts together, and treating the combined capsule parts by cold shrinking.
The inventive polymer composition is also useful for encapsulating and sealing the two capsule halves in a process in which one or more layers of the composition are applied over the seam of the cap and body, or by a liquid fusion process wherein the filled capsules are wetted with a hydroalcoholic solution that penetrates into the space where the cap overlaps the body, and then dried.
The improved properties of the polymer composition are demonstrated by the following composition and comparative examples.
COMPOSITION EXAMPLES:
COMPOS
COMPOS.
COMPOS.
COMPOS.
COMPONENTS
1
2
3
4*
HPMC(1)
99.26%
99.62%
99.46%
98.1%
Gellan
0.54%
0.22%
0.54%
0
Na citrate
0.20%
0
0
0
Citric Acid
0
0.16%
0
0
Carrageenan
0
0
0
1.3%
KCl
0
0
0
0.6%
*According to EP0714656
(1)HPMC equilibrated at 50% RH (equivalent to a water content between 5 to 7%)
Composition 5: Conventional transparent hard gelatin capsule
Composition 6: Conventional opaque hard gelatin capsule
Mechanical impact test:
Capsule body parts are submitted to mechanical impact stress of 80 mJ and the percentage of fractured capsules are checked.
EQUILIBRIUM
COMPOS.
COMPOS.
COMPOS.
COMPOS.
RH
1
2
5
6
50%
0
0
0
0
10%
0
0
0
5
2.5%
0
0
10
45
Inhalator piercing test:
Capsules are pierced by inhalator device and the percentage of cracks and/or fracture is recorded.
EQUILIBRIUM
COMPOS.
COMPOS.
COMPOS.
COMPOS.
RH
1
2
5
6
50%
0
0
0
0
10%
0
0
95
80
2.5%
0
0
95
75
Capsule transparency test:
Capsule bodies are measured for transmittance at 650 nm
CAPSULE
TRANSPARENCY
Composition 1
74%
Composition 2
75%
Composition 4
60%
Composition 5
81%
Dissolution test:
Acetaminophen dissolved from capsules immersed in deionised water at 37° C. (USP XXII), listed is the percentage of acetaminophen after 45 min.
CAPSULE
% DISSOLVED
Composition 1
90%
Composition 2
90%
Composition 3
63%
Composition 5
91%
Dissolution test after exposure to crosslinking agent:
Capsules were filled with lactose containing 40 ppm of HCHO and stored under room conditions for one month, measured is the percentage of acetaminophen dissolved after 45 min.
CAPSULE
% DISSOLVED
Composition 1
90%
Composition 5
22%
Moisture exchange test:
Capsules were filled with dry carboxymethylcellulose sodium salt (CMC) and stored in closed bottle under room conditions.
INITIAL WATER
FINAL WATER
CONTENT
CONTENT
CAPSULE
Capsule
Fill
Capsule
Fill
Composition 1
6.4%
0%
1.4%
1.1%
Composition 5
14%
0%
4.7%
2.0%
|
The present invention relates to non-animal polymer compositions suitable for film forming, particularly hard and soft capsules, comprising water soluble cellulose ethers, hydrocolloides and sequestering agents.
| 0
|
FIELD OF THE INVENTION
[0001] The invention relates to a method and an apparatus for improving the consistency of data and of metadata and their links following an editing process of the data or metadata.
BACKGROUND OF THE INVENTION
[0002] Broadcast systems like DVB, MHP, TV-Anytime, etc. provide a large amount of additional information, which is being distributed together with audio and video services. These added-value information services will even increase in future.
[0003] A user will have the ability of storing more and more data on storage media with increasing capacity. Furthermore, such data can be copied multiple times to other devices or storage media, without any loss of quality due to their digital format. The merging of broadcast-independent added-value service information, e.g. an Internet Television Guide, with recorded broadcast signals, and their later editing, will become increasingly common.
[0004] U.S. Pat. No. 5,870,753 describes a method for using the UUID (universal unique identifier), which is carried and persistently stored in an object reference data structure. But the history of the object and the information to which object a UUID belongs are not kept in memory.
[0005] In U.S. Pat. No. 6,163,811 the versioning control information is kept using a UUID that distinguishes between source files of the different vendors.
SUMMARY OF THE INVENTION
[0006] In both prior art cases no tracking or editing is possible. But all the technical possibilities listed above bear a huge technical problem: the problem of consistency. Added value-data (metadata) usually include a link that is pointing to the content they are related to (e.g. the summary of a movie will have a link to the start of the video at the time when it will be requested). This link, however, must be kept consistent even after editing processes are executed by a user. Editing means: copying, cutting, new arrangement, etc. of A/V streams (audio and/or video) and of metadata.
[0007] A problem to be solved by the invention concerns consistent storage, links and interaction between metadata and essence data that are still useful following editing of the metadata or essence data.
[0008] Every asset (metadata or essence) gets a unique identifier, e.g. a UUID, and information about the last action applied to an asset.
[0009] This includes storage of the essence (A/V) of a recording on one storage medium, e.g. on a recordable disc, and of the metadata belonging to this recording on another storage medium.
[0010] If a recording is being edited, the metadata may become scattered on several media. Editing can include:
[0011] a) adding additional metadata links, which point to the A/V stream, or
[0012] b) copying parts of the data (essence or metadata) onto different storage media or discs.
[0013] In order to keep the link-resolving process working properly, it is necessary to adapt the metadata links correctly. The adaptation ensures that the A/V data can be played back using the metadata link, even if the link has been previously moved. However, the adaptation of metadata links is very complicated and may even fail in case of distributed media storage, i.e. if A/V data have been moved to another storage medium, or deleted.
[0014] The invention encompasses three elements, which all work together:
[0015] 1st Element:
[0016] The identifier (e.g. UUID, GUID (global unique identifier), etc.) identifies every essence and metadata. The identifier can be generated autarkical by every device and is unique for e.g. every 100 nsec until e.g. the year 3400 A.D.
[0017] 2nd Element:
[0018] The XML scheme provides an identifier (e.g. UUID) for every asset, which is being stored on the device. The identifier is stored within the LogEntry structure. The LogEntry structure (which is e.g. a first list or a first data field or a first table) encompasses the identifier and an action item. Furthermore, the XML scheme includes a LogEntryHistory structure (e.g. a further list or a further data field or a further table, or a corresponding extension of the first list or data field or table) which will contain obsolete LogEntry elements.
[0019] 3rd Element:
[0020] The third element is a decision table or list or data field that provides a control mechanism for the XML scheme elements and all assets, which were filled correctly into the XML scheme together with their content according to the processes executed on it.
[0021] These three elements are put together in order to support the decision process. The decision process is for instance necessary for a metadata link pointing to an essence and for making it possible for a user to get access to the essence linked to this metadata.
[0022] Every asset (which can be either metadata or essence) is labelled with an identifier (e.g. a UUID) and with the last action applied to this asset. Both items of information are stored within a list or data field denoted LogEntry, which is available for all assets.
[0023] When an A/V stream is being recorded it will receive an identifier, and the corresponding LogEntry action is ‘created’.
[0024] In case some other time a copy operation for this A/V stream is generated and the copy process is physically duplicating the stream, a new UUID will also be created as well as a new LogEntry action ‘copy’ for the LogEntry of the copied item. The previous LogEntry elements of the copy that are now being redundant, will be added to the LogEntryHistory element. Every additional editing process will do the same, so that the LogEntryHistory will carry all LogEntries that ever have been assigned to this asset.
[0025] When a resolving process is searching for an asset, it will be able to identify this asset by its identifier within the LogEntry due to the fact that the LogEntry is unique.
[0026] The big advantage of the invention is, that the editing process is much easier, because it is no longer necessary to handle all the changes within all links referring to the assets that are being edited. Changing all links will even become obsolete if the referencing elements are located on a storage medium that is not accessible for the update processing in the devise.
[0027] The consistency of this invention is provided by a decision table, list or data field, which is easy to implement, and by the resolving process being able to match assets by examining the LogEntryHistory entries. When using this inventive decision table for the editing process, the resolver is able to find even assets that would have been lost if using the conventional editing process.
[0028] In principle, the inventive method is suited for making a consistency decision, wherein metadata are checked automatically or electronically for consistency, including the steps:
[0029] requesting search for a link for an identifier in a LogEntry, e.g. a UUID or GUID;
[0030] analysing the LogEntry whether an identifier was found;
[0031] in case no LogEntry was found:
[0032] examining a LogEntryHistory for a matching identifier;
[0033] analysing the LogEntryHistory for an identifier found;
[0034] determining whether more than one matching identifier is available;
[0035] if this is true, consistency checking for the best matching identifier based on the action item;
[0036] returning the location of the matching identifier.
[0037] In principle, the inventive apparatus matches assets by automatically or electronically checking said assets or part of said assets for consistency, the apparatus including:
[0038] means for requesting the search for a link for an identifier in a LogEntry, e.g. a UUID or GUID;
[0039] means for analysing the LogEntry whether an identifier was found, and in case no LogEntry was found for providing this information to:
[0040] examining means for examining a LogEntryHistory for a matching identifier;
[0041] means for analysing the LogEntryHistory for an identifier found;
[0042] means for determining whether more than one matching identifier is available;
[0043] means for checking, if more than one identifier was found, the consistency of the identifiers found and for selecting the best matching identifier based on the action item;
[0044] an identifier-location provider to which the location of the matching or best matching, respectively, identifier is returned.
[0045] Advantageous additional embodiments of the invention are disclosed in the respective dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] Exemplary embodiments of the invention are described with reference to the accompanying drawings, which show in:
[0047] [0047]FIG. 1 LogEntry and LogEntryHistory structures of an asset;
[0048] [0048]FIG. 2 Flow chart according to the invention;
[0049] [0049]FIG. 3 Structure of an apparatus according to the invention;
[0050] [0050]FIG. 4 Basic asset processing request flow chart.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0051] [0051]FIG. 1 shows the structure of a LogEntry characteristic of an asset. The LogEntry contains the recent identifier (e.g. a UUID) and the corresponding action entries of an asset. As a kind of a memory, the LogEntryHistory contains all previous identifiers and all former action items of this asset.
[0052] The editing process steps for a recording, and the process of storing a recording, are depicted in FIG. 4. Each time an asset processing is requested and a corresponding processing started, this asset will get a new UUID that is entered into a newly created LogEntry, or is overwritten in the current LogEntry. However, before the current UUID and action is deleted or overwritten in the LogEntry, the current UUID and action is appended to the LogEntryHistory.
[0053] There may be some special actions where no new UUID is necessary, e.g. in case a protection flag is changed.
[0054] The action entry describes the actually performed manipulation, e.g. ‘create new’, etc.. The LogEntryHistory includes all LogEntry elements that were previously attached to an asset during its life time.
[0055] After the new UUID and LogEntry have been created the desired actual action for the asset is executed and the asset stored.
[0056] The flow chart of FIG. 2 demonstrates the inventive resolving process. In a first step, the resolving process searches 21 for an identifier (e.g. a UUID) in all available LogEntries. If the resolving process will find 22 a LogEntry it will output 27 the matching link in return. If the resolving process cannot find the desired identifier within the first step, the resolving process will continue with a second step.
[0057] In the second step the process searches 23 for the identifier within all available LogEntryHistory entries. If no identifier can be found 24 the process has failed (FAIL), which result can be signalled to the user. If a single identifier only is found 24 , 25 , the location of this identifier will be returned and the process will be terminated 27 .
[0058] In case more than one hit (matching identifier) is found 24 , 25 , the resulting action entry supports making a decision in a consistency check 26 enabling the process to determine whether the asset is still valid, and for returning 27 the best matching link based on the action item.
[0059] In FIG. 3 the apparatus searches in a requester 31 for the identifier (e.g. a UUID) in all available LogEntries. If the LogEntry analyser 32 finds a LogEntry, it will output in return the matching link to an identifier-location provider stage 37 . If LogEntry analyser 32 can not find the desired identifier within the LogEntry, an examining means 33 will search for the identifier within all available LogEntryHistory entries.
[0060] If a history analyser 34 that is associated with said examining means 33 determines that a single or multiple identifiers have been found, it will return the location of this identifier or theses identifiers to a threshold detector 35 . If the history analyser 34 determines that no identifier was found it outputs a fail signal (FAIL), which can be signalled to a user.
[0061] The threshold detector 35 determines whether more than one identifier was found. If a single identifier only was found, the location of this identifier is returned to the identifier-location provider stage 37 . In case multiple matching identifiers were found, the threshold detector provides the corresponding information to a consistency checker 36 in order to support making a decision therein, whether the asset is still valid. If this is true, the consistency checker 36 return the best matching link to the identifier-location provider stage 37 .
[0062] The invention can be used when recording audio, video and/or other data, which includes storing the essence (A/V) of a recording on one medium (e.g. a recordable disc), and of the metadata belonging to this recording on another medium.
[0063] The invention can also be used in editing processes by the user. If the action elements show non-disruptive edit actions like e.g. ‘copy’, the asset was not changed and can be used. In case the action elements show disruptive actions, the resolving process can decide by means of the targeted part of the A/V stream if it is still valid.
EXAMPLE
[0064] [0064] Movie “ Flipper”<mediumID UUID=“{...128bit ...0008}”> <PlayList name =“ 04711 .rpls” <logEntry UUID=“{... 03Jan01-08:17:23 00A ...}” Action=“create”/> <logEntry UUID=“{... 13Jan01-15:34:09 00C ...}” Action=“modified”/> . . . /> Metadata for the Movie “ Flipper<MetaDataDescriptor . . . <logEntry UUID=“{...03Jan01-08:17:23 002..}” Action=“create”/> <contentReference> <meta:terget link=“urn”> <meta:logEntry UUID=“{...03Jan01-08:17:23 00A...}” Action=“create”/> <meta: dvrLinkParameter type=“all”/> </meta:target> </contentReference> . . .</ MetaDataDescriptor > </mediumID> Copy of the Movie “ Flipper”<mediumID UUID=“{...128bit ...1003}”> <PlayList name =“ 00103 .rpls” <logEntry UUID=“{... 03Jan01-07:17:23 00A ...}” Action=“create”/> <logEntry UUID=“{... 13Jan01-15:34:09 00C ...}” Action=“modified”/> <logEntry UUID=“{... 29Jun01-12:04:37 70E ...}” Action=“ copied ”/> . . . </ . . . > Copy of Metadata for the Movie “ Flipper”<MetaDataDescriptor . . . <logEntry UUID=“{... 03Jan01-08:17:23 002 ...}” Action=“create”/> <logEntry UUID=“{... 28Jun01-12:04:37 4F2 ...}” Action=“ copied ”/> <contentReference> <meta:target link=“urn”> <meta:logEntry UUID=“{... 03Jan01-08:17:23 00A ...}” Action=“create”/> . . . </ . . . > </mediumID>
[0065] Editing operations can be: creating, copying, cutting, appending, new arrangement, etc. of A/V streams and of meta-data. If the action elements show edit actions like “copied”, the asset will not be changed and will be used. Or, if the action element shows actions like “cut tail”, “cut head”, “merged” etc., the resolving process can decide by means of the targeted part of the A/V stream if it is still valid.
|
According to the invention every asset (metadata or essence) is labelled with a unique identifier and with the last action applied to this asset.
A problem to be solved by the invention is to faclitate storage of a recording, thereby storing the essence (A/V) of a recording on one storage medium and the metadata belonging to this recording on another storage medium.
| 7
|
TECHNICAL FIELD
This invention relates generally to rectification and is particularly useful for cryogenic rectification such as the cryogenic rectification of feed air.
BACKGROUND ART
A major expense of a rectification plant for the separation of a fluid mixture into components based on their relative volatility is the cost of the column casing and the space required for the column. This is particularly the case where two or more columns are required to conduct the separation. Such multi-column systems are often used in cryogenic rectification, such as in the cryogenic rectification of feed air, where columns may be stacked vertically or located side by side. It would be highly desirable to have a system which will enable rectification to be carried out with reduced column cost and with reduced space requirements for the columns.
Accordingly it is an object of this invention to provide a column system for rectification which has reduced costs and space requirements over comparable conventional systems.
SUMMARY OF THE INVENTION
The above and other objects, which will become apparent to one skilled in the art upon a reading of this disclosure, are attained by the present invention, one aspect of which is:
An annular column for carrying out rectification, said column comprising:
(A) a cylindrical main column wall defining a first column region;
(B) an annular column wall radially spaced from the main column wall demarcating a second column region between the main column wall and the annular column wall;
(C) means for passing fluid into the first column region and means for withdrawing fluid from the first column region; and
(D) means for passing fluid into the second column region and means for withdrawing fluid from the second column region.
Another aspect of the invention is:
Apparatus for carrying out cryogenic rectification of feed air comprising:
(A) a higher pressure column and an annular column, said annular column comprising a cylindrical main column wall defining a first column region and an annular column wall radially spaced from the main column wall demarcating a second column region between the main column wall and the annular column wall;
(B) means for passing feed air into the higher pressure column, means for passing fluid from the higher pressure column into the first column region, and means for passing fluid from the first column region into the second column region;
(C) means for recovering at least one of product nitrogen and product oxygen from the first column region; and
(D) means for recovering product argon from the second column region.
Yet another aspect of the invention is:
Apparatus for carrying out cryogenic rectification of feed air comprising:
(A) an annular column comprising a cylindrical main column wall defining a lower pressure region, and an annular column wall radially spaced from the main column wall demarcating a higher pressure region between the main column wall and the annular column wall;
(B) means for passing feed air into the higher pressure region, and means for passing fluid from the higher pressure region into the lower pressure region; and
(C) means for recovering at least one of product nitrogen and product oxygen from the lower pressure region.
A further aspect of the invention is:
Apparatus for carrying out cryogenic rectification of feed air comprising:
(A) a lower pressure column and an annular column, said annular column comprising a cylindrical main column wall defining a main column region and an annular column wall radially spaced from the main column wall demarcating a side column region between the main column wall and the annular column wall;
(B) means for passing feed air into the main column region, means for passing fluid from the main column region into the lower pressure column, and means for passing fluid from the lower pressure column into the side column region; and
(C) means for recovering product oxygen from the side column region.
As used herein the term "product oxygen" means a fluid having an oxygen concentration greater than 80 mole percent, preferably greater than 95 mole percent.
As used herein the term "product nitrogen" means a fluid having a nitrogen concentration greater than 95 mole percent, preferably greater than 99 mole percent.
As used herein the term "product argon" means a fluid having an argon concentration greater than 80 mole percent, preferably greater than 95 mole percent.
As used herein the term "column" means a distillation or fractionation column or zone, i.e. a contacting column or zone, wherein liquid and vapor phases are countercurrently contacted to effect separation of a fluid mixture, as for example, by contacting of the vapor and liquid phases on a series of vertically spaced trays or plates mounted within the column and/or on packing elements such as structured or random packing. For a further discussion of distillation columns, see the Chemical Engineer's Handbook, fifth edition, edited by R. H. Perry and C. H. Chilton, McGraw-Hill Book Company, New York, Section 13, The Continuous Distillation Process.
Vapor and liquid contacting separation processes depend on the difference in vapor pressures for the components. The high vapor pressure (or more volatile or low boiling) component will tend to concentrate in the vapor phase whereas the low vapor pressure (or less volatile or high boiling) component will tend to concentrate in the liquid phase. Partial condensation is the separation process whereby cooling of a vapor mixture can be used to concentrate the volatile component(s) in the vapor phase and thereby the less volatile component(s) in the liquid phase. Rectification, or continuous distillation, is the separation process that combines successive partial vaporizations and condensations as obtained by a countercurrent treatment of the vapor and liquid phases. The countercurrent contacting of the vapor and liquid phases is generally adiabatic and can include integral (stagewise) or differential (continuous) contact between the phases. Separation process arrangements that utilize the principles of rectification to separate mixtures are often interchangeably termed rectification columns, distillation columns, or fractionation columns. Cryogenic rectification is a rectification process carried out at least in part at temperatures at or below 150 degrees Kelvin (K).
As used herein the term "indirect heat exchange" means the bringing of two fluids into heat exchange relation without any physical contact or intermixing of the fluids with each other.
As used herein the term "feed air" means a mixture comprising primarily oxygen, nitrogen and argon such as ambient air.
As used herein the term "reboiler" means a heat exchange device that generates column upflow vapor from column liquid.
As used herein the term "condenser" means a heat exchange device that generates column downflow liquid from column vapor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of one preferred embodiment of the invention wherein the annular column is used in a cryogenic rectification system which produces argon.
FIG. 2 is a more detailed view of the embodiment illustrated in FIG. 1.
FIG. 3 is a schematic representation of another preferred embodiment of the invention wherein the annular column is used in a double column type cryogenic rectification system.
FIG. 4 is a schematic representation of another preferred embodiment of the invention wherein the annular column is used in a side column type cryogenic rectification system.
FIG. 5 is a more detailed view of the embodiment illustrated in FIG. 4.
The numerals in the Drawings are the same for the common elements.
DETAILED DESCRIPTION
The invention will be described in detail with reference to the Drawings. FIGS. 1 and 2 illustrate one embodiment of a cryogenic rectification system wherein the annular column of the invention may be employed.
Referring now to FIGS. 1 and 2, feed air 1 is compressed in compressor 2 and cooled of the heat of compression by passage through cooler 3. The pressurized feed air is then cleaned of high boiling impurities such as water vapor, carbon dioxide and hydrocarbons by passage through purifier 4 which is typically a temperature or a pressure swing adsorption purifier. Cleaned, compressed feed air 5 is then cooled by indirect heat exchange with return streams in primary heat exchanger 6. In the embodiment illustrated in FIG. 1, a first portion 7 of feed air 5 is further compressed by passage through booster compressor 8, a second portion 9 is further compressed by passage through booster compressor 10, and resulting further compressed feed air portions 11 and 12 and remaining compressed feed air portion 50 are cooled by passage through primary heat exchanger 6 to produce compressed, cleaned and cooled feed air, in streams 51, 52, and 53 respectively. Stream 52 is turboexpanded to form stream 54 by passage through turboexpander 55 to generate refrigeration for the subsequent cryogenic rectification and then passed into annular column 24. Streams 51 and 53 are each passed into higher pressure column 21.
Within higher pressure column 21 the feed air is separated by cryogenic rectification into nitrogen-enriched vapor and oxygen-enriched liquid. Nitrogen-enriched vapor is passed in stream 22 into reboiler 23 wherein it is condensed by indirect heat exchange with annular column 24 bottom liquid to form nitrogen-enriched liquid 25. A portion 26 of nitrogen-enriched liquid 25 is returned to higher pressure column 21 as reflux, and another portion 27 of nitrogen-enriched liquid 25 is subcooled in heat exchanger 6 and then passed into annular column 24 as reflux. Oxygen-enriched liquid is passed from the lower portion of higher pressure column 21 in stream 28 and a portion 56 is passed into argon condenser 29 wherein it is vaporized by indirect heat exchange with argon-richer vapor, and the resulting oxygen-enriched fluid is passed as illustrated by stream 30 from condenser 29 into annular column 24. Another portion 57 of the oxygen-enriched liquid is passed directly into annular column 24.
Annular column 24 comprises a cylindrical main column wall 70 and a cylindrical annular column wall 71 radially spaced from the main column wall. Concentric cylindrical walls 70 and 71 define a first column region 72 and a second column region 73. Second column region 73 is the volume between the main column wall and the annular column wall and first column region 72 comprises at least some of the volume enclosed by the main column wall but not part of second column region 73. Second column region 73 is closed off from first column region 72 at the upper end of second column region 73 by separator 74, and is in flow communication at lower end of second column region 73 with first column region 72 through distributor 75. Preferably, as illustrated in FIGS. 1 and 2, the vapor/liquid contacting internals in second column region 73 are annular trays 76. The vapor/liquid contacting internals in first column region 72 preferably comprise packing.
Vapor comprising mostly oxygen and argon passes from first column region 72 through distributor 75 into second column region 73 wherein it is separated by cryogenic rectification with downflowing liquid into argon-richer vapor and oxygen-richer liquid. The oxygen-richer liquid is returned to first column region 72 through distributor 75 as shown by flow arrows 33. The argon-richer vapor is passed in stream 34 into condenser 29 wherein it condenses by indirect heat exchange with the vaporizing oxygen-enriched liquid as was previously described. Resulting argon-richer liquid is returned in stream 35 to second column region 73 to be the aforesaid downflowing liquid. A portion 36 of the argon-richer liquid may be recovered as product argon indirectly from second column region 73. Alternatively, or in addition to stream 36, a portion of the argon-richer vapor may be recovered directly from second column region 73 as product argon.
Annular column 24 is operating at a pressure less than that of higher pressure column 21. Within first column region 72 of annular column 24 the various feeds into the first column region are separated by countercurrent cryogenic rectification into nitrogen-rich fluid and oxygen-rich fluid. Nitrogen-rich fluid is withdrawn from the upper portion of annular column 24 as vapor stream 37, warmed by passage through primary heat exchanger 6 and recovered as product nitrogen 38. A waste stream 58 is withdrawn from the upper portion of annular column 24, warmed by passed through heat exchanger 6 and removed from the system in stream 59. Oxygen-rich fluid is withdrawn from the lower portion of annular column 24 as vapor and/or liquid. If withdrawn as a liquid, the oxygen-rich liquid may be pumped to a higher pressure and vaporized either in a separate product boiler or in primary heat exchanger 6 prior to recovery as high pressure product oxygen. In the embodiment illustrated in FIG. 1 oxygen-rich fluid is withdrawn from annular column 24 as liquid stream 39, pumped to a higher pressure through liquid pump 60, vaporized by passage through primary heat exchanger 6, and recovered as product oxygen 40. A portion 61 of the liquid oxygen may be recovered as liquid product oxygen.
The annular column used in the system described in conjunction with FIGS. 1 and 2 takes the place of the lower pressure column and the argon sidearm column of a conventional cryogenic air separation plant. In the embodiment of the invention illustrated in FIG. 3 the annular column takes the place of higher pressure and lower pressure columns of a conventional cryogenic air separation plant. The embodiment of the invention illustrated in FIG. 3 also includes an annular arrangement similar to that described in conjunction with FIGS. 1 and 2 for the production of product argon. It is understood, however, that such product argon capability is not necessary or can be provided by use of a conventional argon sidearm column when practicing the embodiment of the invention illustrated in FIG. 3. Those aspects of the system illustrated in FIG. 3 which are the same as previously discussed in connection with the system illustrated in FIGS. 1 and 2 are given common numerals and will not again be discussed in detail.
The subject annular column illustrated in FIG. 3 differs from that illustrated in FIGS. 1 and 2 in that the annular column wall 80 is outside of the cylindrical volume defined by main column wall 81 and the second column region 82 is at a higher pressure than is first column region 83, whereas in the embodiment illustrated in FIGS. 1 and 2 the annular column wall is within the volume defined by the main column wall and, in addition, the pressure in the second column region is about the same as that in the first column region.
Referring now to FIG. 3, feed air streams 51 and 53 are passed into second column region or higher pressure region 82 and within higher pressure region 82 the feed air is separated by cryogenic rectification into nitrogen-enriched vapor and oxygen-enriched liquid. Nitrogen-enriched vapor is passed in stream 84 into reboiler 85 wherein it is condensed by indirect heat exchange with bottom liquid from first column region or lower pressure region 83 to form nitrogen-enriched liquid 86. A portion 87 of nitrogen-enriched liquid 86 is returned to higher pressure region 82 as reflux, and another portion 88 of nitrogen-enriched liquid 86 is subcooled in heat exchanger 6 and then passed into the upper portion of lower pressure region 83 as reflux. Oxygen-enriched liquid is passed from high pressure region 82 in stream 89 and a portion 90 is passed into condenser 29 wherein it is vaporized by indirect heat exchange with argon-richer vapor, and the resulting oxygen-enriched fluid is passed in stream 30 from condenser 29 into lower pressure region 83. Another portion 91 of the oxygen-enriched liquid is passed directly into lower pressure region 83.
Within lower pressure region 83 the various feeds are separated by countercurrent cryogenic rectification into nitrogen-rich fluid and oxygen-rich fluid. oxygen-rich fluid, in the embodiment illustrated in FIG. 3, is withdrawn from the lower portion of lower pressure region 83 in stream 92. A portion 93 of stream 92 is passed into liquid pump 94 and from there into reboiler 85 wherein it is vaporized by indirect heat exchange with condensing nitrogen-enriched vapor as was previously described. Resulting oxygen-rich vapor is then passed into the lower portion of lower pressure region 83 from reboiler 85 in stream 95. Another portion 96 of stream 92 is pumped to a higher pressure through liquid pump 97, vaporized by passage through primary heat exchanger 6, and recovered as product oxygen 98. A portion 99 of the liquid oxygen may be recovered as liquid product oxygen.
In the embodiment of the invention illustrated in FIGS. 4 and 5 the annular column is employed in place of a side column and a higher pressure column of a conventional cryogenic air separation plant.
Referring now to FIGS. 4 and 5 annular column 100 has cylindrical main column wall 101 defining first column region or main column region 102 and annular column wall 103, radially spaced from main column wall 101, demarcating second column region or side column region 104 between main column wall 101 and annular column wall 103. Annular column wall 103 is within the cylindrical volume defined by main column wall 101 and side column region 104 is at a lower pressure than is main column region 102. Side column region 104 is separated from main column region 102 at the top of side column region 104 by separator 105 and at the bottom of side column region 104 by separator 106. Side column region 104 preferably contains annular trays as the mass transfer internals.
Feed air stream 51 is divided into stream 108, which is passed into lower pressure column 109, and into stream 110 which is passed into main column region 102. Feed air stream 12 undergoes partial traverse of main heat exchanger 6 and resulting stream 111 is turboexpanded by passage through turboexpander 55 which, in the embodiment illustrated in FIG. 4, is directly coupled to and serves to drive compressor 10. Resulting turboexpanded feed air stream 112 is then passed from turboexpander 55 into lower pressure column 109.
Feed air stream 53 is passed into heat exchanger 113 wherein it is at least partially condensed and passed in stream 114 into main column region 102. Within main column region 102 the feed air is separated by cryogenic rectification into nitrogen-enriched vapor and oxygen-enriched liquid. Nitrogen-enriched vapor is passed in stream 115 into reboiler 23 wherein it is condensed by indirect heat exchange with lower pressure column 109 bottom liquid to form nitrogen-enriched liquid 116. If desired, as illustrated in FIG. 4, a portion 117 of nitrogen-enriched vapor 115 may be passed through main heat exchanger 6 and recovered as high pressure product nitrogen vapor.
Nitrogen-enriched liquid 116 is passed into main column region 102 as reflux. If desired, a portion 119 of nitrogen-enriched liquid 116 may be recovered as higher pressure product nitrogen liquid. Oxygen-enriched liquid is withdrawn from the lower portion of main column region 102 in stream 120, subcooled by passage through subcooler 121, and the resulting subcooled oxygen-enriched liquid is passed as illustrated by stream 122 into lower pressure column 109. A liquid stream 123 taken from main column region 102 and comprising nitrogen and oxygen is subcooled by passage through subcooler 121 and then passed as stream 124 into the upper portion of lower pressure column 109.
Lower pressure column 109 is operating at a pressure less than that of main column region 102. Within lower pressure column 24 the various feeds into the column are separated by cryogenic rectification into nitrogen-containing fluid and oxygen-containing fluid. Nitrogen-containing fluid is withdrawn from the upper portion of lower pressure column 109 as vapor stream 125, warmed by passage through subcooler 121 and primary heat exchanger 6 and removed from the system in stream 126. Oxygen-containing fluid is withdrawn from the lower portion of lower pressure column 109 in stream 127 and passed into side column region 104 wherein it is separated by countercurrent cryogenic rectification into oxygen-richer fluid and oxygen-poorer fluid. Oxygen-poorer fluid is passed as vapor stream 128 from side column region 104 into the lower portion of lower pressure column 109. A portion of the oxygen-richer fluid is passed as liquid stream 129 from side column region 104 into heat exchanger 113 wherein it is at least partially vaporized by indirect heat exchange with aforesaid at least partially condensing feed air stream 53, and resulting oxygen-richer fluid is returned to side column region 104 from heat exchanger 113 in stream 130. Another portion of the oxygen-richer fluid is withdrawn from side column region 104 as liquid in stream 131, pumped to a higher pressure through liquid pump 132, vaporized by passage through main heat exchanger 6, and recovered as product oxygen 133. A portion 134 of liquid oxygen stream 120 may be recovered as liquid product oxygen.
Now with the use of this invention one can carry out rectification of a multicomponent mixture using less space and less material, particularly column casing material, than has heretofore been necessary to effect an equivalent separation. Although the invention has been described in detail with reference to certain preferred embodiments, those skilled in the art will recognize that there are other embodiments of the invention within the spirit and the scope of the claims. For example, although the invention was discussed in detail with reference to cryogenic rectification, such as the rectification of air, it is understood that the invention may be employed to carry out other rectification processes such as, for example, oil fractionations, hydrocarbon separations and alcohol distillations.
|
An annular column, particularly useful for cryogenic rectification, comprising coaxially oriented, radially spaced cylindrical column walls defining a first column region, and a second column region between the walls, wherein different fluid mixtures are rectified in each of the first column and second column regions.
| 8
|
Reference to related application, assigned to the assignee of the present invention, the disclosure of which is hereby incorporated by reference; patent application U.S. Ser. No. 06/686,211, filed Dec. 26, 1984, GOBEL et al (corresponding to German No. P 34 03 894).
The present invention relates to a flame hydrolysis coating apparatus to coat articles with a silicon oxide layer which promotes adhesion of the articles, typically dental prostheses, and is an improvement over the application U.S. patent application Ser. No. 06/686,211, filed Dec. 26, 1984, assigned to the assignee of the present application, the disclosure of which is hereby incorporated by reference.
BACKGROUND
The referenced U.S. patent application Ser. No. 6/686,211 describes an arrangement which is particularly suitable to coat metallic dental prosthesis components by flame hydrolysis. The arrangement includes holders to hold the metallic dental prosthesis parts, located at some distance from a source of silicon oxide. By flame hydrolysis, the dental prosthesis parts are coated with a silicon oxide layer which promotes adhesion of the metallic parts with plastics and the like injected, later, about the metallic parts. The referenced application describes placing the metallic parts within the flame cone of a flame hydrolysis burner, directed towards the dental prosthesis parts or elements. The length of the flame cone is at the most 25% longer than the distance between the flame hydrolysis burner and the dental prosthesis element. This insures the element to be coated is located outside of the region of the flame cone which might cause carbonization or deposit of carbon and soot. The part, also, is outside of the tip of the flame. During coating, the holder, which is located on a turret, is rotated with respect to the flame hydrolysis burner. Adjustment in various directions is possible; the turret insures that sequentially, different surface regions of the prosthesis elements, as well as single, different elements of the prosthesis are exposed to the flame cone. To insure that the prosthesis parts are coated at all sides, it is necessary to move the holder and/or the prosthesis element, from time to time, in its position relative to the flame cone. The arrangement has been found entirely suitable in actual use.
THE INVENTION
It is an object to improve a flame hydrolysis apparatus as described in the referenced application by improving the utilization of the region of the flame of the flame hydrolysis burner, and which further improves uniform coating of the articles or elements over their entire surfaces without having to shift the articles or elements with respect to the flame cone, or to shift the holders thereof, and which is simple and easily. adjusted for various articles to be coated.
Briefly, means are provided to generate turbulence at the tip of an elongated flame cone, formed, for example, by deflection surfaces located--with respect to flame projection or the length of the flame cone--beyond the holders for the articles. The deflection surfaces are positioned to be impinged by the tip of the flame, so that the tip is deflected thereby from the original cone form, to introduce turbulence at the end or tip portion of the flame and in the region of the articles held in the article holders, so that the articles, in the holders, are surrounded, essentially, from all sides by the projected flame and reflected, and deflected flame portions which have impinged on the deflection surface.
The deflection surface, located downstream--in the direction of the flame cone--from the articles to be coated prevents free flow or formation of the flame cone and turbulence at the tip of the flame cone is generated. The soot component which is present at the tip of the flame cone is thus heavily diluted, so that it no longer will interfere with coating of the articles. A higher, and highly desirable and advantageous, increased volume of the reaction zone is obtained, so that various articles, and typically dental prostheses, can be coated all around in one passage through the flame, as reflected and deflected by the deflection surface, by the swirl of the flame about the articles.
The composition of the flame and thus the characteristics of the coated zone are less dependent on the particular location of the respective coated zones on the articles, since the flame will, effectively, surround the articles at all sides. By generating tip turbulence upon impingement of the flame on the deflection surface, the back portions of the articles, typically dental prostheses, are also coated although they are remote from the sides or surfaces facing the burner generating and projecting the flame cone. Thus, the desired silicon coating layer can be applied to the prosthesis parts from all sides without having to turn the parts or their holders on the apparatus passing the parts through the flame, typically a turret.
A cylindrical or substantially cylindrical deflection surface has been found particularly suitable. The cylindrical deflection surface is so positioned that the cylinder axis forms an extension of the axis of rotation of a turret. A plurality of small dental prosthesis elements can be located around the cylindrical deflection surface element; it is also possible to locate one large dental prosthesis element in position in front of the cylindrical deflection surface. The articles to be coated are located on a turret and are passed in a repetitive cycle in front of the flame hydrolysis burner. The turret, together with the deflection surface, is rotated, for example and preferably, at a speed of about 30 to 60 rpm. This speed insures that excessive heating of the portion of the deflection surface which is behind the articles to be coated is avoided. The rotation of the elements additionally cools the elements between successive flame hydrolysis coating, that is, when they are again subjected to the flame as it impinges the cylindrical deflection surface. By using an essentially cylindrical deflection element, a plurality of articles located circumferentially outside of the deflection surfaces will, reliably, with uniform coating.
In accordance with a feature of the invention, the deflection surface can be formed as a dished deflection element having an axis of rotation extending parallel to the direction of the flame projected by a flame burner, the articles being located in front of the dished deflection surface. The offset between the axis of rotation of the turret which, in this arrangement, can be formed directly by the dished deflection surface, with respect to the axis of projection of the flame cone, preferably, is adjustable, the offset being so arranged that the articles will be subjected to the flame as it is being projected thereagainst. In this arrangement, the dished deflection surface directly forms the holder turret for the articles, which results in a particularly simple construction, and is suitable especially for small articles, such as small prosthesis components.
The deflection surface, preferably, is concave with respect to the flame; this increases the turbulence at the end or tip of the flame and, additionally, guides the flame in the region of the back portion of the articles. This effect is even enhanced by positioning the concave region above the flame--since hot air rises--so that, due to heat convection, the flame tip which tends to bend upwardly is deflected downwardly by the concave-shaped portion of the deflection surface. A radius of the profile of the concave surface of up to about 3 cm, and suitably less than that, has been found suitable when coating dental prosthesis elements.
DRAWINGS
FIG. 1 is a schematic pictorial view of the flame hydrolysis apparatus using an upwardly expanding, essentially cylindrical deflection element;
FIG. 2 is a side view, partly in section, of the apparatus using a dish-shaped deflection element;
FIG. 3 is a schematic section of the shape of a deflection element;
FIG. 4 is a top view of an essentially cylindrical deflection element with inwardly concave niches or depressions, extending axially, or cup-shaped depressions;
FIG. 5 is a top view of a cylindrical flame deflection surface with cooling slits;
FIG. 6 is a top view of a cylindrical deflection element formed of a mesh or cellular construction, to provide enhanced cooling;
FIG. 7 is a schematic side view of a holder for sample articles to be coated;
FIG. 8 is a view similar to FIG. 7 and showing another embodiment;
FIG. 9 is an axial view, partly schematic, illustrating connection of two holder arms located diametrically opposite a deflection element as shown in FIG. 1;
FIG. 10 is a detail perspective view of a holder arrangement;
FIG. 11 is a schematic top view of a holder arrangement for a deflection element as shown in FIG. 4;
FIG. 12 illustrates a holder arrangement for articles, suitable with the deflection element of FIG. 1;
FIG. 13 is a detail view showing holders for articles using alligator clips; and
FIG. 14 is a top view of an essentially cylindrical deflection surface showing, in highly schematic form, different articles retained on the holders in the apparatus.
The various Figures utilize identical reference numerals for similar components and, if the elements have similar function but are structurally different, they will be given prime, double prime, etc. notation.
DETAILED DESCRIPTION
Referring first to FIG. 1: A motor 1 is connected via a drive belt 2 to a shaft 3 of a turret 4. A cylindrical body 5, the surface of which forms a deflection surface for a flame--to be described below--is secured to the turret 4 such that the axis 6 of the body 5 is congruent with the axis of rotation 3.
The deflection body 5 is a thin-walled hollow cylinder made of special steel, which is expanded, in tulip form, at its free end 7, so that the outer contour or surface 8 of the body 5 has a concave profile with respect to the flame 9 projected from a burner, e.g. a gas burner, to which, additionally, a silicon containing substance can be added--as known, and as described in greater detail in the referenced application.
A plurality of holders 11 having support arms 12 are secured to the cylindrical body 5, projecting from the outer circumference of the surface 8 and being angled upwardly, as seen at 13, to retain samples, for example dental prosthesis element 15, thereon. The upward angling of the holders 12, as shown at 13, extends approximately at right angles to the surface 8, and upwardly towards the concave surface 14 of the body 5. The portion of the surface behind the articles 15--looked at in the direction of projection of the flame--causes extensive turbulence at the tip 16 of the flame projected from the burner 10--see FIG. 1--so that no disturbing soot deposition from the tip of the flame will occur. The tip portion of the flame is highly diluted, and thus provides a large effective reaction volume for the articles 15 to be coated. This arrangement insures coating of the articles from all sides and on all surfaces, that is, also on the surface which is opposite that of the flame 9 projected by the burner 10, without requiring repositioning of the articles 15 during coating.
Operation: For coating, the various articles 15 are carried, by rotation of the motor 1, past the flame 9 from the burner 10, and thus are cyclically coated. The turret 4 can be used to be flush with the outer circumference of the body 5, or--and as shown in FIG. 1, may form a projecting flange. This projecting flange additionally guides the shape and formation of the flame. An additional flame and air stream guide ring 17 may be placed about the body 5; since this is not a necessary feature, it is shown in broken lines in FIG. 1. Such a guide ring 17 is located, preferably, below the arms 12 and rotates with the body 5. It may be axially adjustable, and for different articles, a plurality of such rings 17, with different outer diameters, may be provided.
In the embodiment of FIG. 1, the axis of rotation 3, and hence the axis 6 of the body 5 extends vertically. In the embodiment of FIG. 2, the axis of rotation 3' of the turret 4' is horizontal, being offset, however, vertically downwardly with respect to the flame 9'. The axis of rotation 3' and the direction of the flame 9 are parallel to each other. In this arrangement, the impingement surface 8' for the flame is formed directly by the turret 4' which is shaped to have a concave circumferential zone 18, in the region of the flame 9. The respective support arms 12' for the samples are carried through the dish-shaped turret, forming simultaneously the impingement body. The support arms 11', 12' are axially shiftable in the direction through the dish-shaped impingement body 5' forming, simultaneously, the turret 4', in the direction of the arrow 20, and can be held in position by set screws 19. This arrangement, in a very simple manner, insures that the spacing of the holders 13' and articles thereon can be readily changed with respect to their distance from the flame and/or the impingement surface 8' of the body 5'. Additionally, the entire turret 4', and hence the impingement body 5', is axially shiftable in the direction of the arrow 21, so that the entire impingement surface together with all the article holders and the articles thereon can be shifted relative to the flame 9', projected from the burner 10'. This dual adjustability of the turret 4' as well as of the support holders 11', 12' permits optimum adjustment of the reaction volume with respect to the articles held in the holders 12', 13'. The holders in FIG. 2 are shown as alligator clips, and will be described below in detail in connection with FIG. 13.
The impingement body 5 of FIG. 1 is cylindrical--except for the flared expansion at the free end 17 thereof. Other shapes are possible. FIG. 3 illustrates a cross-sectional line drawing of an impingement body 5", which has a substantially constricted portion 22 in the region of its free end 7". Only the region 23, adapted for seating on the turret 4, is cylindrical. The constriction is, looked at in vertical direction, non-symmetrical. Above the apex of the constriction, the curvature is tight, and gradually extends towards the base portion 23 of the body 5". The radius of curvature of the contour in the zone behind the position of the articles, both in the embodiment of FIGS. 1 and 3, preferably should be less than 3 cm. This radius r is only showh in FIG. 3 for clarity. A similar radius of less than 3 cm is preferred for the region 18 of the impingement surface 14' of the body 5' of FIG. 2.
The constriction 22 can extend rotation-symmetrically about the longitudinal axis 6".
Embodiment of FIG. 4: The impingement bodies shown in FIGS. 1, 2 and 3 may, additionally, be formed with niches or depressions. In the embodiments of FIGS. 1 and 3, the depressions or niches 24 may be formed as cylindrically extending depressions, that is, depressions extending parallel to the cylinder axis 6, 6"--see FIG. 4. The number of these niches and depressions 24 will correspond to the number of the holders 11,12 for the articles to be coated. The radius of curvature 25, preferably, should be less than about 5 cm. The niches 24 additionally increase the turbulence of the tip of the flame. An essentially cylindrical impingement body 5"' (FIG. 4) can be used, however, only for individual articles to be coated, e.g. for metallic support elements for dental crowns. Dental prosthesis parts for which more than one holder is necessary are preferably used with impingement bodies which have uniformly extending rotational surfaces, cylindrical or formed with constrictions 22, and which provide for uniform turbulence of the flame extending over the circumference of the respective impingement body 5', 5", 5"'.
Heat may accumulate within the zone of reaction; excessive heat may interfere with appropriate reaction, and heat exchange is enhanced by providing the impingement body 5, 5', 5" with escape openings for heat, by heat convection, particularly at the curved upper portion thereof. Such heat exit openings may be formed by cooling slits 26, extending, for example, in the direction of the axes (6, 6") of the cylinders. The width of the slits 26 preferably is less than 1 mm. Such slits 26 are shown at FIG. 5. FIG. 6 illustrates another embodiment in which the respective impingement body is formed as a mesh-like wire fabric 28 having exit openings 27 of comparable dimensions, that is, smaller than 1 mm. The textile mesh 27 forms, simultaneously, the impingement surface of the impingement body in the respective region. The operation of the wire mesh, then, will be similar to that of the Davy Miner's Safety Lamp. Of course, the cooling slits 26, or the equivalent, the wire mesh 28 may also be used with the impingement body 5' of FIG. 2.
Holder arrangements, with reference to FIGS. 7-14
Various types of holders may be used in combination with the essentially cylindrical impingement body (FIGS. 1, 3, 4) or the impingement dish (FIG. 2); the respective holders each have their specific applications and advantages.
FIG. 7 illustrates a holder passing through the impingement surface--which may be the cylindrical element of FIGS. 1, 3, 4, or the dish of FIG. 2--having two carrier arms 29, 30 made of thin wire, with angled-off ends 31 extending towards the concave impingement surface 18, and connected at the ends of the angled-off portion. The two carrier wires 29, 30 are guided through respective bores 32 in the wall of the impingement body. They are mechanically stressed with respect to each other. The can be shifted in direction of the double arrow 33, by frictional engagement in the respective holes. The holder is simple, easily adjusted, and highly reliable.
The angle of the upwardly extending portion 31, illustrated at 34, can be changed, for acceptance of various types of articles, by relatively shifting the wires 29, 30, with respect to each other, preferably, and to prevent escape of the wires, the terminal ends of the wires 29, 30 are bent, as shown with respect to wire 30 at 35. The bent portion 35 insures seating of the holder within the impingement body. Yet, it permits removal of the entire holder from the impingement body by slightly downwardly tipping the wire 30 and threading the impingement body outwardly if positive removal is desired; yet, the holder is secured with respect to undesired removal.
FIG. 8 illustrates a modification of the arrangement of FIG. 7, in which the wires 29', 30' are separate elements which can be connected by an additional holding spring, for example a small spiral spring, to form a clamping combination, in that the two wires 29', 30' can be clamped towards each other at the bent-over portion 31'. The wire 30' is prevented from undesired removal by the bent-over portion 35'.
Various other types of holders may be used, for example single-wire holders 12 illustrated in FIG. 9. The single wires are located diametrically opposite each other and retained in a common clamp 37, located within the cylindrical impingement body 5, and, preferably, at the central axis 6 thereof. The holder arms 12 may be retained in the clamp by springs or by friction and permit shifting in the direction of the double arrow 38, individually, with respect to each other. The clamp 37 may be a sheet metal spring or spring strip, bent into V or U shape, having a flat portion 38a (FIG. 10) and two upstanding legs 39. The legs 39 are formed with bores 40 through which the wires 12 can pass. By slight compression of the legs 39, the wires 12 can be shifted in the direction of the arrow 38 (FIG. 9) and, upon release of the legs 39, the springs will be reliably held in position. The clamp 37 can be held by attachment in an opening 41 within the cylindrical body 5, or can be secured to another base structure on the turret.
A plurality of clamps 37 can be located above each other connected, for example, to form a single holder unit, as seen in FIG. 11. Each one of the clamps can be individually adjusted for individual placement of the holder arms 12. This arrangement is particularly suitable for a body as shown in FIG. 4.
FIG. 12 illustrates another arrangement to attach holders on a separate holder support 42. The holder support 42 may be a circumferential spider, arranged with openings to receive holder wires, similar to the holder wires 29, 30 or 29', 30' of FIGS. 7 and 8.
For some apparatus, holders using alligator clips 43 are desirable--see FIG. 13. The alligator clips 43 are located at the end of support arms 44 secured, for example, to the respective support body 5, 5', 5". A ball joint 45 which, preferably, can be clamped by means of a set screw, as well known (not shown in FIG. 13), permits universal placement of the alligator clips 43. Alternatively, the clips 43 can be directly attached to the wall of the impingement body 5, 5', 5", 5"', preferably using a ball joint.
FIG. 14 illustrates a holder arrangement for various types of articles to be coated. Large articles 15, for example for dental bridges or the like, can be clamped in position; if not all of the holders 11 are needed, they can be pushed radially inwardly into the body 5, so that the holders are not exposed to the full force of the direct flame. In such an arrangement, the diameter of the cylindrical body 5 is, preferably, in the order of about 5 cm. This arrangement is particularly suitable for different types of articles 15, 15', 15"'.
The cooling slits 26 (FIG. 5) prevent excessive heat build-up due to the flame, particularly in the end region of the concave surface 18 of the respective bodies 5, 5', 5" . . . A similar effect is obtained by the wire mesh structure of FIG. 6; the mesh width of the structure of FIG. 6 is preferably less than 1 mm; the cooling slits 26 (FIG. 5) should, preferably, not exceed 1 mm in width. The cooling slits should be so located that they are at the upper side of the respective impingement body when subjected to the flame.
Suitable structures for a cylindrical impingement body are hollow cylinders which are upwardly expanded, upwardly constricted with an expansion extension (FIG. 3) and the like; the zone of the constriction preferably is essentially parabolic towards the outer contour.
In accordance with a preferred feature of the invention, the turret is so arranged that various impingement surfaces can be selectively placed thereon. The attachment of the impingement surface to the turret can be in accordance with any well known and suitable construction, for example by a small upwardly extending stepped disk, concentric with the inner diameter of the body 5, 5", for example, with snap-on attachments, a clamping ring, or the like. Alternatively, the turret can be formed with a basic attachment body on which suitably shaped sleeves are placed, which form the actual impingement surfaces. This arrangement is particularly desirable, since the impingement surface is subject to wear, that is, will require eventual replacement due to the exposure to the flame. The turret and/or the impingement body and/or the burner should, preferably, be height-adjustable with respect to each other and, further, be radially adjustable with respect to each other, so that the impingement zone of the flame and the turbulence and reflection and deflection zone of the flame for the flame hydrolysis can be adjusted for optimum results and optimum coating of the articles 15 (FIG. 14).
The depressions or recesses or niches 24 (FIG. 4) increase the turbulence of the tip portion of the flame. These niches may extend axially or may be formed to extend in the shape of radial grooves in the body 5' (FIG. 2). These niches may be formed also as cup-shaped depressions, for example of essentially part-spherical or part-rotational shape or with parabolic-shaped cross section, located in the region behind holders for individual articles. Such depressions or niches can be formed in addition to the concave outer contour of an essentially rotation-symmetrical body 5, 5', 5". The radius of curvature of the depressions, preferably, is less than 5 cm.
The respective articles to be coated should be placed at the optimum spacing to the flame, to obtain optimum volume within the reaction zone. The shape of the holders and the holding arms for the respective articles thus should be adjustable, and holder arms which extend directly from the impingement surface and formed unitary with the impingement surface, are suitable. Such holder arms, secured to the body, can then be placed on the turret as a unit together with the articles to be coated--or which have been coated--so that the articles can be placed on the impingement bodies before being attached to the turret, and removed from the impingement surface, after coating, away from the turret; a plurality of impingement bodies, thus, with the holders thereon may be provided together with a single coating apparatus, to permit loading of the holders on an impingement body while another body is on the turret and coats articles; and unloading coating articles during operation of the coating apparatus with another impingement body. This permits associating the most suitable holder elements with the articles to be coated outside of the coating apparatus. Availability of a plurality of impingement bodies, possibly with different types of holders--see FIGS. 7-13--thus insures rapid and efficient overall coating operation. Alligator clips (FIGS. 2, 13) are particularly suitable, especially when coupled with a ball joint to the respective impingement body, so that the alignment of the articles with respect to the impingement body can be readily adjusted. Holder wires, particularly angled-off holder wires (FIGS. 7, 8, 12) are suitable, especially for smaller articles, and may be used especially for the base structure of a dental crown. Such holders, especially those using two holder arms (FIGS. 7, 8) are simple in construction, easily changed, and highly versatile in application. The two holder arms which extend towards each other with their free ends, and formed, for example, as a thin wire, can be carried through suitable openings or bores in the impingement surface, e.g. through the wire mesh, and by simple sliding of the wires against each other, the spacing from the impingement surface can be changed. The wires, preferably of spring wire, are biassed towards or away from the spacing of the openings, so that they are held by frictional engagement. The elements, converging towards each other, can clamp the articles therebetween.
In some arrangements, the cost of holders--and their replacement, since they are subjected to the flame--justifies a more complex construction. Some holders may be rigidly secured to the turret, and carried through the cylindrical impingement body which, then, is formed with suitable slits 42a (FIG. 12) to permit passage of the holders arms 42 therethrough. This permits replacement of the cylindrical impingement body.
Use of a clamp (FIGS. 10, 11) made of spring sheet steel is particularly simple, especially when located within a hollow cylindrical impingement body 5, 5", 5"'. The arrangement in which two diametrically opposite holder arms are connected by a single clamp improves the stability of both the holder arms as well as of the clamp attachment. The holder arms can be easily shifted by merely compressing the V or U-shaped legs 39 towards each other, thus freeing slightly oversized holes 40 from the wires 12, permitting precise adjustment of the ends of the wires. The clamps can be secured in any suitable manner, for example by an internal spider, by screw connection or the like either to the impingement body or to the turret 4, in accordance with any well known and suitable construction. Of course, dual wires 29, 30 (FIGS. 7, 8) can likewise be attached in this manner.
Various changes and modifications may be made, and features described in connection with any one of the embodiments may be used with any of the others, within the scope of the inventive concept.
For example, the holder 37 (FIG. 9) can be height-adjustable, as schematically indicated by arrow 38b, the openings in the body 5 then being formed with elongated slits 42a (FIG. 12), rather than mere through-bores slightly larger than the holders 12 (FIG. 9), to provide for a greater latitude of adjustment.
|
To improve coating of articles such as dental prostheses by flame hydrolysis, a zone of turbulence is generated at the tip portion of an elongated flame cone by a deflection surface (5, 5') located--with respect to flame projection--beyond holders for the articles and positioned to be impinged by the tip of the flame to be deflected and reflected thereby from the conical form, to cause the flame to swirl about the articles.
| 1
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 60/777,488 filed Feb. 28, 2006, where this provisional application is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a method for improving the recovery of cesium-131 (Cs-131) from barium (Ba). Uses of the Cs-131 purified by the method include cancer research and treatment, such as for use in brachytherapy implant seeds independent of method of fabrication.
[0004] 2. Description of the Related Art
[0005] Radiation therapy (radiotherapy) refers to the treatment of diseases, including primarily the treatment of tumors such as cancer, with radiation. Radiotherapy is used to destroy malignant or unwanted tissue without causing excessive damage to the nearby healthy tissues.
[0006] Ionizing radiation can be used to selectively destroy cancerous cells contained within healthy tissue. Malignant cells are normally more sensitive to radiation than healthy cells. Therefore, by applying radiation of the correct amount over the ideal time period, it is possible to destroy essentially all of the undesired cancer cells while saving or minimizing damage to the healthy tissue. For many decades, localized cancer has often been cured by the application of a carefully determined quantity of ionizing radiation during an appropriate period of time. Various methods have been developed for irradiating cancerous tissue while minimizing damage to the nearby healthy tissue. Such methods include the use of high-energy radiation beams from linear accelerators and other devices designed for use in external beam radiotherapy.
[0007] Another method of radiotherapy comprises brachytherapy. Here, radioactive substances in the form of seeds, needles, wires or catheters are implanted permanently or temporarily directed into/near the cancerous tumor. Historically, radioactive materials used have included radon, radium and iridium-192. More recently, the radioactive isotopes Cs-131, iodine-125 (I-215), and palladium-103 (Pd-103) have been used. Examples are described in U.S. Pat. Nos. 3,351,049; 4,323,055; and 4,784,116.
[0008] During the last 30 years, numerous articles have been published on the use of I-125 and Pd-103 in treating prostate cancer. Despite the demonstrated success in certain regards of I-125 and Pd-103, there are certain disadvantages and limitations in their use. While the total dose can be controlled by the quantity and spacing of the seeds, the dose rate is set by the half-life of the radioisotope (60 days for I-125 and 17 days for Pd-103). For use in faster growing tumors, the radiation should be delivered to the cancerous cells at a faster rate, while simultaneously preserving all of the advantages of using a soft x-ray emitting radioisotope. Such cancers are often found in the brain, lung, pancreas, prostate and other tissues.
[0009] Cesium-131 (Cs-131) is a radionuclide product that is ideally suited for use in brachytherapy (cancer treatment using interstitial implants, i.e., “radioactive seeds”). The short half-life of Cs-131 makes the seeds effective against faster growing tumors such as those found in the brain, lung, and other sites. While prostate cancer is generally considered slower growing, certain prostate cancers are more aggressive and more appropriately treated using an isotope with a shorter half-life such as Cs- 131 . The shorter half-life of Cs-131 is equally effective against the slower growing tumors and thus is applicable for treatment where the aggressiveness of the tumor is not well known in advance (C. I. Armpilia et al., Int. J. Radiat. Oncol. Biol. Phys. 55:378-385 (2003)).
[0010] Cesium-131 is produced by radioactive decay from neutron irradiated naturally occurring Ba-130 (natural Ba comprises about 0.1% Ba-130) or from enriched barium containing additional Ba-130, which captures a neutron, becoming barium-131 (Ba-131). The source of the neutrons can be a nuclear reactor or other neutron generating devices (e.g., neutron generators). Barium-131 then decays with an 11.7-day half-life to cesium-131, which subsequently decays with a 9.7-day half-life to stable xenon-130. Thus, with the decay of Ba-131 comes the buildup of Cs-131. To separate the Cs-131, the barium target is “milked” multiple times over selected intervals such as 7 to 14 days, as Ba-131 decays to Cs-131. With each “milking,” the Curies of Cs-131 present and the gram ratio of Cs to total Ba decreases (less Cs-131 per gram of Ba) until it is not economically of value to continue to “milk the cow” (e.g., after approximately 40 days). The barium “target” can then be returned to the reactor for further irradiation (if sufficient Ba-130 is present) or discarded.
[0011] In order for the Cs-131 product to be useful, the Cs-131 must be exceptionally pure, free from other metal (e.g., barium, calcium, iron, cobalt, etc.) and radioactive ions including Ba-131. A typical radionuclide purity acceptance criteria for Cs-131 is >99.9% Cs-131 and <0.01% Ba-131.
[0012] The objective in producing highly purified Cs-131 from irradiated barium is to completely separate less than 7×10 −7 grams (0.7 μg) of Cs from each gram (1,000,000 μg) of barium “target.” A typical target size may range from several grams to several kilograms of Ba, depending on whether enriched Ba-130 or natural target is used in irradiation (natural Ba comprises about 0.1% Ba-130). Typically, irradiated Ba targets comprise various Ba salts. Most often barium carbonate is used. Because Cs-131 is formed in the BaCO 3 crystal structure during decay of Ba-131, it is assumed that the Ba “target” must first be dissolved to release the very soluble Cs ion.
[0013] As noted above, Cs is a very small fraction (about less than 0.0001%) of the irradiated barium target, and thus it is beneficial to be able to recover the Cs in good yield. This is particularly true where processes for production of Cs-131 from Ba are scaled-up. Current approaches typically involve dissolution of the Ba targets in acid to release Cs +1 ions. Commonly acetic acid is used for dissolution. The dissolution step is followed by precipitation of Ba in the form of a compound with limited solubility in water, while Cs +1 ions remain in solution and thus separated from Ba. Commonly, Ba is precipitated as carbonate using ammonium carbonate (NH 4 ) 2 CO 3 solution as the precipitating reagent. While other carbonates can be used (e.g., Li, Na, etc.), the advantage of using precipitating reagents based on ammonium salts is the ease of separating Cs from ammonium ions.
[0014] Following precipitation, the liquid containing Cs is separated from the barium precipitate by common methods (such as filtering or centrifuging) followed by evaporation to dryness of the acetate or other organic acid salts formed during Cs-131 separation from Ba carbonate. This is then followed by use of dilute acetic acid for dissolution of Cs salts. A disadvantage is that currently the recoveries using such procedures are generally on the order of only 30%-50%. The remaining balance of Cs-131 is associated with an organic, carbonaceous residue formed during evaporation of the filtrate solution containing Cs, ammonium acetate and ammonium carbonate salts. One further disadvantage of the current approaches for using ammonium carbonate solution as a precipitant is the limited solubility of the ammonium carbonate reagent in water (less than 3 moles/L). Limited solubility of the precipitating reagent results in an undesirable increase in the total volume of solution remaining after the Ba precipitation step. Increased solution volume requires larger scale equipment and lengthens the evaporation process. These are particularly problematic for implementation of large scale (>100 g) target processing. In this manner, the disadvantages to the current approach of using ammonium carbonate as the precipitating reagent are associated with the formation of a carbonaceous residue during the evaporation of ammonium acetate and the limited solubility of this reagent in water.
[0015] Due to the need for better Cs-131 recoveries and the deficiencies in the current approaches in the art, there is a need for improved methods. The present invention fulfills this need and further provides other related advantages.
BRIEF SUMMARY OF THE INVENTION
[0016] Briefly stated, the present invention discloses a method for improving the recovery of Cs-131 from Ba. In an embodiment, the method comprises the steps of: (a) dissolving neutron-irradiated barium comprising barium carbonate and Cs-131, in a first solution comprising an acid which reacts with the barium to form a soluble barium salt, whereby the barium and Cs-131 are dissolved in the first solution; (b) precipitating the barium as a carbonate solid, whereby the Cs-131 remains dissolved in the first solution; (c) separating the solids from the solution containing the Cs-131; (d) evaporating the solution containing the Cs-131 to incipient dryness to leave a residue; (e) subjecting the residue to oxidative treatment to yield a digested residue; (f) contacting the digested residue with a solution whereby the Cs-131 goes into the solution; and (g) separating the digested residue from the solution, thereby purifying the Cs-131.
[0017] In an embodiment of the method, step (b) comprises adding the first solution to a second solution comprising ammonium carbonate, under conditions of rate of addition and mixing sufficient to precipitate the barium as a solid, whereby the Cs-131 remains dissolved in the combined solution of the first and second solutions.
[0018] In an embodiment of the method, step (b) comprises adding a second solution comprising aqueous ammonia to the first solution and adding CO 2 as a gas or solid to the combined solution of the first and second solutions under conditions of rate of addition and mixing sufficient to precipitate the barium as a solid, whereby the Cs-131 remains dissolved in the combined solution of the first and second solutions.
[0019] In an embodiment of the method, step (b) comprises adding ammonia gas and CO 2 as a gas or solid to the first solution under conditions of rate of addition and mixing sufficient to precipitate the barium as a solid, whereby the Cs-131 remains dissolved in the first solution.
[0020] In an embodiment of the method, after step (c), steam is delivered to the solution under conditions sufficient to distill volatile ammonium salts from the solution.
[0021] In an embodiment of the method, the separated solids of step (c) are subjected to the steps of: (i) storing the solids to allow additional Cs-131 to form from decay of Ba-131; and (ii) repeating steps (a)-(g) as set forth above.
[0022] In an embodiment of the method, the temperature during the end of evaporation step (d) is less than 250° C.
[0023] In an embodiment of the method, the oxidative treatment of step (e) comprises thermal ashing, followed by digestion of the residue using an oxidizing chemical agent to yield a digested residue.
[0024] In an embodiment of the method, thermal ashing comprises thermal treatment in the presence of an oxidizing environment at temperatures between 250° C.-1000° C.
[0025] In an embodiment of the method, the oxidizing chemical agent is selected from one or more of hot concentrated nitric acid, hot concentrated sulfuric acid, a peroxidisulfate salt, a cerium (IV) compound and a Cr (VI) compound.
[0026] In an embodiment of the method, the acid of step (a) is acetic acid.
[0027] In an embodiment of the method, the acid of step (a) is nitric acid.
[0028] In an embodiment of the method, the solution of step (f) comprises water, acid or base.
[0029] In an embodiment of the method, steps (a) through (g) are repeated on one or more additional neutron-irradiated barium targets and the purified Cs-131 of step (g) and repeated step (g) are combined.
[0030] In an embodiment of the method, prior to step (c), the first solution containing the solid of step (b) is subjected to heat with stirring for a time and temperature sufficient to digest the solid, cooled to room temperature to permit a solid to precipitate, and subjected to step (c).
[0031] In an embodiment of the method, prior to step (d), the solids separated in step (c) are washed with water and the wash solution combined with the solution of step (c) containing the Cs-131.
[0032] The present invention provides purified Cs-131 comprising Cs-131 prepared by a method of the present invention.
[0033] The present invention provides a radioactive brachytherapy implant substance comprising a brachytherapy implant substance containing Cs- 131 prepared by a method of the present invention.
[0034] These and other aspects of the present invention will become apparent upon reference to the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The present invention provides a method for purifying Cs-131 that improves the recovery of Cs-131 from barium carbonate. The barium carbonate may be irradiated target material or a precipitated form of barium. The method is efficient and economical for large scale commercial production of Cs-131. Cesium-131 recoveries using the present invention are on the order of at least 70%-90% (typically in excess of 85%).
[0036] Neutron irradiation of a barium target to produce Ba-131, which then decays to Cs-131, is well known to one in the art (e.g., Harper, P. V. et al., Proceedings of the International Conference on the Peaceful Uses of Atomic Energy, 2 nd, Geneva, Switzerland, 1958, pp. 417-422). The irradiated Ba target comprising barium carbonate and Cs-131 is then dissolved in a solution comprising an acid in order to dissolve the barium and Cs-131. The acid possesses the ability to react with the barium to form a soluble barium salt. Such acids are well known to one in the art, and include, for example, acetic acid, formic acid and nitric acid. It may be desirable that the acid additionally forms readily decomposable ammonium salts. The above listed acids possess this property as well.
[0037] The barium in the solution (with dissolved barium and Cs-131) is precipitated as a carbonate solid, and the Cs-131 remains dissolved in the solution. In one embodiment, the solution with dissolved barium and Cs-131 is then added to a second solution comprising ammonium carbonate under conditions sufficient to precipitate the barium as a solid (e.g., U.S. Application Publication No. US-2006-0024223-A1). The Cs-131 remains dissolved in the combined solution. In another embodiment, a second solution comprising an aqueous solution of ammonia is added to the first solution and CO 2 as a gas or solid is delivered through the mixed solution under conditions sufficient to precipitate the barium as barium carbonate solid, while the Cs-131 remains dissolved. In yet another embodiment of this invention, ammonia gas and CO 2 as a gas or solid are delivered to the solution such that Ba is precipitated as carbonate solid, while Cs-131 remains in solution. The CO 2 may be added to the solution after the ammonia gas is delivered. Alternatively, the ammonia gas and the CO 2 are added simultaneously to the solution.
[0038] The solids produced by any of the embodiments are separated from the solution containing the Cs-131 by techniques well known to one in the art (e.g., U.S. Application Publication No. US-2006-0024223-A1), including by filtration, centrifuging or decanting. Prior to separating the solids from the solution, the solution may be subjected to heat with stirring for a time and temperature sufficient to digest the solids, cooled to room temperature to permit solids to precipitate, and then subjected to the separation step. After the separation step, the solids may be washed one or more times with water and the wash solutions combined with the solution containing the Cs-131 from the separation step. The solids containing the barium are typically stored to allow additional Cs-131 to form from further decay of Ba-131. The solids may then be processed again, as just described for the initial processing of the irradiated Ba target.
[0039] The Cs-131 remains dissolved in the solution from which the barium is precipitated and removed. As described above, evaporation has been used to remove substances in the solution (such as ammonium acetate salts) that are capable of volatilization. The evaporation must be carried out at sufficiently high temperature to enable rapid volatilization. It may be desirable to deliver steam to the solution prior to or during (e.g., at the beginning of) the evaporation step for a period of time so that volatile ammonium salts such as ammonium acetate and organic impurities are volatilized prior to taking the solution to incipient dryness, thus minimizing the amount of carbonaceous (organic) material formed. The evaporation step results in formation of an organic carbonaceous residue. The organic residue material was found to hold a significant amount of Cs-131 which could not be released when the organic residue was treated with mineral acids, acetic acid, ammonia or ammonium acetate. The present invention addresses the problem of poor recovery of Cs-131 from the residue obtained by evaporation of the acetate or other organic acid salts formed during Cs-131 separation from barium carbonate.
[0040] In the present invention, oxidative treatment of the organic residue material using thermal ashing or chemical ashing or both, results in conversion of the organic residue to carbon-like material in a form that allows recovery of the Cs-131 by washing with water or dilute mineral or organic acids. By use of an oxidative treatment step, chemical recovery of the Cs-131 is 70%-90%. Thus, by converting the organic residue to a form from which Cs-131 can be effectively recovered by leaching or washing with an aqueous solution, as much as about a 50% increase in the recovery of Cs-131 may be achieved.
[0041] In embodiments of the present invention, the combined solution containing the Cs-131 (from which the solids containing barium have been separated) is processed as follows. The evaporation (with or without prior or simultaneous steam treatment) of the combined solution containing the Cs-131 is carried out to incipient dryness. In an embodiment, the evaporation step is carried out at controlled temperatures to minimize formation of the organic residue. For example, the temperature during the end of the evaporation step is less than 250° C. It is preferred that heating is carried in a manner that precludes condensation of the volatilized solids on the walls of the vessel (i.e., through uniform heating of the evaporation vessel).
[0042] In an embodiment, the residue formed after evaporation of volatile salts is thermally treated in an oxidizing environment (such as air) at temperatures between about 250° C.-1000° C. to convert organic material to ash or carbon. For example, the temperature for thermal oxidative treatment is between 400° C. and 500° C. The time period for oxidative treatment is typically between about 1 and 24 hours. Alternatively, or in combination with thermal oxidation, the digestion of the organic residue may be carried out by using an oxidizing chemical agent or combinations of such agents. Examples of chemical oxidants that may be used alone or in combination include hot concentrated nitric acid, hot concentrated sulfuric acid, peroxidisulfate salts, cerium (IV) compounds and Cr (VI) compounds. A specific example includes addition of 10 mL of 96% sulfuric acid to the residue and heating the vessel to 300° C. until all the sulfuric acid is volatilized. Based on the disclosure provided herein, it will be evident to one in the art that other chemical oxidants and combinations of oxidants are possible. The chemical digestion process may be carried out at elevated temperature, for example, using resistive or microwave heating in open or closed digestion vessels.
[0043] Following the oxidative treatment, the Cs-131 may be recovered in a variety of ways. For example, any remaining organic residue may be contacted with an aqueous solution. Aqueous solutions include water, acids or bases (e.g., dilute acids or dilute bases). Cesium-131 in the residue will go into the aqueous solution. The residue is separated from the aqueous solution, thereby purifying the Cs-131. The separation may be accomplished by a variety of means. For example, the residue may be removed from the solution by filtration.
[0044] The following is an example of chemical oxidative treatment. In this example, the oxidative treatment is performed using a combination of sulfuric acid and nitric acid. Neutron-irradiated Ba carbonate (1800 g) is processed using acetic acid dissolution. The Ba is precipitated using ammonium carbonate. The solution is separated from the precipitate, and is evaporated to incipient dryness to leave an organic residue. The organic residue is treated with sulfuric acid (1-5 ml) and nitric acid (5-10 ml). Digestion is carried out under conditions that minimize vapor loss. Following a digestion period of 1 to 3 hours, the solution is taken to incipient dryness until complete evaporation of sulfuric acid is achieved. Alternatively for digestion, sulfuric acid may be added to the organic residue in an amount sufficient to wet the residue, digested for several hours under conditions that minimize vapor loss and then the residue is taken to incipient dryness. Following the oxidative treatment (by either the combination of sulfuric acid and nitric acid, or sulfuric acid alone), the Cs-131 is recovered by washing any remaining residue with water, acids or bases (e.g., dilute acids or dilute bases). The digested residue is separated from the Cs-131 containing solution by filtration. Chemical recoveries of Cs-131 are typically in excess of 85%.
[0045] As used herein, the term “separating” two things (e.g., solids and solution, or residue and solution) may refer to the removal of the first from the second, or the second from the first, or the removal of both simultaneously. For example, “separating the Cs- 131 ” may mean removing the Cs-131 from the irradiated barium target, or removing the irradiated barium target from the Cs-131, or removal of both simultaneously. In addition, as used herein, the irradiated barium target may have been partially purified prior to separating the Cs-131.
[0046] Procedures for separating Cs-131 from irradiated barium targets are well known in the art (e.g., U.S. Pat. No. 6,066,302). For example, chemical separation steps can be utilized to isolate Cs-131 from the target material and radioactive impurities that may have been produced in the target material. The solution containing the Cs-131 may also have chemical and radioactive impurities that were present in the irradiated target or that were introduced during processing. Examples of such impurities are cerium (Ce) or chromium (Cr) ions. Separation techniques include precipitation, sorption, extraction, solid phase extraction, ion exchange and combinations thereof. In an embodiment of precipitation, the impurities are precipitated while Cs remains in solution. Examples of precipitates are Fe(OH) 3 , BaCO 3 or BaSO 4 . In an embodiment of precipitation, the Cs is precipitated while the impurities remain in solution. Examples of precipitating reagents that selectively remove Cs leaving the impurities in solution are ammonium molybdophosphate or cyannoferrates. In an embodiment of extraction, the solution is treated with a solvent which is an extractant with affinities for a broad group of metal ions with the exception of the alkali group elements, including Cs. Thus impurities are solvent extracted while Cs remains in solution. An example is the organiphosphoric liquid cation exchanger extractant di(2-ethylhexyl)orthophosphoric acid (HDEHP). In an embodiment of extraction, Cs is extracted into an organic solvent, while the impurities remain in the aqueous phase. Examples of organic solvents include phenols and crown ethers, such as mono- or bis-crown-6 ethers, and crown ether derivatives of calix[4]-arenes. In embodiments of solid phase extraction, extractants are immobilized onto solid supports and may be deployed as packing in columns. As described above, the extractant may have affinity for Cs (so that the impurities remain in solution) or for impurities (so that the Cs remains in solution). In an embodiment of ion exchange, the ion exchange media (which may be used in a column) selectively retains impurities but not Cs. Examples of suitable ion exchange media include chelating resins with suitable functionality such as iminodiacetate (e.g., Chelex 100 from Sigma Aldrich) or similar media. In an embodiment of ion exchange, both Cs and impurities are retained by the ion exchange media (which may be used in a column); however, impurities are preferentially eluted using a complexant. Examples of suitable complexants include EDTA or oxalates. Examples of cation exchange resins include conventional cation exchange resins with sulfonic acid functionalities.
[0047] One or more neutron-irradiated barium targets may be similarly processed (as described in the steps above) and the additional purified Cs-131 may be combined with the purified Cs-131 obtained from initial processing of a more recently irradiated Ba target.
[0048] As described above, Cs-131 is useful for example for radiotherapy (such as to treat malignancies). Where it is desired to implant a radioactive substance (e.g., Cs-131) into/near a tumor for therapy (brachytherapy), Cs-131 may be used as part of the fabrication of brachytherapy implant substance (e.g., a seed). A brachytherapy implant substance containing Cs-131 may be incorporated into a device. The use of Cs-131 in brachytherapy implant substances is not dependent on the method of fabrication of the substances. A method of the present invention provides purified Cs-131 for these and other uses.
[0049] The following Examples are offered by way of illustration and not by way of limitation.
EXAMPLE
Cs/BA Separation Procedure
[0050] Dissolve 1500 g of irradiated BaCO 3 in 3.7 liters of water using 20 moles of glacial acetic acid (17.4 M). Perform addition of the acetic acid slowly to minimize foaming. Provide gentle heat and stirring to speed the dissolution process.
[0051] Slowly add solution to 7.3 liters of saturated ammonium carbonate solution. Provide stirring to allow barium carbonate precipitate to form.
[0052] Heat the precipitate to near boiling temperature for 2 hours with stirring to digest the precipitate.
[0053] Cool the mixture to room temperature.
[0054] Filter the precipitate and rinse the solids twice with 1 liter of water.
[0055] Combine the filtrate and wash solutions (˜14.1 liters) and evaporate to incipient dryness.
[0056] Digest carbonaceous residue at 500° C. for 2 hours. Allow to cool to ambient temperature.
[0057] Add 20 mL of 96% sulfuric acid. Heat to 300° C. until the acid is volatilized and no further evolution of white fumes is evident.
[0058] Cool to room temperature.
[0059] Add two portions of 50 mL of water, stir and filter the precipitate.
[0060] Combine the filtrate and evaporate to dryness in a suitable container. Chemical recovery of Cs-131 is approximately 90%. The Cs-131 product contains no detectable Ba-131.
[0061] All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety.
[0062] From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
|
The present invention provides a method for improving the recovery of cesium-131 (Cs-131) from barium (Ba) carbonate. Uses of the Cs-131 purified by the method include cancer research and treatment, such as for the use in brachytherapy. Cesium-131 is particularly useful in the treatment of faster growing tumors.
| 2
|
THE FIELD OF THE INVENTION
The present invention relates to printers and to ink supplies for printers. More particularly, the invention relates to a pressure ink level sensing system including a digital compensation system for an ink supply.
BACKGROUND OF THE INVENTION
The art of inkjet technology is relatively well developed. Commercial products such as computer printers, graphics plotters, and facsimile machines have been implemented with inkjet technology for producing printed media. Generally, an inkjet image is formed pursuant to precise placement on a print medium of ink drops emitted by an ink drop generating device known as an inkjet printhead assembly. An inkjet printhead assembly includes at least one printhead. Typically, an inkjet printhead assembly is supported on a movable carriage that traverses over the surface of the print medium and is controlled to eject drops of ink at appropriate times pursuant to command of a microcomputer or other controller, wherein the timing of the application of the ink drops is intended to correspond to a pattern of pixels of the image being printed.
Inkjet printers have at least one ink supply. An ink supply includes an ink container having an ink reservoir. The ink supply can be housed together with the inkjet printhead assembly in an inkjet cartridge or pen, or can be housed separately. When the ink supply is housed separately from the inkjet printhead assembly, users can replace the ink supply without replacing the inkjet printhead assembly. The inkjet printhead assembly is then replaced at or near the end of the printhead life, and not when the ink supply is replaced.
For some hard copy applications, such as large format plotting of engineering drawings and the like, there is a requirement for the use of much larger volumes of ink than can be contained within inkjet cartridges housing an inkjet printhead assembly and an ink supply. Therefore, relatively large, separately-housed ink supplies have been developed.
In an inkjet device, it is desirable to know the level of the ink supply so that the inkjet printhead assembly is not operated in an out-of-ink condition. Otherwise, printhead damage may occur as a result of firing without ink, and/or time is wasted in operating a printer without achieving a complete printed image, which is particularly time consuming in the printing of large images which often are printed in an unattended manner on expensive media.
Some existing systems provide each ink container with an on-board memory chip to communicate information about the contents of the container. The on-board memory typically stores information such as manufacture date (to ensure that excessively old ink does not damage the print head,) ink color (to prevent misinstallation,) and product identifying codes (to ensure that incompatible or inferior source ink does not enter and damage other printer parts.). Such a chip may also store other information about the ink container, such as ink level information. The ink level information can be transmitted to the printer to indicate the amount of ink remaining. A user can observe the ink level information and anticipate the need for replacing a depleted ink container.
In one prior art ink level sensing (ILS) technique, a coil is positioned on each side of the ink reservoir. One coil acts as a transmitter, and the other coil acts as a receiver. As the ink in the ink reservoir is used up, the reservoir collapses and the coils come closer together. Signal level in the receiver provides a measure of the ink level in the ink reservoir. The coils function as a non-contacting inductive transducer that indirectly senses the amount of ink in the ink reservoir by sensing the separation between the opposing walls of the reservoir. An AC excitation signal is passed through one coil, inducing a voltage in the other coil, with a magnitude that increases as the separation decreases. The change in voltage in the coil results from the change in the mutual inductance of the coils with change in the separation between the coils. The output voltage is readily related to a corresponding ink volume. The use of this ILS technique is relatively expensive, however, and typically results in about 60 cc of stranded ink.
In a second technique, a pressure ink level sensing (P-ILS) system is used to sense ink level. A P-ILS system has the potential advantage of 50% less cost, and typically strands about 50% less ink than the coil ILS technique. However, P-ILS systems require a compensation system to compensate or correct the output of a pressure sensor. Existing compensation systems use resistors or similar means to set compensation values. The resistors are typically laser trimmed or mechanically trimmed to provide the desired compensation values, which is a relatively complex process. In addition, the compensation resistors require space on the integrated assembly, making it more difficult to reduce the size of the assembly
There is a need for a pressure ink level sensing (P-ILS) system that includes a compensation system without the disadvantages of prior compensation systems.
SUMMARY OF THE INVENTION
The present invention provides a printing system that includes an inkjet printhead for selectively depositing ink drops on print media. An ink reservoir stores ink to be provided to the inkjet printhead. An ink level sensing circuit provides an ink level sense output that is indicative of a sensed volume of ink in the ink reservoir. A memory device stores sensor compensation information. A processor responsive to output of the memory device and the ink level sense output generates a compensated ink level sense output. The processor provides an estimate of available ink based on the compensated ink level sense output.
One aspect of the invention is directed to an ink container for an inkjet printing system having an inkjet printhead that selectively deposits ink drops on print media. The ink container includes an ink reservoir for storing ink to be provided to the inkjet printhead. A sensor provides an ink level sense signal that is utilized by a controller. An information storage device stores sensor compensation information that is utilized by the controller to provide a compensated ink level sense signal.
Another aspect of the invention is directed to a method for determining an amount of ink remaining in an ink container installed in a printing system having an inkjet printhead for receiving ink from the ink container and selectively depositing ink drops on print media. An ink level sense signal is provided that is indicative of a sensed volume of ink in the ink container. Digital compensation values are also provided. Compensated ink level sense values are generated based on the ink level sense signal and the digital compensation values. The amount of ink remaining in the ink container is calculated based on the compensated ink level sense values.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a block diagram of a printer/plotter system in which the present invention can be incorporated.
FIG. 2 illustrates a block diagram depicting major components of one of the print cartridges of the printer/plotter system of FIG. 1 .
FIG. 3 illustrates a block diagram depicting major components of one of the ink containers of the printer/plotter system of FIG. 1 .
FIG. 4 illustrates a simplified isometric view of an implementation of the printer/plotter system of FIG. 1 .
FIG. 5 illustrates a typical pressure sensor output, showing offset and non-linear response characteristics.
FIG. 6 illustrates a P-ILS system with an analog compensation system.
FIG. 7 illustrates a preferred P-ILS system according to the present invention, with a digital compensation system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
The P-ILS system of the present invention will be discussed in the context of a printer/plotter with an ink supply housed separately from an inkjet printhead assembly. However, it will be understood by those of ordinary skill in the art that the techniques described herein are also applicable to other devices employing inkjet technology with ink supplies housed either separately from or together with inkjet printhead assemblies, including, but not limited to, computer printers and facsimile machines.
FIG. 1 illustrates a block diagram of a printer/plotter 50 in which the present invention can be employed. Such a printer/plotter is described in commonly-assigned U.S. Pat. No. 6,151,039 to Hmelar, which is hereby incorporated by reference. The Hmelar patent also discloses a technique for ink level estimation using an ink level sensor. In one embodiment, the ink level sensor in Hmelar is a two-coil sensor, which was described above in the Background of the Invention section.
As shown in FIG. 1, a scanning print carriage 52 holds a plurality of printer cartridges 60 - 66 , which are fluidically coupled to an ink supply station 100 that supplies pressurized ink to printer cartridges 60 - 66 . In one embodiment, each of the cartridges 60 - 66 comprises an inkjet printhead and an integral printhead memory, as schematically depicted in FIG. 2 . As shown in FIG. 2, printer cartridge 60 includes an inkjet printhead 60 A and an integral printhead memory 60 B. The ink provided to each of the cartridges 60 - 66 is pressurized to reduce the effects of dynamic pressure drops.
Ink supply station 100 contains receptacles or bays for accepting ink containers 110 - 116 , which are respectively associated with and fluidically connected to respective printer cartridges 60 - 66 . Each of the ink containers 110 - 116 includes a collapsible ink reservoir, such as collapsible ink reservoir 110 A that is surrounded by an air pressure chamber 110 B. An air pressure source or pump 70 is in communication with air pressure chamber 110 B for pressurizing the collapsible ink reservoir 110 A. In one embodiment, one pressure pump 70 supplies pressurized air for all ink containers 110 - 116 in the system. Pressurized ink is delivered to the printer cartridges 60 - 66 by an ink flow path that includes, in one embodiment, respective flexible plastic tubes connected between the ink containers 110 - 116 and respectively associated printer cartridges 60 - 66 .
In one embodiment, each of the ink containers 110 - 116 comprises an ink reservoir 110 A, an ink level sensor 110 C, and an integral ink cartridge memory 110 D, as schematically depicted in FIG. 3 for ink container 110 .
Referring again to FIG. 1, scanning print carriage 52 , printer cartridges 60 - 66 , and ink containers 110 - 116 are electrically interconnected to printer microprocessor controller 80 . Controller 80 includes printer electronics and firmware for the control of various printer functions, including analog-to-digital (A/D) converter circuitry for converting the outputs of the ink level sensing circuits 110 C of ink containers 110 - 116 . In one embodiment, each one of the ink containers 110 - 116 includes its own A/D converter for converting the output of ink level sensing circuit 110 C to digital values. Controller 80 controls the scan carriage drive system and the printheads on the print carriage to selectively energize the printheads, to cause ink droplets to be ejected in a controlled fashion on the print media 40 . Printer controller 80 further estimates remaining ink volume in each of the ink containers 110 - 116 , as described more fully herein.
A host processor 82 , which includes a CPU 82 A and a software printer driver 82 B, is connected to printer controller 80 . In one embodiment, host processor 82 comprises a personal computer that is external to printer 50 . A monitor 84 is connected to host processor 82 , and is used to display various messages that are indicative of the state of the inkjet printer. Alternatively, the printer can be configured for stand-alone or networked operation wherein messages are displayed on a front panel of the printer.
FIG. 4 shows in isometric view of a large format printer/plotter 120 in which the present invention can be employed. Printer/plotter 120 includes four off-carriage ink containers 110 , 112 , 114 , 116 , which are shown positioned in an ink supply station 100 . The printer/plotter 120 of FIG. 4 further includes a housing 54 , a front control panel 56 , which provides user control switches, and a media output slot 58 . While this exemplary printer/plotter 120 is fed from a media roll, it should be appreciated that alternative sheet feed mechanisms can also be used.
Ink level sensor 110 C (shown in FIG. 3) is a preferably a pressure ink level sensor (P-ILS). In one embodiment, ink level sensor 110 C uses a piezo-resistive strain gauge bridge to measure pressure. Such bridges, while low-cost and reliable, require compensation to produce a desired output. The compensation processes typically include offset correction, slope or gain adjustment, linearization correction, and temperature compensation.
FIG. 5 illustrates a typical pressure sensor output 508 showing offset 514 and non-linear response characteristics. Compensation is used to produce a linear response, so that a given output voltage from ink level sensor 110 C can be related to a predictable pressure value. FIG. 5 shows two examples of linearization approximations, which are a “Best Straight Line Fit” approximation represented by line 510 and a “Straight Line Fit” approximation represented by broken line 512 .
Pressure sensor compensation has previously been accomplished by an analog compensation system as shown in FIG. 6 . P-ILS system 600 includes strain gauge bridge 602 , differential amplifier 604 , electronic correction system 606 , and analog-to-digital (A/D) converter 608 . The pressure applied to strain gauge 602 produces a differential output that is amplified by differential amplifier 604 . The output from amplifier 604 is provided to electronic correction system 606 . Electronic correction system 606 includes corrective inputs for offset, slope or gain, and linearization coefficients. Electronic correction system 606 modifies the uncompensated, amplified output from strain gauge 602 based on the offset, slope and linearization inputs to produce an analog compensated output.
The offset, slope and linearization inputs of correction system 606 are typically implemented using variable resistors. The variable resistors are set mechanically or trimmed automatically with lasers during manufacturing. The compensation resistors are trimmed to appropriate values based on characteristics of the sensor. The compensation resistors are then included as part of the pressure sensor assembly 600 .
The analog compensated output from correction system 606 is converted to digital values by A/D converter 608 for use by printer controller 80 (shown in FIG. 1 ). Each digital value output by A/D converter 608 is proportional to an associated pressure measurement. Printer controller 80 uses the digital values output by A/D converter 608 to estimate the ink level in the associated one of ink containers 110 - 116 .
FIG. 7 illustrates a preferred P-ILS system 700 according to the present invention. Strain gauge bridge 702 and amplifier 704 function the same as described with respect to FIG. 6 . Instead of modifying the amplifier output by a correction system 606 as in I-ILS system 600 , P-ILS system 700 provides the output from amplifier 704 directly to A/D converter 708 . Thus, the digital output produced by A/D converter 708 reflects uncorrected values with all of the offset, gain and non-linearization dependencies typically found in this sensor system.
During manufacture, the offset, gain and non-linearization correction components of P-ILS system 700 are determined based on characteristics of the sensor, just as in the analog system 600 of FIG. 6 . Instead of requiring correction factors to be stored in hardware resistor values, the correction factors of P-ILS system 700 are determined and stored in the associated memory 706 , which is integrated with the P-ILS system 700 . Since memory 706 is an integral part of the ILS system, storing compensation values in memory 706 costs nothing in terms of physical space within the system, as the values are stored along with the traditional values associated with the ink container. In one embodiment, memory 706 is an EEPROM. In one embodiment, selected compensation values are determined and stored in memory 706 after manufacture of the device. As one example, the offset compensation value can be stored in memory 706 after insertion of the ink container in the printer. By storing the compensation values after manufacture of the device, any changes in the sensor characteristics that occur during or after manufacture of the device will be taken into account and corrected by the digital compensation system.
The positioning of memory 706 depends upon the particular printer configuration. In a system where the inkjet printhead assembly and the ink supply are separately housed, such as the system shown in FIG. 1, a memory 706 is preferably positioned with each one of ink containers 110 - 116 (e.g., positioned like memory 110 D shown in FIG. 3 ). In a system where the inkjet printhead assembly and the ink supply are housed together in an inkjet cartridge, memory 706 is positioned with the inkjet cartridge.
In use, printer controller 80 addresses the integrated P-ILS system 700 digitally, and reads the digital output from the P-ILS system 700 and the compensation values stored in memory 706 . Printer controller 80 compensates the digital output from A/D converter 708 using the compensation values obtained from memory 706 , thereby producing a corrected pressure value for each sampled uncompensated pressure value. Printer controller 80 then estimates the ink level in the associated one of ink containers 110 - 116 based on the corrected pressure values. In one embodiment, the calculated ink level is output from printer controller 80 back to memory 706 , where it is stored. Thus, even if the ink container with memory 706 is removed from the printer and put in a second printer, the ink level in the ink container is easily obtainable by the second printer.
The digital compensation system of the present invention provides several advantages over the analog compensation system shown in FIG. 6 . Digital compensation values can be stored in memory 706 easier than analog resistors can be trimmed mechanically or automatically by laser trimmers. The cost of storing digital compensation values in memory 706 is less expensive than using on-board resistors or other on-board compensation components. Further, more elaborate compensation factors (such as a least-squares line fit) do not appreciably increase the cost of compensation.
Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve the same purposes may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. Those with skill in the chemical, mechanical, electro-mechanical, electrical, and computer arts will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the preferred embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
|
A printing system includes an inkjet printhead for selectively depositing ink drops on print media. An ink reservoir stores ink to be provided to the inkjet printhead. An ink level sensing circuit provides an ink level sense output that is indicative of a sensed volume of ink in the ink reservoir. A memory device stores sensor compensation information. A processor responsive to output of the memory device and the ink level sense output generates a compensated ink level sense output. The processor provides an estimate of available ink based on the compensated ink level sense output.
| 1
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to computer systems and methods in which data resources are shared among concurrent data consumers while preserving data integrity and consistency relative to each consumer. More particularly, the invention concerns improvements to a mutual exclusion mechanism known as “read-copy update,” in which lock-free data read operations run concurrently with data update operations.
[0003] 2. Description of the Prior Art
[0004] By way of background, read-copy update is a mutual exclusion technique that permits shared data to be accessed for reading without the use of locks, writes to shared memory, memory barriers, atomic instructions, or other computationally expensive synchronization mechanisms, while still permitting the data to be updated (modify, delete, insert, etc.) concurrently. The technique is well suited to multiprocessor computing environments in which the number of read operations (readers) accessing a shared data set is large in comparison to the number of update operations (updaters), and wherein the overhead cost of employing other mutual exclusion techniques (such as locks) for each read operation would be high. By way of example, a network routing table that is updated at most once every few minutes but searched many thousands of times per second is a case where read-side lock acquisition would be quite burdensome.
[0005] The read-copy update technique implements data updates in two phases. In the first (initial update) phase, the actual data update is carried out in a manner that temporarily preserves two views of the data being updated. One view is the old (pre-update) data state that is maintained for the benefit of operations that may be currently referencing the data. The other view is the new (post-update) data state that is available for the benefit of operations that access the data following the update. In the second (deferred update) phase, the old data state is removed following a “grace period” that is long enough to ensure that all executing operations will no longer maintain references to the pre-update data.
[0006] FIGS. 1A-1D illustrate the use of read-copy update to modify a data element B in a group of data elements A, B and C. The data elements A, B, and C are arranged in a singly-linked list that is traversed in acyclic fashion, with each element containing a pointer to a next element in the list (or a NULL pointer for the last element) in addition to storing some item of data. A global pointer (not shown) is assumed to point to data element A, the first member of the list. Persons skilled in the art will appreciate that the data elements A, B and C can be implemented using any of a variety of conventional programming constructs, including but not limited to, data structures defined by C-language “struct” variables.
[0007] It is assumed that the data element list of FIGS. 1A-1D is traversed (without locking) by multiple concurrent readers and occasionally updated by updaters that delete, insert or modify data elements in the list. In FIG. 1A , the data element B is being referenced by a reader r 1 , as shown by the vertical arrow below the data element. In FIG. 1B , an updater u 1 wishes to update the linked list by modifying data element B. Instead of simply updating this data element without regard to the fact that r 1 is referencing it (which might crash r 1 ), u 1 preserves B while generating an updated version thereof (shown in FIG. 1C as data element B′) and inserting it into the linked list. This is done by u 1 acquiring a spinlock, allocating new memory for B′, copying the contents of B to B′, modifying B′ as needed, updating the pointer from A to B so that it points to B′, and releasing the spinlock. All subsequent (post update) readers that traverse the linked list, such as the reader r 2 , will thus see the effect of the update operation by encountering B′. On the other hand, the old reader r 1 will be unaffected because the original version of B and its pointer to C are retained. Although r 1 will now be reading stale data, there are many cases where this can be tolerated, such as when data elements track the state of components external to the computer system (e.g., network connectivity) and must tolerate old data because of communication delays.
[0008] At some subsequent time following the update, r 1 will have continued its traversal of the linked list and moved its reference off of B. In addition, there will be a time at which no other reader process is entitled to access B. It is at this point, representing expiration of the grace period referred to above, that u 1 can free B, as shown in FIG. 1D .
[0009] FIGS. 2A-2C illustrate the use of read-copy update to delete a data element B in a singly-linked list of data elements A, B and C. As shown in FIG. 2A , a reader r 1 is assumed be currently referencing B and an updater u 1 wishes to delete B. As shown in FIG. 2B , the updater u 1 updates the pointer from A to B so that A now points to C. In this way, r 1 is not disturbed but a subsequent reader r 2 sees the effect of the deletion. As shown in FIG. 2C , r 1 will subsequently move its reference off of B, allowing B to be freed following expiration of the grace period.
[0010] In the context of the read-copy update mechanism, a grace period represents the point at which all running processes having access to a data element guarded by read-copy update have passed through a “quiescent state” in which they can no longer maintain references to the data element, assert locks thereon, or make any assumptions about data element state. By convention, for operating system kernel code paths, a context (process) switch, an idle loop, and user mode execution all represent quiescent states for any given CPU (as can other operations that will not be listed here).
[0011] In FIG. 3 , four processes 0 , 1 , 2 , and 3 running on four separate CPUs are shown to pass periodically through quiescent states (represented by the double vertical bars). The grace period (shown by the dotted vertical lines) encompasses the time frame in which all four processes have passed through one quiescent state. If the four processes 0 , 1 , 2 , and 3 were reader processes traversing the linked lists of FIGS. 1A-1D or FIGS. 2A-2C , none of these processes having reference to the old data element B prior to the grace period could maintain a reference thereto following the grace period. All post grace period searches conducted by these processes would bypass B by following the links inserted by the updater.
[0012] There are various methods that may be used to implement a deferred data update following a grace period, including but not limited to the use of callback processing as described in commonly assigned U.S. Pat. No. 5,727,209, entitled “Apparatus And Method For Achieving Reduced Overhead Mutual-Exclusion And Maintaining Coherency In A Multiprocessor System Utilizing Execution History And Thread Monitoring.” The contents of U.S. Pat. No. 5,727,209 are hereby incorporated herein by this reference.
[0013] The callback processing technique contemplates that an updater of a shared data element will perform the initial (first phase) data update operation that creates the new view of the data being updated, and then specify a callback function for performing the deferred (second phase) data update operation that removes the old view of the data being updated. The updater will register the callback function (hereinafter referred to as a “callback”) with a read-copy update subsystem so that it can be executed at the end of the grace period. The read-copy update subsystem keeps track of pending callbacks for each processor and monitors per-processor quiescent state activity in order to detect when each processor's current grace period has expired. As each grace period expires, all scheduled callbacks that are ripe for processing are executed.
[0014] The successful implementation of read-copy update requires efficient mechanisms for deducing the length of a grace period. One important class of implementations passes a grace period token from one processor to the next to signify that the end of a grace period has been reached for the processor owning the token. The grace period token can be a distinguished value that is expressly passed between processors. However, two memory write accesses are required when using this technique—one to remove the token from its current owner and another to pass the token to its new owner. A more efficient way of handling the grace period token is to pass it implicitly using per-processor quiescent state counters and associated polling mechanisms. According to this technique, whenever a processor passes through a quiescent state, its polling mechanism inspects the quiescent state counter of a neighboring processor to see if the neighbor's counter has changed since the current processor's last grace period. If it has, the current processor determines that a new grace period has elapsed since it last had the token. It executes its pending callbacks and then changes its quiescent state counter to an incrementally higher value than that of its neighbor. The next processor then sees this processor's changed counter value, processes its pending callbacks, and increments its own counter. This sequence continues, with the grace period token ultimately making its way through all of the processors in round-robin fashion.
[0015] Regardless of how the grace period token is implemented, each processor only processes callbacks when it receives the token. Insofar as the grace period token must travel through all other processors before reaching the processor that is the current holder, the current processor is always guaranteed that the other processors have passed through a quiescent state since the last time the current processor owned the token, thus ensuring that a grace period has elapsed.
[0016] Because grace period detection using token manipulation consumes processor cycles as the processors pass through their quiescent states, it is undesirable to incur such overhead unless there are pending callbacks in the read-copy update subsystem. For that reason, efficient token-based read-copy update implementations use a shared indicator (i.e., a global variable) that is tested before grace period token processing to determine if the read-copy update subsystem is idle. If it is, the grace period token does not need to be passed and the associated processing overhead can be avoided. The shared indicator is typically a count of the number of pending callbacks. Whenever a callback is registered at a given processor, the shared indicator is manipulated to reflect the new callback. Thereafter, when that callback is processed, the shared indicator is again manipulated to reflect the removal of the callback from the read-copy update subsystem.
[0017] A disadvantage of using a shared indicator to test for the existence of pending callbacks is that atomic instructions, locks or other relatively expensive mutual exclusion mechanisms must be invoked each time the shared indicator is manipulated in order to synchronize operations on the indicator by multiple processors. Moreover, conventional hardware caching of the shared indicator by each processor tends to result in communication cache misses and cache line bouncing. In the case of a bitmap indicator, a further disadvantage is that a large number of processors cannot be gracefully accommodated.
[0018] It is to solving the foregoing problems that the present invention is directed. In particular, what is required is a new read-copy update grace period detection technique that avoids unnecessary grace period token processing without incurring the overhead of a shared indicator of pending callback status.
SUMMARY OF THE INVENTION
[0019] The foregoing problems are solved and an advance in the art is obtained by a method, system and computer program product for avoiding unnecessary grace period token processing while detecting a grace period without atomic instructions in a read-copy update subsystem or other processing environment that requires deferring removal of a shared data element until pre-existing references to the data element are removed. Grace period detection includes establishing a token to be circulated between processing entities sharing access to the shared data element. A grace period can be determined to elapse whenever the token makes a round trip through the processing entities. A distributed indicator is associated with each of the processing entities that is indicative of whether there is a need to perform removal processing on the data element or on other data elements shared by the processing entities (e.g., whether there are pending callbacks warranting callback processing if the invention is implemented in a callback-based read-copy update system). The distributed indicator is processed at each of the processing entities before token processing is performed at the processing entities. Token processing is performed at the processing entities only when warranted by the distributed indicator. In this way, unnecessary token processing can be avoided when the distributed indicator does not warrant such processing.
[0020] In exemplary embodiments of the invention, the distributed indicators are stored as local variables in the cache memories associated with the processing entities (and replicated from one cache memory to another during the course of processing via conventional cache coherence mechanisms). In such embodiments, the distributed indicators can represent different kinds of information depending on design preferences. For example, the distributed indicators can alternatively represent the number of processing entities that have pending requests to perform updates to data elements shared by the processing entities, the total number of updates, or a bitmap identifying the processing entities having pending update requests.
[0021] The propagation of changes made to the distributed indicators by the various processing entities can also be performed in different ways according to design preferences. In exemplary embodiments, the processing entities periodically consult a distributed indicator maintained by a neighboring processing entity, and adjust the indicator as necessary to reflect changes in data element removal request activity (e.g., callback registrations) at the current processing entity. Whether there has been a change in data element removal request activity can include determination of various factors, such as whether there are a threshold number of pending data element removal requests at one of the processing entities to warrant circulation of the token. Alternatively, such determination could be based on whether there are any pending data element removal requests at one of the processing entities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The foregoing and other features and advantages of the invention will be apparent from the following more particular description of exemplary embodiments of the invention, as illustrated in the accompanying Drawings, in which:
[0023] FIGS. 1A-1D are diagrammatic representations of a linked list of data elements undergoing a data element replacement according to a conventional read-copy update mechanism;
[0024] FIGS. 2A-2C are diagrammatic representations of a linked list of data elements undergoing a data element deletion according to a conventional read-copy update mechanism;
[0025] FIG. 3 is a flow diagram illustrating a grace period in which four processes pass through a quiescent state;
[0026] FIG. 4 is a functional block diagram showing a multiprocessor computing system that represents one exemplary environment in which the present invention can be implemented;
[0027] FIG. 5 is a functional block diagram showing a read-copy update subsystem implemented by each processor in the multiprocessor computer system of FIG. 4 ;
[0028] FIG. 6 is a functional block diagram showing a cache memory associated with each processor in the multiprocessor computer system of FIG. 4 ;
[0029] FIG. 7 is a table showing exemplary quiescent state counter values in a hypothetical four-processor data processing system implementing read-copy update;
[0030] FIG. 8 is a functional block diagram showing the four processors of FIG. 7 as they pass a grace period token from time to time during read-copy update processing;
[0031] FIG. 9 is a flow diagram showing the manipulation of a distributed callback indicator implemented as a count of processors having pending callbacks;
[0032] FIG. 10 is a table showing exemplary quiescent state counter values and distributed callback indicator values in a hypothetical four-processor data processing system implementing read-copy update;
[0033] FIG. 11 is a functional block diagram showing the four processors of FIG. 10 as they pass a grace period token from time to time during read-copy update processing;
[0034] FIG. 12 is a flow diagram representing a modification of the flow diagram of FIG. 9 ;
[0035] FIG. 13 is a flow diagram showing the manipulation of a distributed callback indicator implemented as a count of pending callbacks;
[0036] FIG. 14 is a flow diagram showing the manipulation of a distributed callback indicator implemented as a bitmap identifying processors having pending callbacks; and
[0037] FIG. 15 is a diagrammatic illustration of storage media that can be used to store a computer program product for implementing read-copy update grace period detection functions in accordance with the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0038] Turning now to the figures, wherein like reference numerals represent like elements in all of the several views, FIG. 4 illustrates an exemplary computing environment in which the present invention may be implemented. In particular, a symmetrical multiprocessor (SMP) computing system 2 is shown in which multiple processors 4 1 , 4 2 . . . 4 n are connected by way of a common bus 6 to a shared memory 8 . Respectively associated with each processor 4 1 , 4 2 . . . 4 n is a conventional cache memory 10 1 , 10 2 . . . 10 n and a cache controller 12 1 , 12 2 . . . 12 n . A conventional memory controller 14 is associated with the shared memory 8 . The computing system 2 is assumed to be under the management of a single multitasking operating system adapted for use in an SMP environment.
[0039] It is further assumed that update operations executed within kernel or user mode processes, threads, or other execution contexts will periodically perform updates on shared data sets 16 stored in the shared memory 8 . Reference numerals 18 1 , 18 2 . . . 18 n illustrate individual data update operations (updaters) that may periodically execute on the several processors 4 1 , 4 2 . . . 4 n . As described by way of background above, the updates performed by the data updaters 18 1 , 18 2 . . . 18 n can include modifying elements of a linked list, inserting new elements into the list, deleting elements from the list, and many other types of operations. To facilitate such updates, the several processors 4 1 , 4 2 . . . 4 n are programmed to implement a read-copy update (RCU) subsystem 20 , as by periodically executing respective read-copy update instances 20 1 , 20 2 . . . 20 n as part of their operating system functions. Although not illustrated in the drawings, it will be appreciated that the processors 4 1 , 4 2 . . . 4 n also execute read operations on the shared data sets 16 . Such read operations will typically be performed far more often than updates, insofar as this is one of the premises underlying the use of read-copy update.
[0040] As shown in FIG. 5 , each of the read-copy update subsystem instances 20 1 , 20 2 . . . 20 n includes a callback registration component 22 . The callback registration component 22 serves as an API (Application Program Interface) to the read-copy update subsystem 20 that can be called by the updaters 18 2 . . . 18 n to register requests for deferred (second phase) data element updates following initial (first phase) updates performed by the updaters themselves. As is known in the art, these deferred update requests involve the removal of stale data elements, and will be handled as callbacks within the read-copy update subsystem 20 . Each of the read-copy update subsystem instances 20 1 , 20 2 . . . 20 n additionally includes a quiescent state counter manipulation and polling mechanism 24 (or other functionality for passing a token), together with a callback processing system 26 . Note that the functions 24 and 26 can be implemented as part of a kernel scheduler, as is conventional.
[0041] The cache memories 10 1 , 10 2 . . . 10 n associated with the processors 4 1 , 4 2 . . . 4 n respectively store quiescent state counters 28 1 , 28 2 . . . 28 n and one or more callback queues 30 1 , 30 2 . . . 30 n . The quiescent state counters 28 1 , 28 2 . . . 28 n are managed by the counter manipulation and polling mechanism 24 (a token manipulator) for the purpose of passing a grace period token among the processors 4 1 , 4 2 . . . 4 n . It will be appreciated that if some other form of token passing is used, the quiescent state counters 28 1 , 28 2 . . . 28 n will not be required. The callback queues 30 1 , 30 2 . . . 30 n are appended (or prepended) with new callbacks as such callbacks are registered with the callback registration component 22 . The callback processing system 26 is responsible for executing the callbacks referenced on the callback queues 30 1 , 30 2 . . . 30 n , and then removing the callbacks as they are processed.
[0042] FIGS. 7 and 8 illustrate how the quiescent state counters 28 1 , 28 2 . . . 28 n can be used to pass a grace period token between processors in an exemplary four processor system as the processors pass through quiescent states. Each column in FIG. 7 shows exemplary values for all processor quiescent state counters at a given point in time. The shaded cells indicate that the corresponding processor is the owner of the grace period token. In each case, the owner is the processor whose counter has the smallest value and whose neighbor has a counter value representing a discontinuity relative to the token owner's counter value.
[0043] The token passing technique represented by FIGS. 7 and 8 is known in the art and these figures are therefore labeled as “Prior Art.” As described by way of background above, a given processor checks to see if it owns the grace period token by referring to the quiescent state counter maintained by one of neighbors (e.g., that processor whose processor number is one greater than the current processor, modulo (%) the number of processors). If the neighbor's quiescent state counter has not changed since the current processor's last grace period (i.e., there is no discontinuity in the counter values), the current processor determines that a new grace period has not yet elapsed and resumes normal processing. If the neighbor's counter has changed since the current processor's last grace period (i.e., there is a discontinuity in the counter values), the current processor determines that a new grace period has elapsed. It processes its pending callbacks and increments its own quiescent state counter to one greater than the neighbor's value, thereby moving the discontinuity in counter values to itself. By way of example, at time t=0 in FIG. 7 , processor 3 that has the lowest quiescent state counter value ( 1 ) sees a discontinuous counter value ( 4 ) at processor 0 . This signifies to processor 3 that there have been three (4−1) quiescent states experienced by its peer processors since processor 3 's last grace period. Processor 3 thus concludes that a new grace period has elapsed and that it now has the grace period token. It performs callback processing and sets its quiescent state counter value to 4+1=5. At time t=1, processor 2 , having a quiescent state counter value of 2, now sees the discontinuous counter value 5 at processor 3 . It determines that it has the grace period token, performs callback processing, and sets its counter value to 5+1=6. Continuing this sequence, processor 1 obtains the grace period token at time t=2 and processor 0 obtains the token at time t=3. At time t=4, the token returns to processor 3 and the pattern repeats. As can be seen by the shaded table entries in FIG. 7 , and as additionally shown in the token-passing diagram of FIG. 8 , processors 0 - 3 will obtain the token (shown by the circle labeled “T” in FIG. 8 ) at the following times: 1) processor 3 will obtain the token at times t=0, 4 and 8; 2) processor 2 will obtain the token at times t=1 and 5; 3) processor 3 will obtain the token at times t=2 and 6; and 4) processor 0 will obtain the token at times t=3 and 7.
[0044] As also described by way of background above, prior art implementations of read-copy update seek to avoid unnecessary token processing by manipulating a global variable that serves as a shared indicator of whether there are pending callbacks in the read-copy update subsystem that require processing. For example, as disclosed in P. McKenney et al., “Read Copy Update,” Ottawa Linux Symposium (2002), a Linux implementation of read-copy update known as “rcu-sched” uses a shared variable “rcu_pending” that represents a count of the number of pending callbacks in the read-copy update subsystem. The Linux atomic increment primitive “atomic_inc” is invoked to increment rcu_pending when a new callback is registered by way of the function call “atomic_inc(&rcu_pending).” The Linux atomic decrement primitive “atomic_dec” is then invoked to decrement rcu_pending after the callback is processed by way of the function call “atomic_dec(&rcu_pending).” It should also be pointed out that “rcu-sched” is an example of a read-copy update implementation that uses a counter-based, grace period token passing scheme as shown in FIGS. 7 and 8 .
[0045] In order to avoid the disadvantages associated with the use of atomic operations (or other concurrency control mechanisms) to increment and decrement a shared indicator of callback pendency, the present invention proposes an alternative approach. As shown in FIG. 6 , a distributed callback indicator 32 can be maintained in the cache memory 10 of each of the processors 4 1 , 4 2 . . . 4 n and manipulated as a local variable to reflect changes in the read-copy update subsystem 20 . Each distributed callback indicator 32 provides a representation of the state of the read-copy update subsystem 20 . An associated callback indicator handling mechanism 34 (shown in FIG. 5 ) within each of the read-copy update subsystem instances 20 1 , 20 2 . . . 20 n can then consult the local distributed callback indicator 32 to determine whether grace period token processing is required. The local distributed callback indicator 32 may show that the read-copy update subsystem is idle, in which case the token does not need to be passed. On the other hand, the local distributed callback indicator 32 may show that there are callbacks pending in the read-copy update subsystem, and that grace period token processing is required at the current processor.
[0046] In order to keep the distributed callback indicators 32 current as conditions change within the read-copy update subsystem 20 , a propagation technique that is somewhat analogous to the grace period token passing scheme of FIGS. 7 and 8 may be used. Other implementations would also be possible. According to the propagation technique, as each of the processors 4 1 , 4 2 . . . 4 n passes through a quiescent state, its callback indicator handling mechanism 34 consults the distributed callback indicator 32 of a neighbor processor and adjusts its own local callback indicator according to the neighbor's value, coupled with consideration of the local callback history since the current processor's last grace period.
[0047] In one embodiment of the invention, the distributed callback indicator 32 is implemented as a per-processor counter of the number of processors having pending callbacks. These processors may be referred to as “callback processors,” and the distributed callback indicator 32 may be thought of as a callback processor counter. To manipulate this counter, a processor checks to see if there has been any change in its local callback state since this processor's last grace period. If no change has occurred, the current processor's counter will be set to the same value as a neighbor processor's counter. If a processor's callback history shows that no local callbacks were registered the last time the grace period token left this processor, but a requisite number of new local callbacks have been registered since the last grace period, the current processor's counter will be incremented to one higher than the value of the neighbor processor's counter. If a processor's callback history shows that local callbacks were registered the last time the grace period token left this processor, but a requisite number of new local callbacks have not been registered since the last grace period, the current processor's counter will be decremented so as to be one lower than the value of the neighbor processor's counter.
[0048] In a second embodiment of the invention, the distributed callback indicator 32 is implemented to track an indication of the total number of pending callbacks. In that case, the distributed callback indicator 32 can be thought of as a callback counter. To manipulate this counter, a processor compares the number of local callbacks that have been registered since this processor's last grace period to the number of local callbacks that were registered the last time the grace period token left the processor. The current processor's counter is set to the value of a neighbor processor's counter with an adjustment to reflect the net gain or loss of local callbacks.
[0049] In a third embodiment of the invention, the distributed callback indicator 32 is implemented as a bitmap identifying processors that have pending callbacks. To manipulate the bitmap, a processor determines if there are a requisite number of local callbacks that have been registered since the last time the grace period token left this processor. If there are, the current processor's bitmap is set to correspond to a neighbor processor's bitmap, but with the current processor's bit set to 1. Otherwise, if a requisite number of local callbacks have not been registered since the last grace period, the current processor' bit value in the bit map is set to zero. One disadvantage of this implementation is that it does not gracefully handle large numbers of processors due to need to process correspondingly large bitmaps.
[0050] FIG. 9 illustrates an exemplary sequence of processing steps that may be performed according to the first above-described embodiment in which the distributed callback indicator 32 is, by way of example only, a count of the number of processors 4 1 , 4 2 . . . 4 n that have pending callbacks. The process of FIG. 9 uses a per-processor local variable called “cbcpus” (shorthand for “callback cpus”) as the distributed callback indicator. This variable is a count of processors having callbacks needing processing. Another per-processor local variable, called “lastcbs” (shorthand for “last callbacks”), is a flag indicating whether the current processor had callbacks registered the last time the grace period token left this processor. A third per-processor variable, called “numcbs” (shorthand for “number of callbacks”) is a count of the number of callbacks registered at the current processor since the last grace period. Note that the foregoing variable names are used for illustration purposes only.
[0051] In step 40 of FIG. 9 , the nth processor's callback indicator handling mechanism 34 obtains the value of cbcpus of the processor n+1 (processor n−1 could also be used depending on the desired propagation direction). In step 42 , processor n determines if there are any new callbacks (numcbs) that meet the criteria for starting a grace period. In some cases, the presence of a single callback will satisfy these criteria. In other cases, it may be desirable to batch process callbacks by establishing a callback threshold specifying the number of callbacks necessary to start a grace period, and an elapsed time threshold that triggers callback processing even if the callback threshold is not reached. If in step 42 there are new callbacks requiring processing, then in step 44 the current processor's value of cbcpus is set to one greater than the neighbor processor's value of cbcpus, less the current processor's value of lastcbs. The value of lastcbs is then set to 1 in step 46 if and only if the callbacks on the current processor meet the criteria for starting a grace period. If in step 42 there are no new callbacks requiring processing, then in step 48 the current processor's value of cbcpus is set equal to the neighbor processor's value of cbcpus, less the current processor's value of lastcbs. The value of lastcbs is then set to 0 in step 50 if and only if there are no new callbacks on the current processor that meet the criteria for starting a grace period.
[0052] As each processor performs the foregoing processing while passing through a quiescent state, changes due to the registration of new callbacks or the processing of old callbacks will be quickly reflected by each of the distributed callback indicators (cbcpus in this example). By testing the propagated distributed callback indicator at each processor, potentially expensive token processing can be avoided when there are not enough callbacks warranting grace period token circulation. The table of FIG. 10 is illustrative of such processing in an exemplary four-processor system. FIG. 10 is based on FIG. 7 but shows, for each processor 0 , 1 , 2 , and 3 , both a grace period token on the left side of each table element and a distributed callback indicator (cbcpus in this example) on the right side of each table element. The shaded cells again indicate that the corresponding processor is the owner of the grace period token. In each case, the owner is the processor whose quiescent state counter has the smallest value and whose neighbor has a counter value representing a discontinuity relative to the token owner's counter value.
[0053] In FIG. 10 , processor 3 receives the grace period token from processor 0 . However, no token processing takes place because processor 3 's distributed callback indicator has a value of 0. In the current example in which the distributed callback indicator 32 is a count of callback processors (cbcpus), the 0 value means there are no processors having a requisite number of callbacks warranting processing. Processor 3 thus determines that the read-copy update subsystem for this group of processors is idle. At time t=1 in FIG. 10 , processor 2 determines that it has had new callback activity and sets its distributed callback indicator to a value of 1. Processor 3 is unaffected (since it only looks to processor 0 for callback indicator activity according to the current example) and again performs no grace period token processing. At time t=2, processor 2 's distributed callback indicator value is propagated to processor 1 . Processor 3 is unaffected and again performs no grace period token processing. At time t=3, processor 1 's distributed callback indicator value has propagated to processor 0 . Processor 3 is unaffected and again performs no grace period token processing. At time t=4, processor 0 's distributed callback indicator value has been propagated to processor 3 , causing it to perform grace period token processing and pass the token to processor 2 . At time t=5, processor 2 has performed grace period token processing and passed the token to processor 1 . At time t=6, processor 1 has performed grace period token processing and passed the token to processor 0 . In addition, it is assumed that processor 2 has determined that its callbacks have been processed and set its distributed callback indicator to 0. At time t=7, processor 0 has performed grace period token processing and passed the token to processor 3 . In addition, processor 2 's distributed callback indicator has been propagated to processor 1 . At time t=8, processor 3 has performed grace period token processing and passed the token to processor 2 . In addition, processor 1 's distributed callback indicator has been propagated to processor 0 . Assuming no new callbacks are registered in the system of FIG. 9 , the grace period token will now idle at processor 2 because its distributed callback indicator is 0.
[0054] FIG. 11 summarizes the foregoing processing. It shows that processor 3 will obtain the token (T) at times t=0, 7. The token will then idle at processor 3 during times t=1, 2 and 3. Processor 2 will then obtain the token at times 4 , 8 . Processor 1 will obtain the token at time t=5. Processor 0 will obtain the processor at time t=6.
[0055] Turning now to FIG. 12 , an alternative to the distributed callback indicator processing of FIG. 9 is shown. According to this alternative approach, step 42 a (corresponding to step 42 of FIG. 9 ) inquires whether numbcbs is nonzero, without regard to whether a threshold has been reached. Step 46 a (corresponding to step 46 of FIG. 9 ) sets lastcbs to 1 if and only numcbs is greater than 0. Step 50 a (corresponding to step 50 of FIG. 9 ) sets lastcbs to 0 if and only numcbs is 0. The advantage of this alternative approach is that it permits processors with only a few callbacks to “piggyback” their callback processing needs onto another processor's grace period token circulation and keep the token moving. The disadvantage is that additional grace period detection operations can result.
[0056] FIG. 13 illustrates an exemplary sequence of processing steps that may be performed according to the second above-described embodiment in which the distributed callback indicator 32 is, by way of example only, a count of the number of pending callbacks. The process of FIG. 13 uses a per-processor local variable called “cbspen” (shorthand for “callbacks pending”) as the distributed callback indicator. Another per-processor local variable, called “lastcbs” (shorthand for “last callbacks”), is a value indicating the number of callbacks that the current processor had registered the last time the grace period token left this processor. A third per-processor variable, called “numcbs” (shorthand for “number of callbacks”) is a count of the number of callbacks registered at the current processor since the last grace period. Note that the foregoing variable names are used for illustration purposes only.
[0057] In step 60 of FIG. 13 , the nth processor's callback indicator handling mechanism 34 obtains the value of cbspen of the processor n+1 (processor n−1 could also be used depending on the desired propagation direction). In step 62 , the current processor's value of cbspen is set to the neighbor processor's value of cbspen, plus the current processor's value of numcbs, less the current processor's value of lastcbs. The value of lastcbs is then set to numcbs in step 64 .
[0058] FIG. 14 illustrates an exemplary sequence of processing steps that may be performed according to the third above-described embodiment in which the distributed callback indicator 32 is, by way of example only, a bit map showing which processors have pending callbacks. The process of FIG. 14 uses a per-processor local bitmap variable called “cbcpumap” (shorthand for “callback cpu map”) as the distributed callback indicator. Another per-processor local variable, called “numcbs” (shorthand for “number of callbacks”) is a count of the number of callbacks registered at the current processor since the last grace period. Note that the foregoing variable names are used for illustration purposes only.
[0059] In step 80 of FIG. 14 , the nth processor's callback indicator handling mechanism 34 obtains the value of cbcpumap of the processor n+1 (processor n−1 could also be used depending on the desired propagation direction). In step 82 , processor n determines if there are any new callbacks (numcbs) registered at this processor that satisfy some established threshold (e.g., as discussed above relative to FIG. 9 ). If in step 82 there are new callbacks requiring processing, then in step 84 the current processor's cpcumap is set equal to that of processor n+1, but the nth bit of cbcpumap is set to 1. If in step 82 there are no new callbacks requiring processing, then in step 86 the current processor's value of cpcpumap is set equal to that of processor n+1, but the nth bit of cbcpumap is set to 0.
[0060] Accordingly, a technique for read-copy update grace period detection has been disclosed that does not require atomic instructions and which can be implemented to gracefully handle large numbers of processors. It will be appreciated that the foregoing concepts may be variously embodied in any of a data processing system, a machine implemented method, and a computer program product in which programming means are recorded on one or more data storage media for use in controlling a data processing system to perform the required functions. Exemplary data storage media for storing such programming means are shown by reference numeral 100 in FIG. 15 . The media 100 are shown as being portable optical storage disks of the type that are conventionally used for commercial software sales. Such media can store the programming means of the invention either alone or in conjunction with an operating system or other software product that incorporates read-copy update functionality. The programming means could also be stored on portable magnetic media (such as floppy disks, flash memory sticks, etc.) or on magnetic media combined with drive systems (e.g. disk drives) incorporated in computer platforms.
[0061] While various embodiments of the invention have been described, it should be apparent that many variations and alternative embodiments could be implemented in accordance with the invention. It is understood, therefore, that the invention is not to be in any way limited except in accordance with the spirit of the appended claims and their equivalents.
|
A method, system and computer program product for avoiding unnecessary grace period token processing while detecting a grace period without atomic instructions in a read-copy update subsystem or other processing environment that requires deferring removal of a shared data element until pre-existing references to the data element are removed. Detection of the grace period includes establishing a token to be circulated between processing entities sharing access to the data element. A grace period elapses whenever the token makes a round trip through the processing entities. A distributed indicator associated with each processing entity indicates whether there is a need to perform removal processing on any shared data element. The distributed indicator is processed at each processing entity before the latter engages in token processing. Token processing is performed only when warranted by the distributed indicator. In this way, unnecessary token processing can be avoided when the distributed indicator does not warrant such processing.
| 8
|
[0001] This application is a continuation of U.S. patent application Ser. No. 14/096,339, filed Dec. 4, 2013, which is a continuation of U.S. patent application Ser. No. 13/854,232, filed Apr. 1, 2013, now U.S. Pat. No. 8,688,085, which issued Apr. 1, 2014, which is a continuation of U.S. patent application Ser. No. 13/117,507, filed May 27, 2011, which is now U.S. Pat. No. 8,521,140, which issued Aug. 27, 2013, which is a continuation of U.S. patent application Ser. No. 12/495,190, filed on Jun. 30, 2009, which is now U.S. Pat. No. 7,953,390, which issued on May 31, 2011, which is a continuation of U.S. patent application Ser. No. 12/015,320, filed Jan. 16, 2008, which is now U.S. Pat. No. 7,778,595, which issued on Aug. 17, 2010, which is a continuation of U.S. patent application Ser. No. 10/947,755, filed on Sep. 23, 2004, which is now U.S. Pat. No. 7,324,833, which issued on Jan. 29, 2008, which is a continuation of U.S. patent application Ser. No. 09/537,812, filed on Mar. 28, 2000, which is now U.S. Pat. No. 7,187,947, which issued on Mar. 6, 2007, the disclosures of which are all hereby incorporated herein by reference in their entirety for all purposes.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to digitally stored content and, more specifically, to a content delivery system and method.
BACKGROUND
[0003] The first commercial radio stations in the United States began operation around 1920. Today, there may be as many as 12,000 radio stations in the United States programming in several distinct formats. When broadcasting their respective signals, these radio stations often use an analog signal, which may be modulated based on frequency or amplitude. Frequency modulated (FM) radio appears to be the dominant entertainment medium while amplitude modulated (AM) radio seems to be a popular outlet for news and information.
[0004] Unfortunately, analog radio may be unable to provide the sound quality and consistency that radio listeners desire. As such, several broadcasting related companies have begun to consider a movement to digital radio. Unlike analog radio reception, digital radio reception may be able to provide compact disk (CD) quality sound while remaining virtually immune to interference. Being immune to interference may result in reducing static growls or “multipath” echoes, echoes caused by signal reflections off buildings or topographical features.
[0005] Some countries, like Canada and many European countries, may choose to have digital radio operate in a single digital radio band such as the L-band between 1452-1492 megahertz (MHz). This band would allow the reception of both terrestrially and satellite-originated signals. By comparison, FM radio typically operates between 88 and 108 MHz while AM radio typically operates between 0.525 and 1.705 MHz. Neither of these bands allows for easy transmission via satellite.
[0006] Canada proposed using the L-Band for digital radio as early as 1992. Several countries throughout the world have since agreed to use the L-Band for digital radio with one notable exception. It appears the United States has chosen not to operate its digital radio within the L-Band. In the United States, the L-Band may already be committed for military uses. Apparently, the United States plans to adopt a system called in-band on-channel, or IBOC, which fits within the AM and FM frequencies.
[0007] IBOC technology may offer some advantages over L-Band transmissions. For example, there may be no need for new spectrum allocations. There may be backward and forward compatibility with existing AM and FM systems on both the transmitter and receiver sides, and there may be a low-investment upgrade to digital systems. Unfortunately, a workable IBOC solution is yet to be seen though technology may someday make IBOC digital radio commercially possible.
[0008] Even if an IBOC solution becomes commercially available in the United States, IBOC digital radio may suffer from several shortcomings. For example, there may global standardization problems. Though the United States favors IBOC, the European and Canadian communities seem to favor L-Band making the establishment of a global standard difficult.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
[0010] FIG. 1 depicts a general system for wirelessly communicating selective information to an electronic device in accordance with one aspect of the present invention;
[0011] FIG. 2 illustrates a block diagram of a method of wirelessly communicating selected information to an electronic device;
[0012] FIG. 3 illustrates an electronic device operable to receive selected audio information in accordance with the teachings of the present invention;
[0013] FIG. 4 illustrates a graphical user interface (GUI) for displaying selectable audio information according to one aspect of the present invention;
[0014] FIG. 5A illustrates a portable radio system having a mount for an electronic device according to one embodiment of the present invention;
[0015] FIG. 5B illustrates an automobile console having a mount for coupling an electronic device according to one aspect of the present invention;
[0016] FIG. 6 illustrates a block diagram of a system for communicating voice mail messages using email according to one embodiment of the present invention;
[0017] FIG. 7 illustrates a flow chart for providing voice email messages according to one embodiment of the present invention;
[0018] FIG. 8 illustrates a flow diagram of a method for providing selected audio information to an electronic device according to one embodiment of the present invention; and
[0019] FIG. 9 illustrates an automobile console having a mount for an electronic device according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0020] The conceptual groundwork for the present invention includes wirelessly communicating selective information to an electronic device. According to one aspect, a user may interact with the Internet to select information, such as audio information, and wirelessly communicate the selected information to an electronic device. The electronic device receives the information via a wireless communications network and processes the information accordingly. In a particularized form, a user may select information from an Internet website operable to allow selectivity of audio information such as songs, on-line radio stations, on-line broadcasts, streaming audio, or other selectable information. Upon selecting the audio information, information or data associated with the selected audio information is wirelessly communicated to an electronic device. The electronic device may then be used to process the selected audio information. In this manner, a user may receive selective audio information via a wireless electronic device.
[0021] In one form, the electronic device may be operable to communicate with an individual's automobile audio system. A user may select audio information utilizing a personal computer with access to a website operable to display selectable audio information. The selected audio information may then be wirelessly communicated to the electronic device associated with an automobile's audio system. Therefore, upon receiving the selected audio information, a user may access and play the received audio information utilizing the electronic device in association with the automobile's audio system.
[0022] The present invention is not limited to communicating only audio information. One skilled in the art can appreciate that other types of information, such as video, textual, etc. may be communicated utilizing the systems and methods disclosed herein without departing from the spirit and scope of the present invention. Additionally, it will be understood that information may be formatted in a plurality of ways at different phases of communication without loosing the underlying content of the selected information. For example, an audio file may be formatted, segmented, compressed, modified, etc. for the purpose of providing or communicating the audio invention. Therefore, the term “audio information” or “information” is used in a general sense to relate to audio information in all phases of communication.
[0023] FIG. 1 depicts a general system for wirelessly communicating selective information to an electronic device in accordance with one aspect of the present invention. The system, illustrated generally at 100 , includes a digital engine 101 coupled to a communications engine 102 . Communications engine 102 is remotely coupled to an electronic device 103 . Digital engine 101 may be directly or indirectly coupled to storage device 105 operable to store information. Digital engine 101 maintains information or data associated with selected information in a digital format. The information may be stored within storage device 105 or other storage devices operable to maintain data or information associated with the selected information.
[0024] Communications engine 102 is communicatively coupled to digital engine 101 and operable to wirelessly communicate the selected information to electronic device 103 . During operation, audio information may be selected by a user utilizing a personal computer or other devices operable to communicate with an information network. Digital engine 101 is operable to maintain information associated with the selected audio information. For example, the information could be several songs or titles configured as an audio file and formatted in a digital format such as an MP3 file, wave file, etc. The maintained information may also be a reference to a network location where an audio file may be stored, a network location where a network broadcast of audio information may be located, etc. or other network locations having information associated with the selected audio information. Therefore, digital engine 101 may maintain a plurality of different types of information or data associated with the selected audio information.
[0025] System 100 , utilizing communication engine 102 , may wirelessly communicate data or information associated with the selected audio information to electronic device 103 thereby providing wireless communication of selected information to an electronic device operable to receive wireless communications. In one embodiment, digital engine 101 may be used in association with an Internet website configured to provide access to selectable information. The Internet website operably associated with digital engine 101 allows a user to select information to be wirelessly communicated to electronic device 101 utilizing a network environment. The Internet website may include several different types of information related to audio information.
[0026] FIG. 4 , described in greater detail below, illustrates one embodiment of providing an Internet website for displaying selectable audio information. For example, the Internet website may include music and/or artist search engines, playlists, top 10 charts, artists by genre, and other information associated with audio information. A user may select information associated with the audio information and digital engine 101 can maintain the information or data associated with the selected information in a digital format. Communications engine 102 coupled to digital engine 101 may wirelessly communicate data associated with the selected audio information to electronic device 103 . Therefore, a user may access and select audio information via an Internet website and wirelessly communicate the data to an electronic device. As such, system 100 advantageously allows for wireless communication of selected audio information to electronic devices that may be remotely located from a conventional terrestrial communication network.
[0027] Electronic device 105 may be configured in a plurality of ways for receiving wireless communication of selected audio information. In one embodiment, electronic device 105 may be operable as a component configured to receive a cellular signal comprising the selected information communicated by the communication engine. For example, a device having a cellular modem may be operable to receive the information at specified intervals. Upon receiving the information the electronic device may process the received information. Electronic devices are described in more detail below and may include a network radio, a modular device, an audio system, a personal digital assistant (PDA), a cellular phone, or other electronic devices operable to receive information wirelessly communicated by communication engine 102 .
[0028] Communications engine 102 may be operable to wirelessly communicate selected information to electronic device 103 in a plurality of ways. The present invention advantageously allows for several different embodiments of wirelessly communicating selected audio information to electronic device 103 and is not limited to any specific configuration described below. Several different types or combinations of wireless communication may be realized by the present invention. Communications engine 102 may be operable to wirelessly communicate the selected information from an information network, such as the Internet, to an electronic device operable to receive wireless communications. In one embodiment, communications engine 102 may comprise a conduit to interface information with a wireless communication network. The conduit may configure the information located within the information network into a format operable to be transmitted via wireless communication.
[0029] For example, a wireless device may be operable to receive packets of information having a specific size and in a specific format. In such an embodiment, communications engine 102 could format the information into a desirable format for wirelessly communicating the information to electronic device 103 . Several types of wireless communication may be used by communications engine 102 to communicate the selected information to an electronic device. Communications networks such as GSM, Digital Satellite communication, SB, Radio bands, DRC, SuperDRC or other systems or types of transmission such as TDMA, CDMA, spread spectrum, etc. or frequencies such as between about 1.7 GHz and 2.0 GHz may be realized by the present invention for communicating information or data representing the selected audio information to electronic device 103 .
[0030] In one embodiment, the selective information may be communicated using a digital broadcast signal. Digital broadcast includes providing information via a signal such as AM, FM, and the like. Digital information may be included or encoded as a sub-carrier within the broadcast signal and received by electronic device 103 . A digital sub-carrier may include a selective bandwidth of frequencies for a specific radio station (i.e., 6 MHz for FM). The selective information may be wirelessly communicated to electronic device 103 utilizing a communication engine 102 operable to communicate the selective information via a digital FM signal. In this manner, selective information may be communicated within digital FM sub-carriers to an electronic device operable to receive the information. For example, a user may subscribe to communicate the information via an FM sub-carrier and receive the selective data through wireless communication via a specified FM sub-carrier.
[0031] In one embodiment, the selected information may be formatted and transmitted to achieve a desirable transmission rate. For example, conventional systems may transmit information at a speed of 10 kilobits per second. Therefore, for 1 megabyte of information to be communicated to an electronic device, a transmission time of approximately 800 seconds may be required. The present invention may allow for a relative increase in transmission speed by removing the requirement that information be communicated asynchronously to an electronic device. For example, conventional wireless communication utilizes a specified frequency to communicate information in two directions (i.e., cellular phones). As such, information is communicated across a channel in an asynchronous manner to provide a continuous audio signal to the recipient.
[0032] The present invention advantageously allows for signals to be transmitted to an electronic device in a less than asynchronous manner. For example, if a user selected a song to be wirelessly communicated to an electronic device, system 100 could communicate the information in a less than asynchronous manner allowing the selected information to be transmitted efficiently thereby decreasing the overall download time for the selected audio information. In one embodiment, the selected information may be compressed and transmitted across the same frequency but at different phases thereby allowing plural signals having different phases to be wirelessly communicated to an electronic device. Therefore, the electronic device may be operable to receive multiple phased signals and process the selective information accordingly.
[0033] In one embodiment, the information may be wirelessly communicated at a relatively slow transmission rate. For example, a user may schedule when the selected audio information may be used by electronic device 103 . The user may select several different audio tracks or songs to be transmitted to an electronic device associated with the user's vehicle such that the user can listen to the user selected audio information during the drive home at the end of a workday. Therefore, it may be desirable to utilize a slower transfer speed due to the extended amount of time available prior to actual use of the selected audio information. In this manner, communications networks having less or slower transfer rates may be used to wirelessly communicate the selected audio information to the electronic device.
[0034] In another embodiment, high-speed wireless communication networks may be used to communicate the selected audio information. For example, a user may want to listen to an Internet broadcast of an Internet radio station. Therefore, high-speed communication may be required to wirelessly communicate or stream the selected audio information to an electronic device. In another embodiment, a hybrid of wireless communication rates may be deployed depending on the requirements of the selected audio information and/or the electronic device. For example, the selected audio information may first be transmitted to the electronic device via high-speed communication until enough information has been wirelessly communicated and buffered into a memory device operably associated with the electronic device. Upon communication of a certain percentage of the selected audio information, slower communication speeds may then be used to communicate additional selected audio information.
[0035] Therefore, system 100 may be configured in a plurality of ways to communicate selected information to electronic device 103 . Digital engine 101 may be used to maintain data or information associated with the selected information and communication engine 102 , communicatively coupled to digital engine 101 , may wirelessly communicate selected information to electronic device 103 .
[0036] FIG. 2 illustrates a block diagram of a method of wirelessly communicating selected information to an electronic device. The method may be used in association with the system illustrated in FIG. 1 or other systems operable to utilize the method of FIG. 2 .
[0037] The method begins generally at step 200 . At step 201 , selectable audio information may be accessed utilizing a network communications device. For example, selectable audio information may be displayed at an Internet website accessible by a personal computer. In another embodiment, the selectable information may be accessed utilizing a wireless communications device such as, a cellular phone, a PDA device, or other devices operable to provide access to the selectable audio information.
[0038] Upon accessing the selectable information, the method proceeds to step 202 where a user can identify or select audio information to be wirelessly communicated to an electronic device. For example, a user may select an entire album to be wirelessly communicated to a PDA device.
[0039] Upon the user selecting the audio information, the method proceeds to step 203 where the method maintains information associated with the selected information. In one embodiment, the information may be an audio file, such as a wave file, and MP3 file, etc. representative of the selected audio information. In another embodiment, a network location that comprises a file representing the selected information may be maintained. Another example may include a network location of a network broadcast of audio information. Therefore, the method at step 203 may maintain several different types of information associated with the selected audio information.
[0040] Upon maintaining information or data associated with the selected information, the method proceeds to step 204 where the method wirelessly communicates information associated with the selected information to an electronic device. For example, if an audio file associated with the selected audio information was maintained, the method would communicate the audio file to the electronic device. In another embodiment, a link or network address broadcasting the selected audio information may be accessed and, at step 204 , wirelessly communicated to an electronic device. In another embodiment, a combination of different types of audio information may be wirelessly communicated to an electronic device. Upon transmitting the selected audio information, the method proceeds to step 205 where the method ends.
[0041] Selected audio information may be communicated in a plurality of ways as described above including communicating via a cellular communications network to an electronic device operable to receive cellularly-communicated signals. For example, the information may be selected from a website operable to display selectable information. Upon selecting the audio information, a data file representing the selected audio information may be wirelessly communicated to an electronic device thereby allowing a user to select audio information via the Internet and wirelessly communicate the information to an electronic device.
[0042] In some embodiments, the wireless communication to an electronic device may occur in an off-line environment. For example, a user may go “on-line” to access a website and select information and then go “off-line” or end the browsing session. The wireless communication may then occur while the user is off-line thereby removing the confines of using an active or on-line browsing environment (i.e. Internet radio broadcast, streaming audio, etc.) for accessing selected information. Therefore, the method of FIG. 2 allows for information, such as audio information, to be communicated from a network location such as a web site, to an electronic device “via” wireless communication. The present invention advantageously allows users to access and download information accessible by a network location to an electronic device operable to receive wireless communications thereby reducing the need for land lines, terrestrial communication networks, etc. for communicating selective information.
[0043] In one embodiment, the method of FIG. 2 may be deployed in association with an Internet website operable to display selectable links for downloading information. The information may include audio information such as MP3s, streaming audio, streaming. Internet broadcasts, etc. are selectable by a user and operable to be wirelessly communicated to an electronic device. By providing a user with a website of selectable audio information operable to be wireless communicated to an electronic device, a user may customize information communicated to an electronic device. In one embodiment, a user may communicate information to an electronic device that may not be owned by the user. For example the method of FIG. 2 could be modified to allow a user to wirelessly communicate audio information to a plurality of electronic devices that may or may not be owned by the user.
[0044] FIG. 3 illustrates an electronic device operable to receive selected audio information in accordance with the teachings of the present invention. Electronic device 300 includes a communication module 301 such as a transceiver coupled to storage medium 303 such as a high speed buffer, programmable memory, or other devices operable to store information. Electronic device 300 may also include processor 302 operably associated with communication module 301 and storage medium 303 . Processor 302 may be operable to process wirelessly communicated selected information and in one embodiment may be integrated as part of communication module 301 of storage medium 303 . In the same manner, as larger scale integration of electronic devices proliferate, communication module 301 , processor 302 , and storage medium 303 may be integrated into one communication component or device operable as electronic device 300 .
[0045] Processor 302 may be operable using software that may be stored within storage medium 303 . In one embodiment, software upgrades may be communicated to electronic device 300 via wireless communication allowing for efficient system upgrades for electronic device 300 . Storage medium 303 may include one or several different types of storage devices. For example, storage medium 303 may include programmable gate arrays, ROM devices, RAM devices, EEPROMs, minidisks or other memory devices operable to store information.
[0046] During use, electronic device 300 receives wireless communications of selective information. The information may be transmitted via a wireless communications network and received by electronic device 300 via transceiver 301 . Transceiver 301 may be operable to convert the received wireless communication signal into a desirable format and store the received information within storage medium 303 . The received information may then be processed by electronic device 300 .
[0047] In one embodiment, electronic device 300 may be operable as an audio player configured to play digital representations of music. For example, electronic device 300 may also include an MP3 player operable to process the received information into an audio signal. Therefore, electronic device 300 may be used to receive wirelessly communicated MP3 audio files and play these files using an MP3 player when desired. In another embodiment, electronic device 300 may be configured as a PDA wherein the PDA includes a web browser operable to wirelessly communicate with the Internet. The PDA device may include a user interface allowing a user to select information to be wirelessly communicated to electronic device 300 .
[0048] By providing a website of selectable information, the PDA devices may provide an efficient embodiment for electronic device 300 in that is allows a user to access and select information using a wireless communication network and receive the selected information using the same or different wireless communication network. In yet another embodiment, electronic device 300 may be configured as a component operable to receive selective information via wireless communication and communicate the information to a second electronic device such as an automobile sound system, home stereo, etc.
[0049] For example, electronic device 300 may utilize transceiver 301 to receive wirelessly communicated information. Electronic device 300 may then be coupled to an automobile sound system using an interface and communicate the received information to the automobile sound system. In this manner, electronic device 300 may be used to provide the automobile sound system with audio files received via wireless communication.
[0050] In another embodiment, electronic device 300 may be operable to communicate the received audio information to an audio system via a localized communications-signaling network. One such network may include utilizing “Bluetooth” communication standard, used to provide communication between electronic devices in a proximal setting. In one embodiment, electronic device 300 may be integrated into an audio component such as a radio receiver. Electronic device 300 integrated into an audio component may be configured to process digital audio files wirelessly communicated to an audio component. In another embodiment, electronic device 300 may be operable to communicate with an analog receiver at a predetermined frequency.
[0051] For example, a specific frequency may be selected (i.e., 93.7 MHz) for communicating the wireless received selected information from electronic device 300 to a localized audio system. Electronic device 300 communication of the wirelessly received information allows a conventional receiver to receive the selected audio information. In one embodiment, the conventional receiver may be configured to receive a digital sub-carrier, on-carrier, or other within a specified frequency. Therefore, electronic device 300 may be operable to locally transmit the signal at a specific frequency thereby allowing the conventional receiver to receive the information. In another embodiment, electronic device 300 may be operable to scan plural bandwidths to receive the selective information. For example, transceiver 301 may be operable to receive selective information across several frequencies and process the received information accordingly.
[0052] In another embodiment, electronic device 300 may be operable to scan several frequencies to obtain the desirable information. For example, a user may select several Internet broadcasts comprised of streaming audio information. Therefore, the information may be transmitted across several wireless frequencies receivable by electronic device 300 . Electronic device 300 may then be operable to allow a user to scan wirelessly communicated Internet broadcast signals thereby providing a user selected virtual broadcast radio network. In another embodiment, electronic device 300 may include a user interface operable to communicate with an Internet website operable to display selectable audio information. The Internet website may be configured as a user-preferred environment displaying a users selected audio information. Internet broadcast selections, streaming audio selections, etc.
[0053] With a display device for displaying a Website having selectable information, electronic device 300 may allow a user to select audio information via a user interface and receive the selected information via wireless communication thereby providing a customizable WebRadio device for the user. In another embodiment, electronic device 300 may be a modular device configured to be coupled to, for example, a portion of a cars interior. For example, electronic device 300 may be mounted to a portion of a car's console thereby providing a removably coupled electronic device operable to wirelessly receive selected audio information. As a removable device, electronic device 300 may also be coupled to a home audio system, a portable radio system or other systems thereby providing a versatile electronic device operable to receive wirelessly communicated selected audio information.
[0054] In another embodiment, electronic device 300 may be operable as a PDA and/or a cellular phone that may be mounted to an automobile's console. Electronic device 300 may then integrate with a user's automobile to provide an all-encompassing communications device. For example, electronic device 300 configured as a PDA and cellular phone may allow for communication with a user's email account, voice mail account, the Internet, as well as allowing for the receipt of selected audio information via wireless communication. Electronic device 300 may be operable in a hands-free mode allowing a user to maintain safe driving fundamentals. During use, electronic device 300 may be processing selective audio information for communicating with an automobile audio system and may further be operating to receive incoming cellular calls.
[0055] Electronic device 300 may be set-up by the user to pause the music being played and allow the received cellular call to be communicated either via an independent speaker or utilizing the automobiles “audio system.” Additionally, electronic device 300 may be operable to adjust the listening level of an automobile's audio system, it may play received voice mail messages, allow a user to view the Internet, etc. In one embodiment, electronic device 300 may be operable as a dual mode electronic device capable of receiving both digital and analog wireless communication signals. In this manner, electronic devices may efficiently utilize available bandwidth for receiving selected information from a communications engine. For example, transceiver 301 may be a wireless communications modem operable to receive digital or analog signals.
[0056] FIG. 4 illustrates a graphical user interface (GUI) for displaying selectable audio information according to one aspect of the present invention. The GUI may be operable with a computer system, cellular device, PDA, or other electronic devices or systems operable to display the GUI of FIG. 4 . The GUI, shown generally at 400 , may be displayed using a conventional web browser 402 such as Microsoft® Internet Explorer, a WAP browser, or other browsers operable to display the audio information. Browser 402 includes browser functions, shown collectively at 403 , for navigating a network such as the Internet or an intranet. Homepage 401 may be displayed using browser 402 and may include several functions, features, information, etc. related to audio information. Home page 401 may be developed using several different types of programming (i.e., HTML, XML, Java, etc.) used to developing a network location or website.
[0057] The present invention is not limited to any one specific type of software and may be realized in plurality of ways as can be appreciated by those skilled in the art. Homepage 401 may also include login region 410 allowing a user to log into homepage 401 and display a user-preferred environment. For example, a user may want Radio Dial 412 to appear when a user logs into homepage 401 . In another embodiment, a user may want to view a current playlist selected by the user or the status of wirelessly communicated playlist. A user may also provide demographic information allowing advertisers to access the demographic information and provide advertisements based upon the demographic information. For example, an advertiser may want to target Hispanic females in the 21-25 year old age group.
[0058] Through providing demographic information to advertisers, when a user logs into homepage 401 selective advertising can be “targeted” for a group of users. Homepage 401 may also include several tabs for efficiently navigating homepage 401 . Library tab 405 may be provided to allow a user to browse available audio information that may be presented by title, genre, artist, decade, culture, etc. Store tab 407 may also be provided for locating items available for purchase such as CDs, PDA devices, MP3 players, wireless communication hardware, interfaces, software or other types of products that may be purchased while on-line. Chat tab 408 may also be provided allowing a user to chat with other users of home page 401 . For example, a guest musical artist may be available to chat with visitors of home page 401 via a chat page associated with chat tab 408 . Home page 401 may also include contest tab 409 for displaying current contests, prizes, and/or winners.
[0059] Radio tab 406 may also be provided for displaying audio information. For example, radio tab 406 may display a collective menu 411 of selectable functions or features associated with audio information. Top ten lists may be provided to a user based on several different billboard polls or genres. A search engine may be provided allowing a user to search for a specific type of audio information such as an artist, song title, and genre. Internet radio station, etc. In one embodiment, a user may input the lyrics to a song within the search engine. As such, the search engine may locate several different songs having the desirable lyrics and allow a user to select the search results. A user may also use a select a device feature that allows a user to select a destination device for communicating selected audio information. For example, a user may want to communicate a playlist to several different devices such as a PDA, a home computer system, a work computer system, etc.
[0060] As such, a user can communicate selective information to several devices without having to download the information separately for each device. A send a friend link may also be provided allowing a user to send selective audio information to a friend's electronic device. A user may also join a group comprised of individuals that select a certain genre of music to be communicated to the user's electronic device. For example, a user may want to join a group that plays only 50s swing music. As such, the user could communicate the group's selected songs to the user's electronic device. A user may also utilize an email account provided by homepage 401 allowing a user to correspond with others via email. A user may also access a list of guest DJs that may provide playlists of songs chosen by the guest DJ and selectable by a user.
[0061] In one embodiment, a user's radio dial 412 may be provided when a registered user logs into homepage 401 . As such, radio dial 412 may include several functional buttons similar to conventional systems such as a volume control and a station control. However, radio dial 412 surpasses the limitations of conventional systems through providing a programmable radio dial of user customized audio information. Radio dial 412 includes several stations that may be programmed using program interface 413 . The preset stations may include several different types of user customized preset information such as user selected playlists, Internet broadcast stations, top lists, group playlists, artist-selected lists, on-line radio station, conventional radio stations. Internet phone, cellular phone, etc. and other functions, features, or information associated with audio information.
[0062] Radio dial 412 may also be displayed as a separate user interface and in some embodiments, does not require a “browsing” environment to view radio dial 412 . For example, an electronic device, such as a PDA, having a display may graphically present radio dial 412 to a user. One example may be using electronic device in association with an automobile audio system. Electronic device may display radio dial 412 and may allow a user to navigate, modify, select, adjust volume, access daytimer, access phone lists, etc. or perform other functions while the electronic device is used in association with an automobile sound system. Therefore, radio dial 412 may be operable as an application for use with several different types of electronic devices (i.e., computer systems, portable computing devices, cellular phones, etc.) operable to display radio dial 412 and in come embodiments may be wirelessly communicated to an electronic device.
[0063] In another embodiment, homepage 401 may allow a user to select when to download the information to an electronic device. For example, a user may want to listen to a certain genre of music at a specific time of day thereby allowing a user to select the information. As such, a user may select a different playlist for every day of the week thereby allowing a user to listen to different songs on different days of the week. The user can further identify when the selected playlist should be available for listening. For example, if a user wanted to listen to “playlist #1” on Monday morning during the drive into work between 8:00 am and 9:00 am, the user would enter the time and the day “playlist #1” would be available for listening. In this manner, the playlist may be communicated to the electronic device thereby allowing a user to listen to selective audio information at a desirable time.
[0064] FIG. 5A illustrates a portable radio system having a mount for an electronic device according to one embodiment of the present invention. Portable radio 500 includes a mount 501 operable to receive electronic device 502 . Mount 501 may include a connector operable to provide communications and power to electronic device 502 . During use, electronic device 502 when mounted within portable radio 500 communicates with portable radio to provide remotely received selective audio information. In one embodiment, electronic device 502 may include a user interface allowing a user to access the Internet. Therefore, selective audio information located on the Internet may be accessed by the user and remotely communicated to electronic device 502 coupled to portable radio 500 .
[0065] In another embodiment, portable radio 500 may include memory operably located within for storing downloaded information. For example, portable radio 500 may include 32 MB of RAM allowing electronic device 502 to receive selective information and download the selective information to memory located within portable radio 500 . In this manner, the downloaded music may be operable to be played within portable radio 500 while allowing electronic device to be removed from portable radio 500 . Therefore, portable radio 500 including electronic device 502 allows a user to communicate selected audio information to portable radio 500 .
[0066] FIG. 5B illustrates automobile console having a mount for coupling an electronic device according to one aspect of the present invention. Console 510 includes mount 511 operable to receive electronic device 512 . Mount 511 may be located in many different locations within an automobile such as coupled to a sun visor, center console, dashboard, floorboard, etc. Mount 511 allows the user to couple electronic device 512 to the automobile and provide an interface for communication between electronic device 512 and the automobile audio system. Mount 511 may also include a power connection that allows electronic device 512 to use the automobiles power during use. The power connection may also be used in association with a recharging circuit operable to recharge a power supply within the electronic device. During operation, electronic device 512 coupled to mount 511 may receive selected audio information via wireless communication and communicate the selective information to the automobile audio system.
[0067] In one embodiment, the automobile may include memory operable associated with the automobile for storing-information. The memory may be used in association with mount 511 and electronic device 512 to store the selected audio information. In this manner, voluminous audio information can be stored within the memory allowing electronic device 512 to receive additional information. In one embodiment, a mount may be provided for a home audio system (not shown) for downloading selected audio information for use with a home audio system. For example, a mount device may be coupled to a home stereo system such that the upon placing an electronic device such as electronic device 500 within the mount, selected audio information may be communicated to the home audio system thereby allowing a home audio system to be used in association with an electronic device.
[0068] FIG. 6 illustrates a block diagram of a system for communicating voice mail messages using email according to one embodiment of the present invention. The system, indicated generally at 600 , includes email server 601 coupled to a voice mail storage device 602 . System 600 further includes a computer system or network terminal 603 such as a computer coupled to network 604 . System 600 further includes mount 605 for mounting electronic device 606 for hardwire communication of information. Device 606 may also communicate with network 604 using a wirelessly communication network operably associated with network 604 and coupled, for example, via tower 607 .
[0069] During operation, system 600 communicates voice mail messages to a user utilizing email server 601 . For example, if a user receives a voice mail message, email server 601 would be notified and a voice mail message would be sent to the user's email account in the form of an email message. For example, a voice mail message would be sent to a user's email account within intranet 604 in the form of an audio file as an attachment to the email. Upon receiving the email, a user may click on the audio file representing the voice mail message to hear the message left by a caller.
[0070] In one embodiment, a user may be accessing the Internet via a phone line and, as such, be unable to receive notification that a voice mail message has been received. System 600 would receive the voice mail message and send an email comprising the voice mail message to the user email account. In this manner, a user can remain connected to the network and receive voice mail without having to log off or disconnect from the Internet. In one embodiment, a user may receive the voice mail message via a portable electronic device. For example, a user may be using remote device 605 operable to receive wirelessly communicated information. System 600 would receive the voice mail message and forward the voice mail message to a user's portable electronic device 606 . In this manner, a user may be capable of receiving voice emails at remote locations.
[0071] In another embodiment, a user may subscribe to use an Internet email account that may be operably associated with system 600 . Utilizing an Internet email account may allow a user the flexibility to check voice email messages from any location in the world. For example, a user may access a “Hotmail” email account while traveling on business in a foreign country. The user, upon gaining access to the “Hotmail” account, would be able to listen to voice mail messages sent to the user via the “Hotmail” email account. Through utilizing an email account to receive voice mail messages, a user may be afforded great flexibility in communicating voice mail messages. For example, a user may be able to forward a voice mail message received in the form of an email to one or a plurality of other email accounts. In this manner, a voice email message may be sent efficiently to other email users.
[0072] For example, a user may maintain a distribution list of individuals working on a particular project that may have a need to hear certain voice email messages. In this manner, a user may efficiently disseminate information to other individuals while adding additional textual information to the body of the email allowing a user to comment on the original voice email message. In another embodiment, a user may forward a received voice email message to another account operable to receive forwarded voice email messages. For example, system 600 may be operable to receive an email message having a voice mail message as an attachment. The system would then be operable to forward the voice mail message to specified phone number, separate email account, and/or voice mail account, etc. thereby providing a user flexibility in receiving voice email.
[0073] In one embodiment, a user may utilize an email account to establish an answering service for voice mails. For example, a user's telephone number may be operable with an email account to provide an answering service. A user may record a message for a specified phone number or extension and, upon receiving an incoming call; the recorded message may be played back to incoming the call's initiator. System 600 would then forward the received voicemail message via an email account to the user. For example, a user may have an account set up at a residence for receiving voicemail messages via a user-defined email account. The user could then forward all received voice mails from the home account to an email account at a place of work. Therefore, the user may have complete access to received voicemail messages. In the same manner, a user could set up their work phone number to forward a voicemail message to the user's home email account thereby allowing a user to receive a voicemail at a home email account. Therefore, system 600 may be operable in a plurality of ways to provide email messages comprised of voicemail messages received via a voice mail or email account.
[0074] FIG. 7 illustrates a flow chart for providing voice email messages according to one embodiment of the present invention. The method begins at step 701 where a voice mail message is left for a user. The message could be at a residence, place of business, etc. The method then proceeds to step 702 where the message may be stored as an audio file within a database operable to store a file comprised of the voice mail message. Upon storing the file, the method proceeds to step 703 where an electronic mail message may be generated. The electronic mail message may be addressed to the recipient of the voice mail message. The method then proceeds to step 704 where the audio file representing the voice mail message is attached to the electronic message.
[0075] Upon attaching the audio file, the method then proceeds to step 705 where the email message may be sent to the email address. Upon sending the email message the method proceeds to step 706 where the method determines if the email message should be sent to a wireless electronic device. If the message is not to be sent to a wireless device, the method proceeds to step 720 where the method ends. If the message is to be sent to a wireless electronic device, the method proceeds to step 707 where a signal may be sent to the wireless electronic device and at step 708 an indication is provided to the electronic device indicating that a voicemail message has been received via a user's email account. The method may then proceed to step 709 where the user decides whether or not to listen to the voice email message. If the user decides not to listen to the voice email message, the method may proceed to step 710 where the method ends. If the user decides to listen to the voice email message, the method proceeds to step 711 where a request may be sent by the electronic device requesting the voice email message be forwarded to the user's electronic device.
[0076] At step 712 , the voicemail message may be sent to the user's electronic device. Upon forwarding the voicemail message to the user the method may proceed to step 720 where the method ends. As such, FIG. 7 depicts one method of providing an email message comprised of a voice mail message. Certainly, other methods may be deployed as advancements in technology and are made without departing for the spirit and scope of the present invention.
[0077] FIG. 8 illustrates a flow diagram of a method for providing selected audio information to an electronic device according to one embodiment of the present invention. The method begins at step 800 where a user accesses a webpage via the Internet. The webpage may be a home page illustrated in FIG. 4 or other web pages operable to display selectable references to audio information. The method proceeds to step 801 where a user selects desirable audio information. For example, a user may select a single song, a plurality different songs, an entire album, a broadcast station, streaming audio, etc. or other selectable audio information. Upon the user selecting a reference to audio information, the method may proceed to step 802 where a playlist may be created that represents the user's selected audio information.
[0078] The playlist may be variable in size and comprised of a plurality of different types of available audio information. Upon creating a playlist, the method may proceed to step 803 where information associated with the playlist is obtained. For example, a list of network or URL locations comprised of the desirable audio information may be obtained. In this manner, desirable audio information may be obtained from many different sources such as URLs, network addresses, hard drives, databases comprised of audio information, etc. The sources may be accessed to obtain the selected audio information.
[0079] Upon obtaining data associated with the customized playlist, the method may proceed to step 804 where the user is prompted for a destination for the playlist. For example, a user may want to communicate the selected audio information to a remote electronic device, an automobile audio system, a home stereo system, a home computer, an electronic device coupled to a home network or computer system, etc. or other locations or devices operable to receive the selected audio information. In one embodiment, a user may select a device owned by a friend to accept the selected audio information. For example, a husband may want to send a romantic playlist to his wife on their anniversary. In this situation, the husband would select his wife's electronic device as the receiving device for the selected audio information.
[0080] Upon selecting a device, the method proceeds to step 805 where the method determines the destination of the selected audio information. If the information is to be sent to a device via a wire line connection, the method proceeds to step 813 where playlist data is sent to a user via a wire line connection. The method may then proceed to step 814 where the playlist is executed at the device. If the information is to be sent to a device requiring wireless communication, the method proceeds to step 806 where the information is formatted for communicating the information to a wireless electronic device. For example, a wireless PDA device may be selected as a destination device for the selected audio information. The PDA device may include an audio player, such as an MP3 player operable to play or execute MP3 audio files. In such an embodiment, the method could format the information such that the information may be wirelessly communicated and subsequently played by the MP3 player.
[0081] Upon formatting the information, the method may then proceed to step 807 where the audio information is wirelessly communicated to the selected device. In some embodiments, the device may be operable to receive a limited amount of information based upon storage capacity of the device (i.e., 16 MB). In such a case, the method may divide the information into component parts and periodically communicate the component parts, such as packets, to the electronic device. Upon communicating the audio information, the method may then proceed to step 808 where the signal may be received by the destination or electronic device.
[0082] The method may then proceed to step 809 where the method determines if all of the audio information has been received. For example, if 16 MB or 32 MB of selected audio information was initially transmitted due to capacity limitations of the selected device, the method may query the selected device to determine if capacity is available. If available memory exists, the method may proceed to step 807 where the method may communicate additional audio information based upon the amount of available memory. The method repeats until all of the selected audio information has been transmitted.
[0083] Upon communicating the selected information, the method may proceed to step 810 where the playlist may be executed. For example, a user may select a continuous communication of selected audio information (e.g., several hours of music. Internet broadcast, etc.). As such, the method may continuously play or execute the received audio information. In another embodiment, the method may proceed to step 811 where the method may store or buffer the received information until it is desirable to execute the received selected audio information. As such, upon executing the selected audio information, the method may proceed to step 809 where the method may repeat. In one embodiment, a user may elect to download a broadcast of an on-line radio station. For example, a user may want to listen to a radio station located in a remote location wherein conventional radio receivers could not receive the desired broadcast. For example, a person living in Houston, Tex. may not be able to receive a radio broadcast signal from a radio station in Seattle, Wash. utilizing a conventional radio receiver.
[0084] In accordance with the teachings of the present invention, a user may select an on-line broadcast or radio station as all or a part of the selected audio information. The user may then receive radio broadcasts without having to use a home computer system or conventional radio receiver.
[0085] At step 804 , a user may select a device that does not require remote communication of information. For example, a user may elect to communicate the selected audio information to device, such as a personal computer, PDA device, MP3 player, etc. coupled via a network connection to the Internet or an Intranet. The user may receive the selected playlist at the determined device for eventual playing. In one embodiment, a user may select a plurality of devices as destination devices for receiving downloads of the selected audio information. For example, the user may want to download the information to a home stereo system, a PDA device, and an automobile stereo. As such, the selected information may be communicated to more than one destination device. In addition, the format of the download may match or conform to the selected destination device(s).
[0086] The present invention may be configured in a plurality of ways to communicate desirable audio information to users by allowing users to select desirable audio information and transmitting the desirable audio information to a specified destination thereby allowing a user to receive on-demand customized audio information. Moreover, the download may occur in an off-line environment, allowing a user to enjoy the selected audio information accessed on-line without having to be on-line or utilizing a browsing environment. In one embodiment of the present invention, the method of FIG. 8 may be modified to allow a user to select a “user group” for receiving customized audio information. For example, a “user group” may include users that prefer contemporary jazz wherein a user may request a certain song. Therefore, a virtual request line may be designed for a specific genre of music allowing “members” to transmit audio information to the “group”.
[0087] In another embodiment of the present invention, the method may be modified to allow a user to select a specific genre to be transmitted to the users device. For example, a user may elect to have random country and western music transmitted to a destination device. The user could efficiently create a radio station format and have the format received at a destination device.
[0088] In a further embodiment, a user may select a group of genres to be downloaded to a desirable device. As such, the method may be modified to allow a user to select several different genres to download random music within the specified genres. In another embodiment, a user may elect to download the same music as another individual. For example, a user may want to download the same music as their best friend. Therefore the user could elect to download the same music as their friend or group of friends. In another example, a user may want to listen to the same music that an artist listens to on a specific weekday of evening. For example, a user may want to listen to the same music that Barry White listens to on a Saturday night.
[0089] Therefore, the user may select “Barry White's” Saturday night playlist and receive the same playlist Barry White receives on Saturday night. In another embodiment, the method of FIG. 8 may be modified to allow a user to manipulate song post download. For example, a user may want to store, delete, replay, copy, forward, etc. received audio information. Therefore, the method of FIG. 4 may be modified such that a user can manipulate or process the received audio information in a plurality of ways. In one embodiment of the present invention, an on-line radio station may be provided. For example, the radio station may be created for transmitting audio or on-line broadcasts. The on-line broadcasters or hosts may create their own format for broadcast. For example, an on-line radio station may be provided that transmits only children's songs.
[0090] Prior to conception of the present invention, conventional radio stations were monetarily limited to be capable of transmitting music such as children's songs to conventional radio receivers. The present invention, by providing a medium for transmitting selectable audio information, enables the existence of on-line broadcasting with little or no overhead cost for a host. A user may select an on-line broadcast for on-line or off-line delivery. In another embodiment, on-line broadcast of audio information representing books or novels may be provided to individuals such as the visually impaired. For example, an on-line broadcast station may provide several hours of audio information broadcast representing books or novels to be broadcast with very little overhead.
[0091] FIG. 9 illustrates an automobile console having a mount for an electronic device according to one embodiment of the present invention. Console 900 includes a conventional audio system 901 comprised of a receiver 902 and CD player 903 . Interface 904 may be coupled to audio system 901 via plug 905 and cable 908 , which may be coupled to an auxiliary line into audio system 901 . Interface 904 may also include contact 906 for contacting electronic device 907 . Cable 908 may be a multiple conductive cable for providing power from the automobiles power system via a protection circuit or fuse 909 for powering electronic device 907 . In one embodiment, interface 904 may be operable to recharge electronic device 907 utilizing a power source associated with an automobile.
[0092] During operation, electronic device 907 may be mounted within interface 904 . Electronic device 907 may also be powered or recharged via power line 910 and communicate with the systems audio system via interface cable or bus line 911 . Audio information communicated to electronic device 907 may be transferred to audio system 901 such that a user may listen to selected audio information. For example, a user may have previously selected a plurality of audio files to be transmitted to electronic device 907 . Electronic device 907 may communicate the selected audio information to the automobiles audio system that utilizes interface 901 thereby allowing the user to listen to selected audio information. In one embodiment, cable 908 may be custom-installed to audio system 901 . For example, the cable may be coupled to an auxiliary line for the system's radio or may be coupled to CD player line 912 .
[0093] In another embodiment, a radio manufacturer may provide interface 904 as a standard interface integrated into the audio system, thereby allowing communication between electronic device 907 , audio system 901 and/or console 900 . Electronic device 907 may include a plurality of different types of devices. For example, electronic device 907 may include a PDA device operable to store selected audio information. The information may be either remotely downloaded using an Internet web browser and wireless communication to the PDA device. In another embodiment, selected audio information may communicated to a PDA device via a hard wire coupled to a computer system interfacing with the Internet. In another embodiment, electronic device 907 may include an audio file player operable to play audio files such as MP3s, etc.
[0094] The audio files may be remotely or locally communicated to electronic device 907 and upon coupling to audio system 901 , the audio files may be transmitted to audio system 901 in a form receivable by audio system 901 . Although the disclosed embodiments have been described in detail, it should be understood that various changes, substitutions and alterations can be made to the embodiments without departing from their spirit and scope.
[0095] The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of the present invention. Accordingly, the present invention is not intended to be limited to the specific form set forth herein, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents, as can be reasonably included within the spirit and scope of the invention as provided by the claims below.
[0096] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.
|
A method for targeted advertising is disclosed. The method includes accessing at least one piece of demographic information associated with a user of a portable device, selecting an advertisement to be delivered to the user based at least in part on the demographic information, and initiating communication of a version of the advertisement configured for presentation at the portable device.
| 7
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a settling method using a credit card, a debit card, or one of various kinds of electronic money utilized by a mobile communication system represented by portable telephones.
[0002] Credit cards and debit cards have now filtered into consumers widely. In convenience stores, payment using a card has become possible. As its settlement method, a method of inserting a credit card into a card reader dedicated to settlement and installed in a store is typical. As for debit cards as well, a method of inserting a card into a card reader dedicated to settlement is adopted in the same way as the settlement of the credit cards. In a store having no card readers, debit cards cannot be used at all under the existing conditions.
[0003] Even if a person has a credit card, a debit card, or one of various kinds of electronic money, it cannot be used provided that a terminal for settlement is not installed in the store. For example, a credit card, a debit card, or various kinds of electronic money cannot be used easily as payment means in ordering pizza delivery.
SUMMARY OF THE INVENTION
[0004] In accordance with the present invention, a settlement method by various payment means using a subscriber terminal device of a mobile communication system that can be connected to the Internet, and the settlement method comprising of a process for originating a call from the subscriber terminal device, conducting communication with a database, and authenticating a payee; a process for displaying views on a screen of the subscriber terminal device in accordance with contents registered in the database, accepting at least a payment due and a payer name entered on the subscriber terminal device, and ascertaining whether there is illegality in the entered contents; a process responsive to no illegality in the entered contents for accepting a settlement number and a term of validity of the various payment means entered on the subscriber terminal device, acquiring an upper limit of use from the database on the basis of the entered contents, and determining whether the payment due is within the upper limit of use; a process for displaying at least the payer name, the payment due, the settlement number and the term of validity of various payment means on the subscriber terminal device if the payment due is within the upper limit of use, and transmitting settlement information from the subscriber terminal device to a settlement site in accordance with a payment operation corresponding to the display; a process for conducting communication from the settlement site, which has received the settlement information, to an administrative corporation of the various payment means, and requesting authentication; and a process responsive to success of the authentication, for executing settlement fixing processing between the settlement site and the subscriber terminal device and displaying settlement completion on the subscriber terminal device.
[0005] In this settlement method, the side of payee, for example, each of employees of a delivery pizza store or a taxi corporation owns a user ID and a password, then, authenticating the payee by using a subscriber terminal device of a payer or a payee side, which enables settlement by various payment means at a destination of delivery pizza or in an automobile. As the various payment means, debit cards and various kinds of electronic money such as prepaid electronic money can also be used besides credit cards.
[0006] There is also proposed a settlement method by various payment means using an adapter connected to an expansion terminal in a subscriber terminal device of a mobile communication system that can be connected to the Internet Includes: a process for originating a call from the subscriber terminal device by connecting the adapter, conducting communication with a database, displaying views on a screen of the subscriber terminal device with adapter in accordance with contents unique to the adapter registered in the database, accepting at least a payment due and a payer name entered on the subscriber terminal device with adapter, and ascertaining whether there is illegality in the entered contents; a process responsive to no illegality in the entered contents for accepting a settlement number and a term of validity of the various payment means entered on the subscriber terminal device with adapter, acquiring an upper limit of use from the database on the basis of the entered contents, and determining whether the payment due is within the upper limit of use; a process for displaying at least the payer name, the payment due, the settlement number and the term of validity of the various payment means on the subscriber terminal device with adapter if the payment due is within the upper limit of use, and transmitting settlement information from the subscriber terminal device with adapter to a settlement site in accordance with a payment operation corresponding to the display; a process for conducting communication from the settlement site, which has received the settlement information, to an administrative corporation of the various payment means, and requesting authentication; and a process responsive to success of the authentication, for executing settlement fixing processing between the settlement site and the subscriber terminal device with adapter and displaying settlement completion on the subscriber terminal device with adapter.
[0007] The adapter in this method incorporates a microcomputer, and it can be made small in size. Therefore, the payee side, for example, each of employees of a delivery pizza store or a taxi corporation can put the adapter in a pocket and carry it easily. By using a subscriber terminal device of a payer or a payee side, settlement using various payment means can be completed at a destination place of pizza delivery or in an automobile, so long as there is an adapter.
[0008] In such a settlement method using the various payment means, contact information of the payer is also entered for ascertainment when entering a payment due and a payer name on the subscriber terminal device with adapter. It is preferred to have formalities to determine whether there is illegality (such as use of a symbol that cannot be entered, or too many number of digit) in it's entering as well. As such contact information, E-mail address or a telephone number (fixed telephone or portable telephone) can be used. If the contact information is ascertained, an administrative corporation of the various payment means can make contact for personal verification at later time. In addition, if the contact information is a telephone number, then it is also possible to ascertain whether the provided phone number actually exists by inquiring a database when ascertaining illegality.
[0009] In the process for determining whether the payment due is within the upper limit of use in the settlement method of the present invention, it is possible to acquire an upper limit of payee provided for the payee (in the case of chained stores, it is desirable to provide an upper limit for each store), an upper limit of number provided for the settlement number of the various payment means, and an upper limit of employee provided for each of employees belonging to the store or an upper limit of adapter provided for an adapter are acquired from the database, and determine whether the payment due does not exceed the acquired upper limits. Each of these upper limits may be an upper limit per use of each time. More preferably, however, amounts of settlement money that have succeeded in totalizing periods determined respectively for the upper limits are inquired of the database and totalized respectively for the upper limits, and it is determined whether sum totals of these totalized amounts of money of settlements and the payment due do not exceed the corresponding upper limits. The totalizing period of the upper limits can be determined to be one month for the upper limit of the payee and the upper limit of the number, and to be one day for the upper limit of the employee or the upper limit of the adapter. In this case, the amount of settlements that have succeeded are totalized between the first day of that month and that day for the upper limit of the payee and the upper limit of the number, and the amount of settlements that have succeeded are totalized until the current point in time on that day for the upper limit of the employee or the upper limit of the adapter. If the totalizing periods are thus determined, it is effective in preventing a crime such as a fraud. In other words, if an upper limit is set for each time, settlement can be executed again and again so long as the upper limit is met each time. In order to prevent this, therefore, it is desirable to determine the upper limit per month or per day.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a flow chart showing a processing process executed in a subscriber terminal device according to the present invention;
[0011] FIG. 2 is a flow chart following the flow chart shown in FIG. 1 ;
[0012] FIG. 3 is a diagram showing a view displayed on a subscriber terminal device when entering a payment due and a credit card owner name;
[0013] FIG. 4 is a diagram showing a view displayed on a subscriber terminal device when entering a credit card number and a term of validity;
[0014] FIG. 5 is a diagram showing a view displayed on a subscriber terminal device when ascertaining a payment due and so on and executing a payment operation, and an error view displayed on a settlement site when an upper limit of use in the amount of money is exceeded;
[0015] FIG. 6 is a diagram showing an error view displayed on a settlement site when authentication could not be conducted by a card corporation;
[0016] FIG. 7 is a diagram showing a view displayed on a subscriber terminal device when settlement has been completed;
[0017] FIG. 8 is a diagram showing mail transmitted to a payee after settlement has been completed;
[0018] FIG. 9 is a flow chart showing a processing process executed in a subscriber terminal device with an adapter inserted therein according to a second embodiment of the present invention; and
[0019] FIG. 10 is a flow chart following a flow chart shown in FIG. 9 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] While exemplifying views displayed on a subscriber terminal device, concrete examples of processing processes in the case where a credit card is used. FIGS. 1 and 2 show flow charts of processing seen from the subscriber terminal device side. FIGS. 3 to 7 show views displayed on the terminal device in the processes.
[0000] (First Embodiment)
[0021] Hereafter, concrete examples of the processing processes will be described. First, a subscriber terminal device is connected to a specific URL (Uniform Resource Locator) via the Internet (step 101 ). Subsequently, a user ID and a password are entered (step 102 ). Authentication work is conducted on the entered user ID and password in a database (DB). If the user ID is already registered, then a store ID and an employee ID which associates with the user ID are acquired (steps 103 and 104 ). In the user ID, a store ID for managing store information and an employee ID for managing information of an employee belonging to the store are associated and registered in a database. As for the password, a one-time password may be used instead of registering a fixed password beforehand. In this case, the password is made disposable each time. Even if a password is stolen, therefore, the same password cannot be used twice, resulting in enhanced security.
[0022] If it is found as a result of the authentication work that there is no registration of the user ID in the DB, then the processing is finished at that time (step 105 ). If there is registration in the DB, then a store name and an image unique to a payee are prepared in accordance with the store ID acquired from the DB (step 106 ). Subsequently, explanation of processing contents to be conducted thereafter is displayed together with a logo as a top page. And an entering form view of a payment due and contact information of a payer (credit card owner), such as a telephone number and a credit card owner name (full name) in the present example, is displayed (step 107 ). An example of a view displayed on the subscriber terminal device at the step 107 is shown in FIG. 3 .
[0023] In accordance with the displayed view, the payee first enters a payment due, hands the subscribed terminal device to the payer, and makes the payer enter the telephone number of communication destination and the credit card owner name by himself or herself. If a return button (displayed as “Next” in FIGS. 3 and 4 ) in the view is clicked, then it is determined whether there is illegality, such as whether characters have been entered by using half size alphanumeric characters, whether a character that cannot be used has been used, or whether a telephone number is unnatural (step 108 ). If as a result there is illegality in the entered contents, then an error is displayed (step 109 ), and the processing returns to the step 107 to retry. The error display at this time is for example, “There is illegality in entering your name. Please enter your name again,” “The telephone number is not right. Please enter your telephone number again,” and “The payment due is not right. Please enter the payment due again.”
[0024] On the other hand, if there are no mistakes in the entered contents, then a unique character string is generated as a shopping ID by a server unit in the settlement site (i.e., encryption is conducted), and the entered contents are recorded in the DB together with the store ID and the employee ID (step 110 ). Subsequently, a URL provided with a program code, a shopping ID, a payment due, an article name, an additional item, and a flag of only authentication is generated, and a query is sent to the server of the settlement site to acquire an internal management number (step 111 ). The “program code” is an agent ID assigned to an agent of pertinent settlement software by the settlement site. The “article name” is an arbitrary character string (such as the agent name) defined in communication specifications for the settlement site. The “additional item” is a character string for internal processing delivered in order to facilitate finding a problem when the problem has occurred.
[0025] Upon acquisition of the internal management number, an entering form view of a credit card number and a term of validity is displayed together with the payment due entered earlier (step 112 ). FIG. 4 shows the entering form displayed at the step 112 . In this example, the full name of the payer and the payment due are displayed in an upper part. An entering column of a credit card number and an entering column of a term of validity are displayed under the upper part. In case of the present example, the term of validity is entered by a selection form.
[0026] If the entering operation is completed and a return button (a button having indication “next”) is clicked, then an upper use limit in the store=an upper limit of the payee, an upper limit of each employee belonging to the store=an upper limit of the employee, and an upper use limit of the card number=an upper limit of the number are acquired from the DB (step 113 ). In case of the present example, the sum total of use per month is determined as an upper limit for the upper limit of the payee and the upper limit of the number, whereas the total sum of use per day is determined as an upper limit for the upper limit of the employee. If at this time an upper limit exception that has not been timed out is set in the DB, then it is given priority. For example, if there is a special increase in the upper limit of the payee or the upper limit of the employee because of campaign (upper limit exception), then the upper limit exception is given priority during the campaign period (unless timeout has occurred).
[0027] Respective upper limits are thus acquired. As for the upper limit of the payee for the store and the upper limit of the number for the credit card number, amounts of money of settlements that have succeeded (that have been set in a settlement completion flag) since the first day of the month until that day are inquired of the DB and totalized. As for the upper limit of the employee for an employee belonging to the store, amounts of money of settlements that have succeeded until the current point in time of that day are inquired of the DB and totalized. The payment due is added to respective total amounts of settlements to calculate respective total amounts (step 114 ).
[0028] Subsequently, comparison is executed for each of upper limits to determine whether the respective calculated total amounts exceed the upper limit of the payee, the upper limit of the number, and the upper limit of the employee (step 115 ). If any of the upper limits is exceeded, then the kind of the exceeded upper limit, i.e., the upper limit of the payee, the upper limit of the number, or the upper limit of the employee is saved in the DB together with the credit card number and the term of validity, an error is displayed in the settlement site, and the processing returns to the step 112 (step 116 ). On the other hand, if any upper limit is not exceeded, then an ascertainment view of the full name, the telephone number, the payment due, the credit card number and the term of validity is displayed (step 117 ). FIG. 5 (A) shows an ascertainment view displayed on the subscriber terminal device at the step 117 . If an error is found at the step 116 , then an error display view shown in FIG. 5 (B) is displayed on the settlement site side.
[0029] If the ascertainment view is displayed at the step 117 and a return button (displayed as “pay” button) in the view is clicked as a payment operation, then transmission to the settlement site is conducted, and items of the above-described credit card owner name, telephone number, payment due, credit card number, and the term of validity, and the internal management number acquired at the step 111 are delivered (step 118 ).
[0030] It is desirable that communication at this time is conducted in the SSL (Secure Sockets Layer).
[0031] If settlement information containing these necessary items is delivered to the settlement site (step 119 ), then authentication is conducted from the settlement site to a card corporation (step 120 ). If the authentication has succeeded, the processing returns from the settlement site (step 121 ). If at this time the card number is imaginary, the card is rejected. In this case, an error view shown in FIG. 6 is displayed.
[0032] The settlement processing of the steps 116 to 121 is conducted by temporarily delivering the processing to the settlement site. For example, however, the settlement processing itself may also be conducted in the present system instead of separating the present system from the settlement site.
[0033] The subscriber terminal, which has delivered the settlement information at the step 118 , inquires of the settlement site whether the settlement may be conducted after a predetermined time (for example, 30 seconds) (step 122 ), and determines whether “OK” is returned (step 123 ). If “OK” is not returned, then it is determined whether the failure has occurred for the first time (step 124 ), If the failure has occurred for the first time, then the user is requested to wait for a predetermined time (for example, approximately 30 seconds) and execute the payment operation once more (step 125 ). If it is found at the step 124 that the failure has not occurred for the first time, then authentication cannot be conducted, and consequently an error display to the effect that the processing is discontinued is conducted, and contents of the error are recorded in the DB, and the processing is finished (step 126 ). It is also possible to prevent the same credit card number from being accepted thereafter, by recording the error contents in the DB.
[0034] If “OK” is returned at the step 123 , then settlement fixing processing is conducted between the present system and the settlement site (step 127 ). It is monitored whether “OK” is returned (step 128 ). If “OK” is not returned, then the process of the step 124 and subsequent steps is executed. If “OK” is returned, then the present system inquires of DB whether settlement is already completed (step 129 ). This is a countermeasure against a back operation (operation of “back” button) of the browser conducted in the subscriber terminal device. If the settlement is not completed (a completion flag is not set) (step 130 ), then a flag indicating the settlement completion is set in the DB and a mark of settlement completion is put (step 131 ). This flag serves as an index when totalizing the amounts of money of the successful settlements every card number.
[0035] Subsequently, the store name and E-mail address are acquired (step 132 ). E-mail to the effect that the settlement has been completed is delivered to the E-mail address, i.e., to the payee (step 133 ). And a payment completion view representing the store name and the payment due is displayed on the terminal screen and the processing is finished (step 134 ). If it is ascertained at the step 130 that the settlement has already been completed (the completion flag has been set), then the processing jumps to the step 134 to display the payment completion view representing the store name and the payment due and the processing is finished.
[0036] FIG. 7 shows the view displayed at the step 134 . FIG. 8 shows contents of the E-mail transmitted to the payee at the step 133 .
[0000] (Second Embodiment)
[0037] As another embodiment, a settlement method using a credit card and an adapter will now be described. First, the adapter is inserted into an expansion terminal in a subscriber terminal device, such as a portable telephone, in a mobile communication system. Thereupon, a microcomputer incorporated in the adapter is started. A call is automatically originated from the subscriber terminal device via the Internet, and the microcomputer is connected to a URL specified beforehand (step 201 ). Subsequently, an SSID (Service Set Identification) unique to the adapter is acquired by discomposing the URL (step 202 ). Inquiries are made in order to acquire a payee ID provided for a payee who is an owner of the adapter, and an adapter ID provided for the adapter itself from a database (DB) of the URL currently connected (step 203 ). In the case where the payee has a plurality of stores, it is desirable to register the payee ID as a store ID by every store. In the present example, a store ID and an adapter ID assigned to each adapter while taking the store as the unit are set.
[0038] Subsequently, it is determined whether there is registration of the SSID in the DB (step 204 ). If there is no registration, then the processing is finished at that point in time (step 205 ). If there is registration in the DB, then a store name and an image unique to a payee are prepared in accordance with the store ID acquired from the DB (step 206 ). Subsequently, explanation of processing contents to be conducted thereafter is displayed together with a logo as a top page. And an entering form view of a payment due and contact information of a payer (credit card owner), such as a telephone number and a credit card owner name (full name) in the present example, is displayed (step 207 ). An example of a view displayed on the subscriber terminal device with adapter at the step 207 is shown in FIG. 3 .
[0039] In accordance with the displayed view, the payee side first enters a payment due, hands the subscribed terminal device with adapter to the payer, and makes the payer enter the telephone number of communication destination and the credit card owner name by himself or herself. If a return button (displayed as “Next” in FIGS. 3 and 4 ) in the view is clicked, then it is determined whether there is illegality, such as whether characters have been entered by using half size alphanumeric characters, whether a character that cannot be used has been used, or whether a telephone number is unnatural (step 208 ). If as a result there is illegality in the entered contents, then an error is displayed (step 209 ), and the processing returns to the step 207 to retry. The error display at this time is for example, “There is illegality in entering your name. Please enter your name again.” “The telephone number is not right. Please enter your telephone number again.” “The payment due is not right. Please enter the payment due again.”
[0040] On the other hand, if there are no mistakes in the entered contents, then a unique character string is generated as a shopping ID by taking a server in the settlement site as the unit (i.e., encryption is conducted), and the entered contents are recorded in the DB together with the store ID and the employee ID (step 210 ). Subsequently, a URL provided with a program code, a shopping ID, a payment due, an article name, an additional item, and a flag of only authentication is generated, and a query is sent to the server of the settlement site to acquire an internal management number (step 211 ). The “program code” is an agent ID assigned to an agent of pertinent settlement software by the settlement site. The “article name” is an arbitrary character string (such as the agent name) defined in communication specifications for the settlement site. The “additional item” is a character string for internal processing delivered in order to facilitate finding a problem when the problem has occurred.
[0041] Upon acquisition of the internal management number, an entering form view of a credit card number and a term of validity is together with the payment due entered earlier (step 212 ). FIG. 4 shows the entering form displayed at the step 212 . In this example, the full name of the payer and the payment due are displayed in an upper part. An entering column of a credit card number and an entering column of a term of validity are displayed under the upper part. In the case of the present example, the term of validity is entered by a selection form.
[0042] If the entering operation is completed and a return button (a button having indication “next”) is clicked, then an upper use limit in the store=an upper limit of the payee, an upper limit of each adapter=an upper limit of the adapter, and an upper use limit of the card number=an upper limit of the number are acquired from the DB (step 213 ). In the case of the present example, the sum total of use per month is determined as an upper limit for the upper limit of the payee and the upper limit of the number, whereas the total sum of use per day is determined as an upper limit for the upper limit of the adapter. If at this time an upper limit exception that has not been timed out is set in the DB, then it is given priority. For example, if there is a special increase in the upper limit of the payee or the upper limit of the adapter because of campaign (upper limit exception), then the upper limit exception is given priority during the campaign period (unless timeout has occurred).
[0043] Respective upper limits are thus acquired. As for the upper limit of the payee for the store and the upper limit of the number for the credit card number, amounts of money of settlements that have succeeded (that have been set in a settlement completion flag) since the first day of the month until that day are inquired of the DB and totalized. As for the upper limit of the adapter for an adapter belonging to the store, amounts of money of settlements that have succeeded until the current point in time of that day are inquired of the DB and totalized. The payment due is added to respective total amounts of settlements to calculate respective total amounts (step 214 ).
[0044] Subsequently, comparison is executed for each of upper limits to determine whether the respective calculated total amounts exceed the upper limit of the payee, the upper limit of the number, and the upper limit of the adapter (step 215 ). If any of the upper limits is exceeded, then the kind of the exceeded upper limit, i.e., the upper limit of the payee, the upper limit of the number, or the upper limit of the adapter is saved in the DB together with the credit card number and the term of validity, an error is displayed in the settlement site, and the processing returns to the step 212 (step 216 ). On the other hand, if any upper limit is not exceeded, then an ascertainment view of the full name, the telephone number, the payment due, the credit card number and the term of validity is displayed (step 217 ). FIG. 5 (A) shows an ascertainment view displayed on the subscriber terminal device with adapter at the step 217 . If an error is found at the step 216 , then an error display view shown in FIG. 5 (B) is displayed on the settlement site side.
[0045] If the ascertainment view is displayed at the step 217 and a return button (displayed as “pay” button) in the view is clicked as a payment operation, then transmission to the settlement site is conducted, and items of the above-described credit card owner name, telephone number, payment due, credit card number, and the term of validity, and the internal management number acquired at the step 211 are delivered (step 218 ). It is desirable that communication at this time is conducted in the SSL (Secure Sockets Layer).
[0046] If settlement information containing these necessary items is delivered to the settlement site (step 219 ), then authentication is conducted from the settlement site to a card corporation (step 220 ). If the authentication has succeeded, the processing returns from the settlement site (step 221 ). If at this time the card number is imaginary, the card is rejected. In this case, an error view shown in FIG. 6 is displayed at the settlement site.
[0047] The subscriber terminal device with adapter, which has delivered the settlement information at the step 218 , inquires of the settlement site whether the settlement may be conducted after a predetermined time (for example, 30 seconds) (step 222 ), and determines whether “OK” is returned (step 223 ). If “OK” is not returned, then it is determined whether the failure has occurred for the first time (step 224 ). If the failure has occurred for the first time, then the user is requested to wait for a predetermined time (for example, approximately 30 seconds) and execute the payment operation once more (step 225 ). If it is found at the step 224 that the failure has not occurred for the first time, then authentication cannot be conducted, and consequently an error display to the effect that the processing is discontinued is conducted, and contents of the error are recorded in the DB, and the processing is finished (step 226 ) It is also possible to prevent the same credit card number from being accepted thereafter, by recording the error contents in the DB.
[0048] If “OK” is returned at the step 223 , then settlement fixing processing is conducted between the present system and the settlement site (step 227 ). It is monitored whether “OK” is returned (step 228 ). If “OK” is not returned, then the process of the step 224 and subsequent steps is executed. If “OK” is returned, then the present system inquires of DB whether settlement is already completed (step 229 ). This is a countermeasure against a back operation (operation of “back” button) of the browser conducted in the subscriber terminal device having an adapter. If the settlement is not completed (a completion flag is not set) (step 230 ), then a flag indicating the settlement completion is set in the DB and a mark of settlement completion is put (step 231 ). This flag serves as an index when totalizing the amounts of money of the successful settlements every card number.
[0049] Subsequently, the store name and E-mail address set so as to be unique to the adapter are acquired (step 232 ). E-mail to the effect that the settlement has been completed is delivered to the E-mail address, i.e., to the payee (step 233 ). And a payment completion view representing the store name and the payment due is displayed on the terminal screen and the processing is finished (step 234 ). If it is ascertained at the step 230 that the settlement has already been completed (the completion flag has been set), then the processing jumps to the step 234 to display the payment completion view representing the store name and the payment due and the processing is finished.
[0050] FIG. 7 shows the view displayed at the step 234 . FIG. 8 shows contents of the E-mail transmitted to the payee at the step 233 .
[0051] In the settlement method as above described, it is also possible to previously collect security money from the payee in order to prevent a fraud. As for remittance from the settlement site administrative corporation to the payee, it is desirable to make a contract so as to conduct the remittance after actual receipt of money from the payer, i.e., the credit card owner. Furthermore, by using the adapter, the labor for entering the user ID and password on the subscriber terminal device can be saved. In addition, if the adapter is provided with a function of a card reader, it is also possible to add information read from the credit card besides the information of the credit card owner obtained by using the subscriber terminal device.
[0052] In the foregoing description of both the first and second embodiments, a credit card is used. Settlement using a debit card or one of various kinds of electronic money, which is a different settlement means, will now be described. For example, if prepaid electronic money is used as electronic money, then the payer enters a settlement number stated on the prepaid card owned by the payer, in the processing process for entering a credit card number included in the processing in the first or second embodiment. At this time, the full name and telephone number of the payer are entered in the same way as the first and second embodiments. Typically, in the case where such a prepaid card is used, it is seldom that the payer's own information is disclosed. Therefore, it is also possible to omit the payer's own information and enter only a number dedicated to settlement. After entering, processing processes similar to those conducted when using a credit card in the first or second embodiment are executed. Settlement processing of the payee and settlement processing of the prepaid card are conducted (not illustrated), and the payment is completed.
[0053] Also when using a debit card, a number of a cash card of a financial agency owned by the payer is entered in the scene in which the credit card number is entered in the first or second embodiment, in the same way as the case where the prepaid card is used. When using a credit card, however, the name and telephone number are entered as information of the payer. However, it is also possible to enter a secret identification number in accordance with the use form of the typical debit card. After the entering, settlement processing of the payee and settlement processing of the debit card are conducted (not illustrated) in the same way as the first or second embodiment, and the payment is completed.
[0054] In order to meet the convenience of the payer, the payer may be made to select a credit card, a debit card, or one of various kinds of electronic money as a payment method in, for example, the view displayed at the step 107 in FIG. 1 or at the step 207 in FIG. 9 (the view shown in FIG. 4 ).
[0055] According to the settlement method of the present invention, it becomes possible to conduct settlement using a credit card, a debit card, or one of various kinds of electronic money by using only a subscriber terminal device of mobile communication, such as a portable telephone, as above described. Therefore, the opportunity of using cards can be greatly widened.
|
There is proposed a settlement method that facilitates use of credit cards, debit cards, and various kinds of electronic money by using a familiar device. A settlement method by various payment means using a subscriber terminal device of a mobile communication system that can be connected to the Internet includes a process for originating a call from the subscriber terminal device, conducting communication with a database, and authenticating a payee; a process for displaying views on a screen of the subscriber terminal device in accordance with contents registered in the database, accepting at least a payment due and a payer name entered on the subscriber terminal device, and ascertaining whether there is illegality in the entered contents; a process responsive to no illegality in the entered contents for accepting a settlement number and a term of validity of the various payment means entered on the subscriber terminal device, acquiring an upper limit of use from the database on the basis of the entered contents, and determining whether the payment due is within the upper limit of use; a process for displaying at least the payer name, the payment due, the settlement number and the term of validity of various payment means on the subscriber terminal device if the payment due is within the upper limit of use, and transmitting settlement information from the subscriber terminal device to a settlement site in accordance with a payment operation corresponding to the display; a process for conducting communication from the settlement site, which has received the settlement information, to an administrative corporation of the various payment means, and requesting authentication; and a process responsive to success of the authentication, for executing settlement fixing processing between the settlement site and the subscriber terminal device and displaying settlement completion on the subscriber terminal device.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/277,449 filed Nov. 25, 2008, the contents of which are incorporated by reference herein in their entirety.
BACKGROUND
Exemplary embodiments relate generally to managing network elements, and more particularly to managing voice over Internet protocol (VoIP) network elements.
Although VoIP technology has been in the market for several years, its service assurance for performance, reliability, and maintenance automation is relatively new in the network management arena. VoIP billing records, referred to as call detail records (CDRs), from multiple network equipment vendors are used separately to monitor and proactively respond to network or service impacting events. Without a common correlation identifier for CDRs among all VoIP network elements, it is difficult to produce an accurate end-to-end view of a telephone call. Network managers are forced to use inexact methods to correlate events, such as relating in-going and out-going Internet Protocol (IP) addresses. These inexact methods can lead to inaccurate call statistics for the entire VoIP network and for each service supported in the VoIP network. In addition, the performance alerts generated from each type of network element may not reflect the actual trouble area.
BRIEF SUMMARY
Exemplary embodiments include a method for managing VoIP network elements. The method includes receiving call details records (CDRs) from a plurality of network elements. The received CDRs include disconnect cause codes and telephone call correlation identifiers. The received CDRs are correlated to telephone calls based on the telephone call correlation identifiers. Two CDR records are associated with the same telephone call when their telephone call correlation identifiers are the same. A master correlated CDR is created for each telephone call. The creating includes assigning a correlated disconnect cause code and classifying the telephone call. The assigning and classifying are responsive to the received CDRs associated with the telephone call. The master correlated CDR includes the correlated disconnect cause code and the telephone call classification. A threshold crossing alert (TCA) is generated in response to a threshold for the correlated disconnect cause code being reached.
Additional exemplary embodiments include a system for managing VoIP network elements. The system includes a CDR collector machine receiving CDRs from a plurality of network elements. The received CDRs include disconnect cause codes and telephone call correlation identifiers. The system also includes a master correlated CDR machine that correlates the received CDRs to telephone calls based on the telephone call correlation identifiers. Two CDR records are associated with the same telephone call when their telephone call correlation identifiers are the same. The master correlated CDR machine also creates a master correlated CDR for each telephone call. The creating includes assigning a correlated disconnect cause code and classifying the telephone call. The assigning and classifying are responsive to the received CDRs associated with the telephone call. The master correlated CDR includes the correlated disconnect cause code and the telephone call classification. The system also includes an alert processing machine generating a TCA in response to a threshold for the correlated disconnect cause code being reached.
Further exemplary embodiments include a computer program product, tangibly embodied on a computer readable medium, for managing VoIP network elements. The computer program product has instructions for causing a computer to execute a method, which includes receiving call details records (CDRs) from a plurality of network elements. The received CDRs include disconnect cause codes and telephone call correlation identifiers. The received CDRs are correlated to telephone calls based on the telephone call correlation identifiers. Two CDR records are associated with the same telephone call when their telephone call correlation identifiers are the same. A master correlated CDR is created for each telephone call. The creating including assigning a correlated disconnect cause code and classifying the telephone call. The assigning and classifying are responsive to the received CDRs associated with the telephone call. The master correlated CDR includes the correlated disconnect cause code and the telephone call classification. A threshold crossing alert (TCA) is generated in response to a threshold for the correlated disconnect cause code being reached.
Other systems, methods, and/or computer program products according to exemplary embodiments will be or become apparent to one with skill in the art upon review of the following drawings and detailed description. It is intended that all such additional systems, methods, and/or computer program products be included within this description, be within the scope of the exemplary embodiments, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several FIGs.:
FIG. 1 illustrates a high level view of a process for managing VoIP network elements that may be implemented by exemplary embodiments;
FIG. 2 illustrates a block diagram of a system that may be implemented by exemplary embodiments to manage VoIP network elements;
FIG. 3 illustrates a process flow for managing VoIP network elements that may be implemented by exemplary embodiments; and
FIG. 4 illustrates a process flow for creating correlated CDRs that may be implemented by exemplary embodiments.
The detailed description explains the exemplary embodiments, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Exemplary embodiments provide, as part of voice over Internet protocol (VoIP) network maintenance automation, an accurate end-to-end view of a telephone call as it travels through the network. This end-to-end view of the telephone call is created by utilizing a common telephone call correlation identifier (ID) for call detail records (CDRs) among all VoIP network elements utilized by the telephone call. The common telephone call correlation ID is utilized to generate a master correlated CDR that reflects the CDRs generated by the network elements utilized by the telephone call. In exemplary embodiments, the common telephone call correlation ID is also utilized to provide an end-to-end view of threshold crossing alerts, and to generate call statistics and reports.
FIG. 1 illustrates a high level view of a process for managing VoIP network elements that may be implemented by exemplary embodiments. VoIP CDRs are generated by network elements (e.g., border elements, central control elements, and application servers) in a VoIP network 102 . A CDR provides detailed information about telephone calls that originate from, terminate at, or pass through each network element in the VoIP. In exemplary embodiments, the CDRs include information that may be utilized for billing such as, but not limited to: arrival time at network element, exit time from network element, record type, disconnect cause code, and telephone call correlation ID. The CDRs are received at a CDR processing module/system 104 to perform CDR collection, correlation, analysis, alerting and reporting.
The CDR processing module/system 104 generates threshold crossing alerts (TCAs) (also referred to herein as TCA performance alerts) when specified thresholds are exceeded. TCA performance alerts may be generated for network conditions such as blockage, cutoff, busy, packet loss, particular disconnect cause codes, data not ready, and ring no answer. In exemplary embodiments, the TCA performance alerts are fed into an alarm correlations module/system 106 along with VoIP network traps (also referred to herein as native traps) from the network elements. The alarm correlations module/system 106 correlates the network element native traps and the TCA performance alerts and generates correlated alerts that are fed into a rules module/system 108 . The rules module/system 108 includes additional rules for further alarm reduction. The rules module/system 108 generates alerts that are fed into a ticketing module/system 110 for generating service tickets that in exemplary embodiments are sent to a work center for evaluation and/or trouble-shooting.
FIG. 2 illustrates a block diagram of a system that may be implemented by exemplary embodiments to manage VoIP network elements. The system includes several network elements 202 , each generating a CDR 210 having data that includes a telephone call correlation ID (labeled “Corr. ID X”) and a disconnect cause code (labeled “DC#”). In the system depicted in FIG. 2 , a fault occurs at the network element 202 labeled “NE4.” In the exemplary embodiment depicted in FIG. 2 , the correlation IDs are the same for all of the CDRs 210 because they all are associated with the same telephone call in the VoIP network. In exemplary embodiments, the disconnect cause codes differ depending on the type of network element, the network element vendor, and the stage of progress of the call. Disconnect cause codes may include, but are not limited to: blockage, cutoff, busy, packet loss, particular disconnect cause codes, data not ready, and ring no answer
As depicted in FIG. 2 , the CDRs 210 are collected by a CDR collector machine 204 . As used herein, the term “machine” refers to computer software and/or hardware elements. The CDR collector machine 204 sends the CDRs 210 to a master correlated CDR machine 206 . The master correlated CDR machine 206 creates master correlated CDRs 212 for each telephone call and transmits them to alert processing and reporting machines 208 . In exemplary embodiments, the master correlated CDRs 212 include a correlated disconnect cause code and a telephone call classification. Additional data may also be provided in the master correlated CDR 212 such as telephone call start and stop time, record type, call direction and network element node name list. In exemplary embodiments, the CDR collector machine 204 , the master correlated CDR machine 206 , and the alert processing and reporting machines 208 make up the CDR processing module/system 104 depicted in FIG. 1 .
In exemplary embodiments, the alert processing and reporting machines 208 generate reports based on the master correlated CDRs 212 . Exemplary embodiments generate master correlated CDR detail reports autonomously to alleviate human intervention. In addition, exemplary embodiments include allowing a report requestor (e.g., a user) to query and view the master correlated CDR data. In further exemplary embodiments, the report requestor may filter, sort, perform trend analysis, transfer, and/or electronically mail the reports.
In exemplary embodiments, the master correlated CDRs 212 are stored for a configurable time period to avoid the necessity of storing individual network element CDRs 210 .
In exemplary embodiments, the alert processing and reporting machines 208 perform master correlated CDR analysis and overall call statistics generation based on the master correlated CDRs 212 . Derived overall telephone call statistics may be generated based on: per call classification, per call direction (e.g., from PSTN to VoIP, from VoIP to VoIP), per call service (e.g, business VoIP), total call attempts, and other criteria. In addition, other overall statistics such as average holding time per call direction and per service may be derived. Statistics derived from the individual network element CDRs 210 and the master correlated CDRs 212 may be stored for a configurable period of time.
FIG. 3 illustrates a process flow for managing VoIP network elements that may be implemented by exemplary embodiments. At block 302 , CDRs, such as the CDRs 210 from a plurality of network elements 202 are received at the CDR collector machine 204 . The CDRs 210 are associated with one or more telephone calls via the common telephone call correlation ID that is assigned by the network elements 202 when CDRs, such as the CDRs 210 are created. At block 304 , the received CDRs 210 are correlated to the telephone calls by the master correlated CDR machine 206 . The CDRs 210 that have the same telephone call correlation ID are associated with the same telephone call. At block 306 , a master correlated CDR 212 , such as the master correlated CDR 212 , is created for each telephone call by the master correlated CDR machine 206 . In exemplary embodiments, the master correlated CDRs 212 include a correlated disconnect cause code and a telephone call classification.
At block 308 in FIG. 3 , a TCA is generated if a performance threshold has been reached. As described previously, TCA performance alerts may be generated for network conditions such as, but not limited to, blockage, cutoff, busy, packet loss, particular disconnect cause codes, data not ready, and ring no answer. The TCA is forwarded to the alarms correlations module/system 106 and rules system 108 for trouble ticket generation. In exemplary embodiment, thresholds on call failure data are set based on expert judgment on the likelihood of events of this type occurring. In other exemplary embodiments a feed of master correlated CDRs 212 is sent to a test system that has a set of trial thresholds implemented. Different network scenarios can then be implemented and sensitivity to the problem adjusted. In addition, a duplicate CDR feed of master correlated CDRs 212 from the live network can be sent to a test system to “soak test” a proposed set of thresholds. It can be appreciated that there is a fine line that needs to be tread between being sensitive to real network problems and generating a lot of false positives which flood network managers with a lot of alerts, which they eventually may become de-sensitized to.
In exemplary embodiments, thresholds are set in order to balance detection of real and persistent problems with generating so many alerts that network managers disregard them. Exemplary systems have the ability to perform persistence and aging processing with alerts being processed at regular specified intervals (e.g. five minutes). In exemplary embodiments, the first time a threshold is crossed in the specified interval, a decision to take no action may be made unless the same problem occurs in the next specified interval. In exemplary embodiments, the threshold for any problems with calls associated with “911” service are set to the lowest possible value in order to trigger an immediate alert. The number of specified intervals can be provisioned to wait after a threshold is crossed before triggering an alert. TCA alerts and corresponding clears are used to indicate that a problem no longer exists. The number of specified intervals can be configured to wait when the threshold for a particular alert is no longer crossed. Clears indicate to network managers that a problem is no longer impacting the network but that they still may need to take some action to see if it may recur. Clear can be set up to automatically close trouble tickets or to remove alerts visually displayed on wall boards used by the network managers to monitor network health.
Master correlated CDRs 212 that indicate defects in associated entities can be aggregated. This includes such targets for aggregation as numbering plan area (area code), network element (e.g., switch), service (e.g., 911 calls, various business offerings), and disconnect code (e.g., timer expiration). Separate thresholds can be set for the number of defect calls aggregated against a node in a specified time period, an area code in a specified time period, and so forth. For example, it may be decided that, if there are one hundred telephone calls with the defect of blocked for a network element 202 within a specified time period, then a network element block alert will be generated if a specified number of additional telephone calls with a defective block are received. If after waiting a further specified time interval, the number of defects has stayed below the threshold of one hundred, then a clear is issued for the event.
FIG. 4 illustrates a process flow for creating master correlated CDRs 212 that may be implemented by exemplary embodiments. In exemplary embodiments, the process depicted in FIG. 4 is implemented by the master correlated CDR machine 206 depicted in FIG. 2 . At block 402 , all CDRs 210 received from network elements 202 with the same telephone call correlation ID are processed. In exemplary embodiments, the system may need to delay a time interval until all of the CDRs 210 for a telephone call are received. At block 404 , telephone call characteristics are determined based on contents of the CDRs 210 associated with the telephone call. In exemplary embodiments this includes characteristics such as earliest start time, latest stop time, record type (attempt or stop), call direction, network element node name list, disconnect cause code list, and other unique and common CDR fields of interest (e.g., to a particular vendor or network element). In exemplary embodiments, a record type of attempt means that the call failed and the disconnect cause code should be taken into account, and a record type of stop means that the call was successful.
In exemplary embodiments, an “n-field rule” that uses the values of a subset of “n” fields in the master correlated CDR 212 is utilized to assign the correlated disconnect cause code and to classify the telephone call. At block 406 , a correlated disconnect cause code is assigned to the master correlated CDR 212 . In exemplary embodiments, the correlated disconnect codes include, but are not limited to: blockage, cutoff, busy, packet loss, particular disconnect cause codes, data not ready, and ring no answer. The individual disconnect codes in the CDRs 210 are examined and a set of rules is implemented. Typically, when something goes wrong in a chain of network elements handling a call, the disconnect code for the failed network element 202 is the most informative. Disconnect codes from network elements 202 previous to it may indicate a success or failure; and network elements 202 after the failed network element 202 will either echo the failed network element's disconnect code or pass along their particular version of it. The chain of disconnect codes on the CDRs 210 are examined to find the first failure. The correlated disconnect code typically reflects the disconnect code of the first failed network element 202 in the chain of network elements handling the telephone call.
An example of a call characteristic is duration time; if all of the calls are suddenly staying up for only a short period of time there may be a problem. Another example call characteristic is packet loss; it may indicate that the call stayed up, but that the audio quality was poor. Often, CDRs 210 contain embedded billing information that relate the call to a particular network provider offering and this can be utilized to indicate that a particular network provider service is having a problem.
At block 408 , a call classification is assigned to the master correlated CDR 212 . Call classifications include, but are not limited to: ring no answer, busy, successful, blocked, and cutoff. In exemplary embodiments, the CDR n-field rules described previously are utilized to classify the calls. For example, one of the “n-fields” indicates whether the call was successful or that it had failed. If the call failed, then another field of the “n-fields” indicates what the problem is related to. It could indicate that the call is related to a block (i.e., the call never even gets set up to the point where user communication takes place), or that the call was “cut-off” (the call got set up okay, but it was terminated due to something other than satisfied users hanging up the phone). Various disconnect codes (more of the n-fields) indicate if the call was a ring no answer, busy, or successful. Other parameters, such as call direction (e.g., VoIP-to-PSTN, PSTN-to-VoIP, VoIP-to-VoIP) help isolate the problem to the VoIP network platform, or the public switched telephone network (PSTN). In exemplary embodiments, a disconnect initiator indicates if the calling party, the called party, or the switch hung up the call. If the call direction is PSTN-to-VoIP and the call terminator is always the called party, and this seems to be happening in excess, then there may be a problem with the VoIP network.
Technical effects and benefits of exemplary embodiments include the ability to utilize a common correlation ID for the CDR 210 from different network elements 202 and different network element vendors. Thus, a master correlated CDR, such as the master correlated CDR 212 , may be generated based on information from the CDR 210 from multiple network elements 202 utilized by a telephone call. This allows for an accurate end-to-end view of call statistics and reporting. In addition, this may lead to a reduction in the amount of time required to analyze performance alerts.
As described above, exemplary embodiments can be in the form of computer-implemented processes and apparatuses for practicing those processes. Exemplary embodiments can also be in the form of computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the exemplary embodiments. Exemplary embodiments can also be in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the exemplary embodiments. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.
While the present disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular exemplary embodiments disclosed for carrying out this invention, but that the present disclosure will include all embodiments falling within the scope of the claims. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
|
Methods, computer program products, and systems for managing VoIP network elements are provided. Methods include receiving call details records (CDRs) from a plurality of network elements. The received CDRs including disconnect cause codes and telephone call correlation identifiers. The received CDRs are correlated to telephone calls based on the telephone call correlation identifiers. Two CDR records are associated with the same telephone call when their telephone call correlation identifiers are the same. A master correlated CDR is created for each telephone call. The creating includes assigning a correlated disconnect cause code and classifying the telephone call. The assigning and classifying are responsive to the received CDRs associated with the telephone call. The master correlated CDR includes the correlated disconnect cause code and the telephone call classification. A threshold crossing alert (TCA) is generated in response to a threshold for the correlated disconnect cause code being reached.
| 7
|
BACKGROUND OF THE INVENTION
The present invention is directed generally to a method and apparatus for locating a catheter and more particularly to a method and apparatus for locating the position of a catheter so that a transducer assembly may be brought into the same horizontal plane as the catheter.
Physiological fluid pressure data is helpful in assessing the health of individuals. For example, intracranial pressure, intrauterine pressure, left atrial pressure, pulmonary artery pressure, and central venous pressure assist health care providers in prescribing and providing health care.
One indicator of a patient's health is her or his blood pressure. Blood pressure may be measured using both noninvasive and invasive techniques. The most common noninvasive techniques are palpation, ultrasound, and flush (each of which utilizes at least one sphygmomanometer cuff). Invasive or direct pressure measurement techniques are also available and widely used by health care providers.
Invasive or direct pressure techniques provide many advantages over noninvasive techniques. For example, long-term continuous observation permits monitoring slight trend-setting changes in the cardiovascular system; the effectiveness of fluid and medication therapies may be determined; and an accurate appraisal may be obtained even if a patient is in shock.
Hemodynamic monitoring of hospital patients requires that the zero (air) port of the monitoring transducer assembly be at the same level as the catheter.
Accordingly, a primary object of the present invention is to provide an improved method and apparatus for locating the position of a catheter.
Another object of the present invention is to provide a method and apparatus for locating the position of a catheter with a single x-ray.
Another object of the present invention is to provide a method and apparatus for locating the position of a catheter that is inexpensive, durable, easy to use, and safe.
Another object of the present invention is to provide a method and apparatus for locating the position of a catheter that is adapted for use with existing hemodynamic monitoring equipment.
Another object of the present invention is to provide a method and apparatus for locating the position of a catheter that allows a patient to be maintained, or repeatedly moved, as comfort requires, in any position necessary before and during hemodynamic monitoring.
Another object of the present invention is to provide a method and apparatus for locating the position of a catheter that does not increase patient trauma.
SUMMARY OF THE INVENTION
The present invention teaches a novel method and apparatus for locating the position of a catheter. The apparatus may be utilized with a leveling device for patient hemodynamic monitoring. The indicator includes a radio transparent sheet material containing a plurality of spaced apart radio opaque material portions. Also provided is a means for fastening the sheet material to a human body.
An X-ray may be taken so that the location of a catheter may be determined in relation to the radio opaque portions of the radio transparent sheet material. Once the location of the catheter is determined a simple bubble level device may be utilized to bring a hemodynamic transducer assembly into level with the inserted catheter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view illustrating a patient seated on a bed next to a nightstand with a pressure transducer assembly connected to an IV stand. Attached to the patient is the catheter position indicator. Also illustrated is a bubble level connected between the catheter position indicator apparatus and the zero level of the pressure transducer assembly;
FIG. 2 is a perspective view of a preferred embodiment of the catheter position indicator showing the radio transparent sheet material, peel away adhesive protective back, and the radio opaque level engagement rings;
FIG. 3 is a perspective view of a string having hooked ends with a bubble level indicator supported thereon for connection between the catheter position indicator and the pressure transducer assembly;
FIG. 4 is a partial front view of a patient showing the thoracic cavity in relation to the catheter position indicator;
FIG. 5 is a side view of a patient showing the thoracic cavity in relation to the catheter position indicator;
FIG. 6 is a partial front view of a patient with the catheter position indicator in place and showing alternative entry locations for the catheter;
FIG. 7 is a partial enlarged, partial sectional detailed view showing the position of a catheter tip within the heart of a patient; and
FIG. 8 is a partial enlarged, partial sectional detailed view showing the position of a Swan-Ganz catheter tip within the heart of a patient.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The catheter position indicator 10 is illustrated in FIG. 2. FIGS. 4 and 5 best illustrate the patient attachment location of the catheter position indicator 10. FIGS. 7 and 8 illustrate the human heart and the preferred position of two different types of catheters used for hemodynamic monitoring. FIG. 6 illustrates the preferred catheter insertion pathways for hemodynamic monitoring. FIG. 3 illustrates a common leveling device for attachment between the catheter position indicator and a pressure transducer assembly. FIG. 1 illustrates the catheter position indicator in use with a hemodynamic monitoring and leveling assembly.
The catheter position indicator 10 is preferably formed of a radio transparent sheet material 12 having an adhesive backing 14 for adhering the sheet material 12 to the epidermal layer 70 of the human body.
The adhesive backing 14 is preferably formed of a non-toxic tack adhesive capable of painless removal from the epidermal layer 70. Also included is a peel-away backing 16 for preventing the adhesive baokinq 14 from adhering to objects prior to placement of the catheter position indicator 10.
Affixed to the front surface of the radio transparent sheet material 12 are a plurality of spaced apart radio opaque hook fasteners 18. The fasteners 18 are spaced apart in a graduated fashion along the surface of the sheet material 12, and are adhered to the sheet material 12 by an adhesive 72.
Radio transparent materials are well known to the art. The sheet material 12 may be formed from an extrudable polyvinyly chloride with a high plasticizer content. One side of the radio transparent sheet material 12 may be calendar coated with a tack adhesive backing 14. So that the release paper or peel-away backing 16 does not become permanently adhered to the adhesive 14 it may be coated with silicon or any other suitable non-stick substance.
Radio opaque materials are well known to the art. The fasteners 18 may be formed of a length of cord treated with a radio opaque dye, stainless steel, or other metallic substance. However, in a preferred embodiment the fasteners as may be formed of a polymer such as nylon or polyvinylchloride with a high metallic powder content.
Additionally, although not shown in the drawings, a rule may be formed within the radio transparent sheet material 12 that has radio opaque graduations along its surface. In this fashion a single fastener 18 may be removably adhered by a hook and loop type fastener along the surface of the catheter position indicator 10.
In operation the catheter position indicator 10 may be utilized as follows. A patient 74, in either a supine, semi Fowler, or seated position may have her or his arm raised so as to expose the axillary region 76. The area may be shaved so as to permit the adhesive 14 of the indicator 50 from adhering to any hair that might be present. The peel-away backing 56 may be removed from the indicator 10 and the indicator, adhesive side first, may be adhered against the epidermal layer 70 of the patient 74.
The indicator 50 should be placed so that it is centered around the phlebostatic axis 40 of the patient 74 (FIGS. 4 and 5). The phlebostatic axis 40 is located at the intersection of the fourth intercostal space 42 where it joins the sternum 44 and the mid axillary line. In this way the indicator 50 covers the outermost point of the posterior chest 72 (FIGS. 4 and 5).
Several physiological fluid pressures are important health indicators in clinical medicine. For example, where peripheral arterial pressure data is necessary a catheter 50 may be inserted through the radial, brachial 32, axillary, or femoral 36 arteries.
Additionally, a determination of mean arterial pressure is helpful in indicating the functional pressure that exists in the peripheral arterial system during all phases of the cardiac cycle. Mean arterial pressure may be measured with a catheter do inserted through the radial, brachial 32, axillary, or femoral 36 arteries.
Further, where efficient regulation of fluid replacement is necessary, central venous pressure may be utilized as a guide. The catheter 50 may be inserted into the left or right brachial vein 34 and passed into the superior vena cava 8.
Where left ventricular 26 performance data is necessary the catheter 10 may be passed far enough into the pulmonary artery 30 so that left atrium 22 pressure is measured (left atrium pressure is considered a good indicator of left ventricle filling pressure). In this procedure the catheter 50 is usually introduced through a large vein in the antecubital area.
Moreover, during a thoracotomy it is useful to measure left arterial pressure. This is usually accomplished by placing a catheter 50 directly into the left atrium 22.
As has been seen, catheter placement is dictated by the type of pressure data desired. It should also be apparent that since health care providers must place catheters in various locations within the cardiovascular system, catheter placement and location is highly important.
Additionally, the anatomy of each individual varies. Likewise, since both hydrostatic pressure and negative pressure heads spoil the accuracy of resulting data, health care providers are desirous of a method and apparatus capable of quickly indicating the location of a catheter that minimizes patient exposure to radiation.
The present invention teaches a novel method and apparatus of achieving this end. Once the indicator 10 and catheter 50 are in position, a chest X-ray may be taken. On examination of the X-ray film the location of the catheter 50 may be seen in relation to the radio opaque fasteners 18.
A level 62 carried by a flexible line 64 with end clips 66, of the type disclosed by Haught, U.S. Pat. No. 4,546,774, may be utilized to bring the hemodynamic transducer assembly 52 into the same horizontal plane as the catheter 50. The transducer assembly 52 may be slidably mounted to an IV stand 46 by an adjustable friction bracket 54.
The zero level 84 of the transducer assembly 52 may be provided with a clip attachment loop 32. A nurse or the like may be provided with a level assembly 6 (62, 64, and 66, FIG. 3). One of the end clips 66 may be connected to the zero level 64 attachment loop 82 of the transducer assembly 52. The other end clip 66 may then be connected to the radio opaque fastener 18 closest to the catheter level as determined from the X-ray.
In this fashion a patient 74 may be maintained, or repeatedly moved, as comfort or function requires, in any position necessary since the catheter 50 and transducer assembly 52 may be quickly brought into level.
FIG. 1 illustrates the bandage and dressing 48 at the catheter insertion point. Also shown are the pressure infusor 58, microdrip filter 60, and the monitor recorder 56 of a hemodynamic monitoring system.
Whereas, the invention has been disclosed in connection with a preferred embodiment thereof, it is apparent that many modifications, substitutions, and additions may be made thereto which are within the intended broad scope of the appended claims.
Thus, there has been shown and described a catheter position indicator for use in hemodynamic monitoring which accomplishes at least all of the stated objects.
|
A catheter position indicator for use with leveling devices adapted for use in hemodynamic monitoring. The indicator includes a radio transparent sheet material containing a plurality of spaced apart radio opaque material portions. Also included is a means for fastening the sheet material to a human body. An X-ray may be taken so that the location of a catheter may be determined in relation to the radio opaque portions of the radio transparent sheet material. Once the location of the catheter is determined a simple bubble level device may be utilized to bring a hemodynamic transducer assembly into level with the inserted catheter.
| 0
|
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] The present application claims priority to U.S. patent application Ser. No. 11/483,021, filed Jul. 7, 2006 and U.S. Provisional Application No. 60/697,872, filed on Jul. 8, 2005 both of which are incorporated herein by reference in their entirety.
[0002] This work was supported by the National Science Foundation through Grant Numbers DMR0451589, DMR021306 and DMR0243001, and US Department of Energy grant DE-FG02-91ER40671.
FIELD OF THE INVENTION
[0003] This invention relates generally to the field of quasicrystalline heterostructures. More particularly the invention relates to the assembly of quasicrystalline photonic heterostructures with specified orientational symmetry in two dimensions, or along any two dimensions in a three-dimensional structure, or with any specified three-dimensional quasicrystalline symmetry, and also the use of holographic optical traps (HOTS) to perform that assembly and to the use of those HOTS assembled structures for a variety of uses.
BACKGROUND OF THE INVENTION
[0004] Crystalline materials have long been exploited in many optical and electronic applications for physical properties arising from their crystalline symmetry. Although such crystalline materials allow many technological applications to be fulfilled, there are limitations imposed by such crystalline symmetry. For example, ordered arrangements of dielectric materials with alternating domains of high and low index of refraction are known to exhibit a property for the transmission of light known as a photonic bandgap. The optical properties of a photonic bandgap material are characterized by a range of frequencies of light for which light cannot propagate, nor is it absorbed. This property is analogous to the electronic bandgaps that arise in semiconductors for the transport of electrons, and should result in a similarly broad spectrum of applications. The extent of a material's photonic bandgap depends both on the dielectric properties of the constituent dielectric materials and also on the symmetries of their three-dimensional arrangement. The limited set of distinct symmetries available for crystalline arrangements require a very large contrast in dielectric constant to achieve a full photonic bandgap, and these symmetries result in optical materials whose optical properties are very sensitive to structural and chemical defects. By contrast, quasicrystals are known that have far higher rotational symmetries than is possible for crystals. They consequently should exhibit larger and more uniform photonic bandgaps than any crystalline arrangement of the same materials, and should have optical properties that are more robust against defects and disorder. Two-dimensional and three-dimensional quasicrystalline arrangements of materials therefore should have a wide range of technological applications based on their optical and other physical properties.
SUMMARY OF THE INVENTION
[0005] It is therefore an object of the invention to provide an improved system and method for fabricating quasicrystalline structures.
[0006] It is another object of the invention to provide an improved system and method for fabricating quasicrystalline photonic heterostructures using holographic optical traps.
[0007] It is also an object of the invention to provide an improved article of manufacture of a three dimensional quasicrystalline photonic heterostructure.
[0008] It is a further object of the invention to provide an improved system and method for constructing materials having photonic band gaps forbidden in crystalline materials.
[0009] It is yet another object of the invention to provide an improved system and method for constructing rotationally symmetric heterostructures having optical, mechanical, chemical, biological, electrical and magnetic properties unachievable by crystalline materials.
[0010] It is an additional object of the invention to provide an improved quasicrystalline heterostructure having programmable optical, mechanical, biological, electrical, magnetic and chemical properties.
[0011] It is also another object of the invention to provide an improved system and method for constructing a quasicrystalline structure with specified Brillouin zones for selected technological applications.
[0012] It is also a further object of the invention to provide an improved system and method for constructing a quasicrystalline material with a substantially spherical Brillouin zones.
[0013] It is yet an additional object of the invention to provide an improved system and method for constructing a quasicrystalline material having long range orientational order without transitional periodicity and constructed to operate in a predetermined manner responsive to at least one of an electrical field, a magnetic field and electromagnetic radiation.
[0014] It is also a further object of the invention to provide an improved system and method for constructing quasicrystalline heterostructures which can be switched from one structural state to another state by repositioning particles to thereby modify physical, biological, and chemical properties of the arrangement.
[0015] It is still another object of the invention to provide an improved system and method for constructing quasicrystalline heterostructures by use of holographic optical traps to dynamically modify chemical and physical properties in accordance with time sensitive requirements.
[0016] It is another object of the invention to provide an improved system and method for constructing quasicrystalline heterostructures having holographic optical traps to form engineered features which enable creation of narrow band waveguides and frequency selective filters of electromagnetic radiation.
[0017] It is yet another object of the invention to provide an improved system and method for organizing disparate components using holographic optical traps to position selectable components in a quasicrystalline heterostructure for establishing chemical, biological and physical properties for a desired technological application.
[0018] It is also an object of the invention to provide an improved system, method of manufacture and article of manufacture with deliberately incorporated defects for programmably achieving a variety of electrical, optical, magnetic, mechanical, biological and chemical properties and applications.
[0019] It is yet an additional object of the invention to provide an improved method and article of manufacture of a quasicrystal with replaced spheres or other components of different size or shape to modify local photonic characteristics of the quasicrystal.
[0020] It is a further object of the invention to provide an improved method and article of manufacture with selective replacement of one or more spheres on other molecular component geometries of different chemical composition or at different sites than a given quasicrystalline site to create new properties or break the quasicrystalline symmetry to create new properties for a variety of applications.
[0021] It is another object of the invention to provide an improved method and article of manufacture of a quasicrystal with a particular domain having a topological defect, such as a phase slip, like a grain boundary in ordinary crystalline molecules, thereby giving rise to new useful properties.
[0022] It is another object of the invention to provide an improved method and article of manufacture of two or more quasicrystalline domains created by holographic trap manipulation to create higher order structures with the resulting combination having optical properties selected from each component domain.
[0023] It is still an additional object of the invention to provide an improved method and article of manufacture for creating combinations of one or more quasicrystalline domains with one or more crystalline domains to create useful higher order structures.
[0024] It is a further object of the invention to provide an improved method and article of manufacture involving assembly of crystalline and quasicrystalline domains using optical tweezers and/or other particle force assembly methodologies including self assembly, electrophoresis, and optical gradient fields to create useful combination structures.
[0025] These and other objects, advantages and features of the invention, together with the organization and manner of operations thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1( a ) illustrates a view of silica spheres organized by holographic optical tweezers into a planar pentagonal quasicrystal (the scale bar indicates 5 micrometers); FIG. 1( b ) illustrates a heptagonal quasicrystalline domain; FIG. 1( c ) illustrates an octagonal quasicrystalline domain arrangement; and FIG. 1( d ) illustrates an octagonal quasicrystalline domain with an embedded waveguide
[0027] FIG. 2( a ) illustrates a first of four views of an icosahedron assembled from dielectric colloidal spheres using holographic optical traps; FIG. 2( b ) illustrates a second view with a 2-fold symmetry axis; FIG. 2( c ) illustrates a third view with a 5-fold symmetry axis and FIG. 2( d ) illustrates a fourth view midplane; FIG. 2( e ) illustrates the progressive assembly of the colloidal quasicrystal illustrated in FIG. 2( a ) -( d ); and
[0028] FIG. 3( a ) shows a holographic assembly of a three dimensional colloidal quasicrystal with the particles trapped in a two dimensional projection of a three dimensional icosahedron quasicrystalline lattice; FIG. 3( b ) shows particles displaced into the fully three dimensional configuration with the shaded region the one embedded icosahedron; FIG. 3( c ) shows reducing the lattice constant to create a compact three dimensional quasicrystal; and FIG. 3( d ) illustrates a measured optical diffraction pattern displaying 10-fold symmetric peaks for the constructed quasicrystal; and FIG. 3( e ) illustrates the progressive assembly of the colloidal quasicrystal illustrated in FIG. 3( a )-( d ).
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] A system and method have been developed for the construction of quasicrystalline heterostructures for a wide variety of technological applications. Various articles of manufacture and compositions of matter can be prepared. In a most preferred embodiment, holographic optical traps are used as the starting tool to position a selected particle in a given position. Therefore, in the preferred embodiment the approach is based on the well known holographic optical trapping technique in which computer-generated holograms are projected through a high numerical aperture microscope objective lens to create large three dimensional arrays of optical traps. In our implementation, light at 532 nm from a frequency doubled diode-pumped solid state laser (Coherent Verdi) is imprinted with phase only holograms using a liquid crystal spatial light modulator (SLM) (Hamamatsu X8267 PPM). The modified laser beam is relayed to the input pupil of a 100×NA 1.4 SPlan Apo oil immersion objective mounted in an inverted optical microscope (Nikon TE2000U), which focuses it into optical traps. The same objective lens is used to form images of trapped objects by using the microscope's conventional imaging train. As a soft fabrication technique, holographic assembly requires substantially less processing than conventional methods such as electron beam lithography and can be applied to a wider range of materials. Assembly with holographic optical traps lends itself readily to creating nonuniform architectures (e.g., microstructural arrangements, articles of manufacture and compositions of matter) with specifically engineered features, such as the channel embedded in the octagonal domain in FIG. 1( d ). Such structures can, for example, act as narrowband waveguides and frequency-selective filters for visible light.
[0030] Holographic trapping's ability to assemble free-form heterostructures extends also to three dimensions. The sequence of images of a rolling icosahedron in FIG. 2( a )-( d ) show how the colloidal spheres' appearance changes with distance from the focal plane. This sequence demonstrates that holographic trapping with a single laser beam can successfully organize spheres into vertical stacks along the optical axis, while maintaining one sphere in each trap.
[0031] The icosahedron itself is the fundamental building block of a class of three dimensional quasicrystals, such as the example in FIGS. 3( a )-( d ). Building upon our earlier work on holographic assembly, we assemble a three dimensional quasicrystalline domain by first creating a two dimensional arrangement of spheres corresponding to the planar projection of the planned quasicrystalline domain (see FIG. 3( a )). Next, we translate the spheres along the optical axis to their final three dimensional coordinates in the quasicrystalline domain, as shown in FIG. 3( b ). One icosahedral unit is highlighted in FIGS. 3( a ) and ( b ) to clarify this process. Finally, the separation between the traps is decreased in FIG. 3( c ) to create an optically dense structure. This particular domain consists of 173 spheres in 7 layers, with typical interparticle separations of 3 μm.
[0032] The completed quasicrystal was gelled and its optical diffraction pattern recorded at a wavelength of 632 nm by illuminating the sample with a collimated beam from a HeNe laser, collecting the diffracted light with the microscope's objective lens and projecting it onto a charge-coupled device (CCD) camera with a Bertrand lens. The well defined diffraction spots clearly reflect the quasicrystal's five-fold rotational symmetry in the projected plane.
[0033] Holographic assembly of colloidal silica quasicrystals in water is easily generalized to other materials having selectable optical, electrical, magnetic, chemical and mechanical properties for a wide variety of technological applications. Deterministic organization of disparate components under holographic control can be used to embed gain media in photonic band gap (PBG) cavities, to install materials with nonlinear optical properties within waveguides to form switches, and to create domains with distinct chemical functionalization. The comparatively small domains we have created can be combined into larger heterostructures through sequential assembly and spatially localized photopolymerization. In all cases, this soft fabrication process results in mechanically and environmentally stable materials that can be integrated readily into larger systems.
[0034] Beyond the immediate application of holographic trapping to fabricating quasicrystalline materials, the ability to create and continuously optimize such a variety of articles of manufacture and compositions of matter enables new opportunities for achieving heretofore unattainable products and perform processes not possible. Many other functionalities can be performed, such as evaluating the dynamics and statistical mechanics of colloidal quasicrystals. The optically generated quasiperiodic potential energy landscapes described herein also can provide a flexible model system for experimental studies of transport through aperiodically modulated environments.
[0035] In other embodiments, the above described methods of fabricating and manipulating quasicrystalline structures can further be employed to manipulate compositions of matter to introduce a variety of particular defects which can establish useful electrical, optical, biological, mechanical, magnetic and chemical attributes. Due to the many degrees of freedom available by virtue of the ability to establish these quasicrystalline structures and associated defects, one can achieve numerous different physical, mechanical and chemical properties, many of which are unachievable with crystalline or amorphous structures. These properties can be used in a wide variety of commercial areas spanning the electronics, computer, biological, chemical, optical, mechanical properties and magnetics fields.
[0036] The technique further permits the manufacture of quasicrystals with replacement of spheres, or other components, with different size or shape spheres or different size or shape components, enabling modification of properties, such as, for example, photonic characteristics. This concept can also be applied to replace spheres or other size and shape component groups at selected locations with constituents of different chemical, mechanical, electrical, magnetic or optical character, thereby allowing controlled designs of quasicrystalline arrangements with different selectable properties useful in many commercial fields.
[0037] In other embodiments domains of quasicrystals can be selectively modified to introduce phase slip boundaries, similar to grain boundaries in crystalline materials, to develop properties of interest for commercial exploitation. In addition, two or more quasicrystalline domains can be created by optical trap manipulation of particles to generate higher order structural components with physical and/or chemical properties characteristic of the properties of each component domain. In addition, such combinations can be integrated with crystalline domains to create further higher order structures for selectable commercial applications.
[0038] The assembly of all these structures can be accomplished not only by use of optical tweezers but also by other particle force movement force sources. These other force movement sources can be used alone or in combination with the optical tweezers and these other particle force sources can include at least one of self assembly, other photonic methodologies and controllable electrical and magnetic fields. These methodologies allow controlled construction of virtually any desired structure exhibiting a wide range of programmed physical, biological or chemical properties.
[0039] The following non-limiting example describes one method of assembling colloidal particles as a quasicrystal.
Example
[0040] Colloidal silica microspheres 1.53 μm in diameter (Duke Scientific Lot 5238) can be organized by first being dispersed in an aqueous solution of 180:12:1 (wt/wt) acrylamide, N,N-methylenebisacrylamide and diethoxyacetophenone (all Aldrich electrophoresis grade). This solution rapidly photopolymerizes into a transparent polyacrylamide hydrogel under ultraviolet illumination, and is stable otherwise. Fluid dispersions were imbibed into 30 μm thick slit pores formed by bonding the edges of #1 coverslips to the faces of glass microscope slides. The sealed samples were then mounted on the microscope's stage for processing and analysis.
[0041] Silica spheres are roughly twice as dense as water and sediment rapidly into a monolayer above the coverslip. A dilute layer of spheres is readily organized by holographic optical tweezers into arbitrary two dimensional configurations, including the quasicrystalline examples in FIGS. 1( a )-( d ). FIGS. 1( a ), ( b ) and ( c ) show planar pentagonal, heptagonal and octagonal quasicrystalline domains, respectively, each consisting of more than 100 particles. Highlighted spheres emphasize each domain's symmetry. These structures all have been shown to act as two dimensional PBG materials in microfabricated arrays of posts and holes. FIG. 1( d ) shows an octagonal quasicrystalline domain with an embedded waveguide.
[0042] While preferred embodiments have been illustrated and described, it should be understood that changes and modifications can be made therein in accordance with one of ordinary skill in the art without departing from the invention in its broader aspects. Various features of the invention are defined in the following claims.
|
A method and system for assembling a quasicrystalline heterostructure. A plurality of particles is provided with desirable predetermined character. The particles are suspended in a medium, and holographic optical traps are used to position the particles in a way to achieve an arrangement which provides a desired property.
| 6
|
FIELD OF THE INVENTION
This invention relates to photoelectrolytic cells, and more particularly to such a cell capable of enhancing the yield of H 2 from such a cell.
BACKGROUND OF THE INVENTION
Recently, in Fong, et al, U.S. Pat. No. 4,022,950, the observation of Chl a photogalvanic water splitting reactions that result from irradiation of the chlorphyll a dihydrate aggregate (Chl a.sup.. 2H 2 O) n in the far red wavelength region was disclosed. However, the quantum efficiency of the observed effects was low, and we were unable to detect the discharge of H 2 by direct analytical means. The photoelectrolysis of water is a direct process for harvesting solar energy to produce gaseous hydrogen for fuel. Considerable attention has been focused on n-type semiconducting photoanodes such as TiO 2 and SrTiO 3 . However, these materials operate in the near ultraviolet wavelength region where the solar radiant energy density is low.
In our earlier photochemical conversion experiments, as reported in J. Amer. Chem. Soc., Vol 99, p. 5802 (1977), the chlorophyll a was plated on a shiny Pt electrode. The photolytic reactions were detected by measuring the flow of electrons in an external circuit of a photogalvanic assembly consisting of a Pt-Chl suspended electrode suspended in an aqueous electrolyte in a half cell and a Chl a-free electrode suspended in another half cell. That apparatus, while novel, provided only a low quantum efficiency.
DESCRIPTION OF THE INVENTION
It occurred to us that the low quantum efficiency of the photoelectrolytic cell described in U.S. Pat. No. 4,022,950 may have resulted from the poor contact between the smooth metal surface of the platinum electrode and the chlorophyll a plated thereon. We accordingly sought to overcome the problem of low quantum efficiency by filling in the crevices that separate the polycrystalline Chl a aggregates from each other and from the smooth metal electrode surface by the addition of finely divided Pt particles. After the addition of the Pt particles in the manner described in detail hereafter, we were successful in accomplishing profuse gaseous H 2 evolution due to water splitting.
THE DRAWINGS
FIG. 1 is a graphic representation of photoelectrolytic cell response wherein the "a" points indicate the response of the cell under an Ar atmosphere, the "b" points represent the cell response when the electrolyte was saturated with O 2 , and the "c" points represent cell response upon purging the O 2 saturated electrolyte with Ar.
FIG. 2a is a mass spectrum analysis of the gas above the electrolyte by the cell of the present invention after light irratiation.
FIG. 2b is a mass spectrum analysis of the gas above the electrolyte by a cell using a plain platinum electrode after light irradiation.
FIGS. 3A and 3B are mass spectrum analyses of the gas above the electrolyte in a cell using the electrode of the present invention, wherein O 18 was injected into the cell, 3A showing the gas analysis after photolysis, and 3B showing gas analysis of the same cell after electrolysis. FIG. 3C is a mass spectrum of the gas from a cell having a plain electrode.
FIG. 4 is a diagram of the photolytic cell of this invention.
FIG. 5 is a magnified (not to scale) cross sectional view of the electrode of the present invention taken on line A--A of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
A shiny Pt foil 10 was platinized by passing a 30 mAmp current for 10 min through a 7 × 10 -2 M chloroplatinic acid solution 12 containing 6 × 10 -4 M Pb acetate, thus leaving a first layer of Pt-black 14 on said foil. A layer of polycrystalline chlorophyll 16*, containing 1.5 × 10 17 Chl a molecules, was deposited on the platinized electrode surface using the procedure described by Tang and Albrecht, Mol. Cryst. Lig. Cryst., Vol 25, p. 53 (1974). The Chl a plated electrode was then platinized again in the same chloroplatinic acid solution, leaving a second layer of Pt-black 18* on the chlorophyll layer 16*, forming a sandwich structure as shown in FIG. 5, except that the 30 mAmp current was passed for only 15 sec. The platinized Chl a was then allowed to equilibrate in a warm water bath at 70° C for several hours.
The action spectra of the photogalvanic response of the platinized Chl a electrode at pH 7 measured in the manner described previously in U.S. Pat. No. 4,022,950, employing as the second half cell a platinized electrode not covered with Chl a, is shown in FIG. 1. The electrode, prepared as described, was then suspended in a case 5 and immersed in an aqueous electrolyte 12 (FIG. 4). Then the electrode was irradiated with light from source 20 which passes through filter 6. The 740 nm maximum of the spectral response shown in FIG. 1 confirms that (Chl a.sup.. 2H 2 O) n is primarily responsible for the observed photogalvanic effects. Under an Ar atmosphere shown in FIG. 1a, the observed photogalvanic response of the Chl a cell is positive. A remarkable change was observed when the electrolyte solution was saturated with O 2 . The photogalvanic current reversed in sign, as shown in FIG. 1b. On purging the O 2 saturated solution with Ar, the photogalvanic response in FIG. 1a was restored, and the trace proving such restoration is shown in FIG. 1c.
In order to enhance the photogalvanic response, the pH values of the Chl a and Chl a-free half cells were maintained at 3 and 11, respectively, in a control experiment. After the half cells were degassed by the passage of Ar gas for about 30 min, the photogalvanic response of the cell was monitored with the entire output from a 1000 watt tungsten halogen lamp 20 focused on the platinized Chl a electrode 22. An initial photocurrent of about 1 μAmp was obtained. After two hours of continuous irradiation, a reversal in sign of the photocurrent was observed, being indicative of a buildup in the O 2 content of the electrolyte solution. Continued irradiation of the cell with an open external circuit led to the observation of profuse gas evolution in the form of bubbles 24 from the Pt-Chl a electrode. The formation of gas bubbles in the illuminated area occurred instantaneously upon irradiation of the Pt-Chl a plated electrode prepared as described. In order to eliminate the possibility that the gas bubbles may have resulted from the degassing of Ar due to heating by the light source, the cell was purged with He and the experiment was repeated under a positive pressure of He. The solubility of He in water increases with increasing temperature, being 0.94 and 1.21 ml/100 water at 25 and 75° C, respectively. Profuse gas evolution was again observed under identical illumination conditions. When a Chl a-free platinized Pt electrode was irradiated under these conditions, no signs of bubbling were detected.
The gaseous content collected above the electrolyte solution after the platinized Chl a electrode was illuminated for 30 minutes was evacuated through tube 26 directly into the sample chamber of a Consolidated Electrodynamics Corporation 21-110-B mass spectrometer. The resulting mass spectrum is shown in FIG. 2a. In addition to the expected He + line at mass 4, a strong peak at mass 2 with an attendant trace peak at mass 3 was observed. The latter peaks are respectively attributed to H 2 + and the triatomic ion H 3 + . These identifications were confirmed by using pure H 2 and He as source. The gaseous content above the electrolyte solution in the Chl a-free cell was also analyzed by mass spectrometry after a similar light treatment of the Chl a-free platinized electrode and the analysis shown in FIG. 2b. No lines at masses 2 and 3 were detected. Small quantities of H 2 + are known to accompany hydrocarbon fragments at masses 13, 15, 25, 26, 27 and 29. These fragments are found to occur in similar intensity ratios in both the sample and blank determinations shown in FIG. 2. The possibility that the observed H 2 + line may have originated from hydrocarbon fragmentation is thus ruled out.
As a verification, the mass spectrum of a 95:5 mixture of n-hexane and ethanol was obtained. The H 2 + line was observed in the hydrocarbon mixture. However, the observed intensity ratios of the H 2 + line to the various hydrocarbon fragments are one to two orders of magnitude smaller than the corresponding ratios in the photoelectrolytic sample. The O 2 + line at 32 is more than an order of magnitude more intense in the sample gas than the corresponding line in the blank. Molecular oxygen is, of course, one of the two principal products in the water splitting reaction.
As a further verification that H 2 is in fact generated by the new cell, a cell using the electrode of the present invention was injected with isotope O 18 and subjected to both photolysis and electrolysis. The results are shown in FIG. 3A and FIG. 3B. The results for a control cell using only a plain platinum electrode are shown in FIG. 3C. The coincidence of the peaks in 3A and 3B is conclusive proof of water splitting as claimed for the present cell.
Under the experimental conditions described above, the dihydrate polycrystal (Chl a.sup.. 2H 2 O) n is stable with respect to acid, heat, intense light and oxygen. Sample analysis after several hours of continuous gas evolution at pH 3 under white light irradiation revealed no detectable traces of Chl a degradation. In order to evaluate long-term stability, a platinized Chl a electrode was prepared and was periodically subjected to experimental observation. This electrode remained photoelectrolytically active, showing no signs of performance deterioration.
About 1 ml of the gaseous photolysis prodicts was collected over a 30 min period. No bubble formation was observed in unplatinized Pt-Chl a cells irradiated under similar conditions over a twenty-hour period. Accordingly, it will be appreciated that the platinization of (Chl a.sup.. 2H 2 O) n polycrystals has enhanced the quantum efficiency of the Chl a-H 2 O cell described in U.S. Pat. No. 4,002,950 by at least two orders of magnitude. At 740 nm, the quantum efficiency of the unplatinized Chl a cell is about 0.2%. We thus estimate that the quantum efficiency of the present cell is at least 20% at 740nm. The rate of gas evolution and estimated monochromatic quantum efficiencies are comparable to corresponding observations on the photolysis of water using SrTiO 3 , except that we have extended the functional range of wavelengths to the entire visible and near infrared regions of the solar spectrum, which is where the great bulk of solar irradiation reaching earth is concentrated.
It will be appreciated by those skilled in the art that the water splitting accomplished by the invention described may be accomplished by other variations, such as by growing a single chlorophyll crystal and coating or impregnating such a crystal with Pt-black. This invention is not limited by the specific construction herein illustrated, nor by the narrow parameters given for construction of a suitable electrode, nor by the specific electrolyte as described, but only by the scope of the appended claims.
|
Platinized chlorophyll a dihydrate polycrystals are used to expedite the photochemical cleavage of water to yield molecular hydrogen and oxygen. The peak quantum efficiency of this photoelectrolytic apparatus at 740 nm is about 20%.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to damped flywheels, especially for motor vehicles, of the kind comprising two coaxial masses, one of which, referred to as the first mass, is adapted to be coupled in rotation to a driving shaft, such as the crankshaft of an internal combustion engine, the other one, referred to as the second mass, being adapted to be connected to a driven shaft, such as the input shaft of a gearbox, and of the type in which the two masses are mounted coaxially through an interposed bearing, such as a ball bearing, and in which coupling means are interposed between the two masses so as to couple the second mass to the first mass.
The coupling means may comprise springs acting either circumferentially or radially, or in another version these means may be of a centrifugal type as described in the document FR-A-1 598 557.
In all cases, the second mass constitutes the reaction plate of a friction clutch, and for this purpose it offers a friction surface to the friction disc which is part of the said clutch. Thus the second mass is arranged to be mounted in rotation on a driven shaft through the interposed friction disc, that is to say in a disconnectable manner.
The friction liners of the friction disc tend to become heated in service, and the same is then true for the second mass which defines the reaction plate.
Under severe driving conditions, this second mass may reach very high temperatures, and this is why, in the document FR-A-1 598 557, ventilation holes were provided in the second mass, between the bearing and the friction surface of the second mass, in order to reduce the temperature in the region of the bearing. These holes thus prevent any risk of over-heating of the bearing. They are located close to the bearing.
SUMMARY OF THE INVENTION
An object of the present invention is to make use of these ventilation holes for an additional purpose.
In accordance with the invention, the ventilation holes are open into the base of a groove which is formed in the second mass at the inner periphery of its reaction plate radially outwardly of the bearing, for collecting a lubricating agent such as oil escaping from the centre of the damped flywheel, and the edge of the base of the groove is interrupted by the ventilation holes.
This oil may be oil that has leaked from the crankshaft of the vehicle or from the gearbox of the latter. In another case there may be grease which has escaped from the bearing. The same groove thus prevents contamination of the friction surface of the reaction plate and of the friction liners of the friction disc.
Thus, the ventilation holes have a double function, namely a ventilating function and a function of evacuating leaked oil and/or grease, which collects in the bottom of the collecting groove. Thus, the lubricating agent (i.e. oil, grease, etc.) will be evacuated, together with any contaminants, in a wholly effective way because the holes are open into the base of the groove.
The holes, which extend from one side of the second mass to the other, may be of round form or of circumferentially oblong form. They may be flared towards the first mass, or vice versa.
The following description illustrates the invention with reference to the attached drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in axial cross section taken on the line 1--1 in FIG. 2, of a damped flywheel in accordance with the invention;
FIG. 2 is a view in the direction of the arrow 2 in FIG. 1, and partly in cross section;
FIG. 3 is a partial view, seen in cross section taken on the line 3--3 in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 to 3 show a damped flywheel for a motor vehicle, consisting essentially of a first mass (or first rotary element) 12 and a second mass (or second rotary element) 14, which are mounted for movement of one with respect to the other about an axial axis of symmetry X--X of the assembly.
In this example the masses 12 and 14 are mounted coaxially through an interposed bearing 28, to be described later herein, and are arranged for movement of one with respect to the other against the action of circumferentially acting resilient means 32 and the action of an axially acting friction device 58.
The first mass 12, which in this example is in the form of a plate, carries a starter crown 16 which is adapted to cooperate with the starter (not shown) of the vehicle. This plate has at its inner periphery an integral central hub 18, while at its outer periphery it has an axially oriented annular peripheral skirt 22.
The plate 20, which is integral with its skirt 22 and its hub 18, is made of a mouldable material, being in this example a casting.
The first mass 12 is adapted to be secured accordingly on the end of the crankshaft of the internal combustion engine, in a manner to be described later herein.
The first mass 12 is thus arranged to be mounted on a driving shaft for rotation with the latter, to which it is fixed in this example by means of studs 1.
The second mass 14 is also made of a mouldable material, being a casting in this example, and comprises a reaction plate 26 having at its outer periphery an axially oriented cylindrical skirt 24, which is of divided form in this example, and which is surrounded by the skirt 22 of the first mass 12.
The second mass 14 is mounted on the hub 18 of the first mass 12, in this example through an interposed ball bearing 28, though in another version this may be another bearing, for example a bearing of the plain type.
The first mass 12 delimits at its outer periphery the greater part of an annular housing (or chamber) 30, which is arranged to receive the circumferentially acting resilient means 32, which in this example consist of a set of helical springs arranged in the form of a crown and being, in this example, concentric with each other.
In the present example there are two sets of concentric springs 32. This number does of course depend on the application.
The housing 30 is mostly delimited, in the present case, by the plate 20, the skirt 22 and a disc 34 which is part of the first mass.
The chamber 30 leaves open at its inner periphery a narrow slot into which there penetrates a disc 42 which is part of the second mass, this penetration being sealed in a manner to be described below.
The disc 34, which is of metal in this example, extends inwardly from the skirt 22 between the two plates 20, 26, and is directed inwardly in the radial direction.
The disc 34 is coupled to the external skirt 22, for rotation with the latter, by being seamed sealingly to it in the manner described in the document FR-A-2 695 579. To this end, the skirt 22 is shouldered, and its shoulder has a groove which is arranged to receive the metal of the metallic disc during the process of seaming the latter in place.
In another version, this sealed fastening may be achieved by screw fastening, in the manner described in the document FR-A-2 687 442.
In a further version, riveting or welding may be used. The said disc 34 constitutes a cover member for the plate 20, the latter being hollow and being bounded by its skirt 22 and its hub 18.
The plate 26 is recessed in order to accommodate the disc 34, which has local pressed-out portions 80 (FIG. 1) for abutment of the circumferential ends of the helical springs 32 thereon.
In facing relationship with these pressed-out portions 80, the plate 20 has thrust inserts 81, which are secured by riveting on the plate, for abutment of the circumferential ends of the said springs thereon.
The disc 34 and the plate 20 define an annular passage containing the springs 32. To this end, the plate 20 has an annular recess at its outer periphery, and the disc 34 is bowed, in order to retain the springs both axially and radially.
The skirt 22 is recessed internally so as to retain the springs 32 radially.
For this purpose, the internal bore has an annular surface portion 23. The plate 20, the skirt 22 and the disc 34 thus hug the profile of the springs 32, and in this example the profile of the outermost springs.
The second mass 14 further includes the disc 42, which is referred to as the inner disc and which is coupled to the second mass 14 for rotation with it, by means of rivets 44, the disc 42 extending radially from the inner periphery of the plate 26 to the annular housing or chamber 30. This chamber 30 is filled partially with, in this example, a pasty or viscous agent for lubricating the springs 32.
In a manner known per se, the plate 26 constitutes the reaction plate of a clutch.
The second mass 14 is thus arranged to be mounted in rotation on a driven shaft, which in this example is the input shaft of the gearbox, through the interposed friction disc 100 of the clutch (which is shown diagrammatically), the friction liners 101 of which are adapted to be clamped between the reaction plate 26 and a pressure plate (not shown) forming part of the mechanism of the clutch, the mechanism being adapted to be attached through its cover plate, by means of screws, one of which can be seen in the upper part of FIG. 1, on the reaction plate 26, which offers on the side opposite to the plate 20 a friction surface for the above mentioned friction disc 100.
The outer edge of the inner disc 42 includes radial lugs 50, and in this example two lugs which are generally diametrically opposed to each other, and which are arranged to serve as end abutments for the circumferential ends of the springs 32.
Thus, the disc 42 penetrates into the housing 30, while the springs 32, bearing on the thrust inserts 81 and the pressed-out portions 80 of the disc 34, are able to be compressed by the lugs 50.
In this example, antiwear pieces 82, which are here of channel section, are interposed radially between the springs 32 and the inner periphery of the skirt 22.
More precisely, these channel pieces 82, the cross section of which is that of an arc of a circle, are received in the annular surface portions 23. The channel pieces 82 extend generally over 90 degrees in this example, hugging the profile of the surface portions 23, which consist here of one surface portion 23 divided by the thrust inserts 81.
The springs 32 are thus adapted so as to be put into contact, under the action of centrifugal force, with the channel pieces 82, which in this example are of steel.
There is a small gap between the plate 20 and the inner periphery of the disc 34, into which the disc 42 penetrates.
Internal sealing of the annular housing is provided by means of two sealing rings 56A, 56B. These rings 56A, 56B consist of two annular members of stamped and press-formed sheet material. They are elastic.
The rings 56A, 56B close off the housing 30 at its inner periphery, the said housing being filled partly with a pasty or viscous agent for lubrication of the springs 32, in a manner to be described later herein.
More precisely, the outer flange of the ring 56A is in elastic engagement against an engagement surface which is formed in facing relationship with it in the plate 20 of the first mass 12, while the outer radial edge of the second sealing ring 56B is in elastic contact against an engagement surface which is formed, in facing relationship with it, in the inner periphery of the disc 34 of the first mass 12.
The rings 56A and 56B are disposed on either side of the disc 42, to which they are attached.
The damped flywheel further includes a friction device 58 which works axially between the two masses.
This device 58 surrounds the hub 18 and includes a friction ring 60, which in this example is of fibre-reinforced plastics material, and which is adapted to engage frictionally on a flat surface portion of the plate 20, together with a ring 62 which in this example is of metal, and which is driven in rotation by the hub 18.
An axially acting resilient ring 64 biasses the ring 62 resiliently into engagement against the ring 60.
The ring 64, which in this example is of the Belleville ring type, but which in another version may be a ring of the corrugated type, bears on a thrust ring 65 which is located axially on the inner ring of the ball bearing 28, the latter being force-fitted on the hub 18.
The hub 18 is formed with holes for the passage through the holes of the studs 1 by which the damped flywheel is fastened on the crankshaft of the engine.
One of these studs 1 can be seen in the central part of FIG. 1.
The studs 1 bear, through their heads, on a ring 2 which locates the inner ring of the ball bearing 28 axially in one direction.
In the other direction, the inner ring is located axially by means of the above mentioned thrust ring 65, which may consist of a circlip engaged in a groove of the hub 18.
The damped flywheel is thus mounted between two rotating assemblies, one of which (i.e. the crankshaft) is coupled to the internal combustion engine of the vehicle, the other one being coupled (in a disconnectable way) to the input shaft of the gearbox.
The ring 60 has at its outer periphery a crown element formed with notches 61. These notches, or slots, 61 are arranged to cooperate with the heads 68 of a set of rivets 66, which are fixed on the internal annular disc 42 of the second mass 14.
As can be seen in FIG. 2, the inner radial edge of the sealing ring 56A is gripped between the head 68 of each rivet 66 and the flat surface portion of the disc 42, the latter being of metal.
Thus the first sealing ring 56A is fixed on the disc 42, and its internal radial flange has for this purpose a set of holes through which the bodies of the rivets 66 are passed.
This arrangement, apart from enabling the ring 60 to be driven in rotation by cooperation of the heads 68 with the edge of the associated slots 61 of the ring 60, also fastens the sealing ring 56A on the disc 42.
This arrangement enables the sealing ring 56A to be mounted and fastened on the disc 42 before the said disc 42 is fixed on to the plate 26 of the second mass 14 by means of a set of fastening rivets 44.
These rivets 44, which are fitted at the inner periphery of the plate 26, as are the rivets 66, fasten the disc 42 only, without fastening the sealing rings 56A, 56B, these latter thus being protected.
The second sealing ring 56B is preferably fixed in the same way as the sealing ring 56A, by means of the fastening members 66.
Thus, the inner radial end of the sealing ring 56B is gripped between the foot of each rivet 66 and the portion of the disc 42 in facing relationship with it.
The inner radial end is formed with holes, through which the bodies of the rivets 66 pass.
Thus, the radial edges of the rings 56A, 56B lie in contact with the disc 42 and on either side of the latter, the whole constituting an assembly which can readily be handled and transported, and which cannot be lost.
As can be seen in FIG. 2, the fastening rivets 66 and the coupling rivets 44 are preferably arranged substantially on a common pitch circle, being spaced apart alternately at regular intervals along this circle.
The second mass 14 has recesses facing the feet of the rivets 66, so as to enable the said feet to pass through. The disc 42 provides axial location of the outer ring of the ball bearing 28 between a shoulder of the second mass 14 and the inner periphery of the disc 42, which is formed with a central hole, as is the disc 34.
It will be recalled that, during operation of the damped flywheel, the springs are caused to be compressed between the arms 50 of the disc 42 and the assembly consisting of the thrust inserts 81 of the plate 20 and the pressed-out portions 80 of the disc 34 of the first mass 12.
In the course of this movement, the heads 68 of the rivets 66 cause the ring 60 to rotate, thus giving rise to friction between the ring 60 and the plate 20.
A further friction effect is produced between the ring 60 and the ring 62, which is mounted on the first mass, for rotation with the latter, by means of a coupling of the tenon and mortice type.
For this purpose, the ring 62 has at its inner periphery lugs 73 which are engaged in complementary grooves 72 formed in the hub 18.
In this way, a friction effect occurs due to the force applied by the resilient ring 64. The disc 34 does of course have a central hole, and it lies radially outside the rivets 44, 66.
It will be noted that the plate 26 (and therefore the second mass 14) has at its inner periphery a plurality of ventilation holes 4, or ventilation passages 4, which are arranged to ventilate the damped flywheel. These holes 4 extend through the reaction plate 26.
Air is thus able to flow between the two plates 20 and 26. This ventilation enhances cooling of the ball bearing 28, the holes being located close to the ball bearing 28. These holes 4 are arranged alternately with the rivets 66 and 44, being located generally on the same pitch circle as the rivets 44 (FIG. 2).
In accordance with the invention, these holes 4 are open in the base of a groove 5 which is formed in the reaction plate 26 at its inner periphery, radially outwardly of the bearing 28, with the said holes interrupting the edge of the base of the groove 5. This groove 5 is adapted to collect oil which escapes from the centre of the damped flywheel, and in particular from the friction disc 100, so as not to contaminate the friction liners 101 of the said friction disc. The groove 5, which is of annular form, has a rounded profile in cross section (FIG. 1). The groove 5 is flared in the inward radial direction towards the axis X--X.
The holes 4 therefore have a double function, namely a ventilation function and a collecting function for the oil which may for example arise from oil leaks that take place in the region of the gearbox, with the said oil passing in particular through the hub mounted in rotation on the input shaft of the gearbox, the said hub being part of the friction disc.
Another case may be where the oil leaks come from the crankshaft via the hub 18 which is axially behind the groove 5 (FIG. 1). In a further case, the leaks may be those of grease from the ball bearing 28.
Thus the oil or grease is thrown centrifugally into the groove 5, and is evacuated via the ventilation holes 4. The friction surface offered by the plate 26 to the appropriate friction liner of the friction disc runs no risk of being contaminated, the groove 5 being located radially inwardly of the working portion of the friction surface (i.e. inwardly of the friction liners 101 in FIG. 1). In this example, the holes 4 are open at the level of the sealing ring 56B, which is stepped so as to define a wall portion 90, which is inclined axially towards the reaction plate 26 (FIG. 1), between its inner radial edge by which it is fastened to the disc 42, and its external radial edge which bears on the disc 34. The wall portion 90 is located at mid-height of the ring 56B.
This inclined wall portion acts as a deflector and throws the oil and/or grease, coming from the ventilation hole 4 or ventilation passage 4, towards the reaction plate 26 between the disc 34 and the plate 26.
The inwardly wall portion 90 is located radially outwardly of the holes 4.
It will be noted that the ring 2, on which the heads of the fastening studs 1 bear, is secured independently to the hub 18 by means of "pop" rivets or dowels 3 force-fitted into the hub 18, and that the pasty or viscous agent is introduced at the outer periphery of the first mass before the housing chamber 30 is closed.
It will be noted that the holes 4 are located radially outwardly of the axially acting friction device 58 which, with the circumferentially acting resilient means 38, constitutes a coupling means acting between the two masses 12, 14, so as to couple the second mass 14, resiliently in this example, to the first mass 12.
In another version, the resilient means may be such as to act radially.
In a further version, the coupling means may be of the centrifugal type, as described in the document FR-A-1 598 557, and may comprise weights which are carried resiliently by the first mass and which are arranged to engage with a rim fixed to the second mass.
The present invention is of course not limited to the embodiment described.
In particular, the holes 4, which are of round form in FIGS. 1 to 3, may be oblong in the circumferential direction. These holes 4 may be flared towards the plate 20.
The sealing rings 56A, 56B may be coated, for example by powder coating, with a layer having a low coefficient of friction, such as "TEFLON", for contact with the plate 20 and the disc 34, and also in order to reduce wear.
For example, these rings 56A, 56B are given a "TEFLON" coating having a thickness of 10 to 50 microns, for example by spraygun application, with curing in an oven at temperatures of the order of 200 to 250 degrees.
In another version, another coating having a low coefficient of friction may be used. This enables the friction effects between the rings 56A, 56B, and those between the plate 20 and the disc 34, to be well controlled.
In general terms, in accordance with the invention the groove 5 collects a lubricating agent, such as oil, escaping from the centre of the damped flywheel.
This groove 5 may have a different profile, such as a profile of trapezoidal form with a flat base and two inclined lateral flanks, one of which is interrupted by the ventilation holes 4.
In general terms, the edge of the base of the groove 5 is interrupted by the ventilation holes or passages 4, and this groove is flared radially inwardly towards the axis of the assembly, in order to prevent the oil from contaminating the above mentioned friction surface which is offset axially with respect to the groove. Thus in FIG. 1, the groove 5 is delimited by a frusto-conical wall portion which is directed radially inwardly.
|
A flywheel having to coaxial members, the first member designed to be rotational integral with a drive shaft such as the crankshaft of an internal combustion engine, the second member designed to be connected with a driven shaft such as a gear box. The coaxial members are mounted via a bearing and coupled to each other. The second member forms a reaction plate of a friction clutch having ventilation holes proximate the bearing. The ventilation holes open into the bottom of a groove provided in the second member around the inner edge of the reaction plate radially above the bearing for collecting lubricating agent such as oil escaping from the center of the flywheel.
| 5
|
FIELD OF THE INVENTION
[0001] This invention relates to carrying cases, and, more particularly, to carrying cases with a double throw, triple action latch mechanism having a locking feature which substantially prevents inadvertent opening of the latch mechanism.
BACKGROUND OF THE INVENTION
[0002] Carrying cases typically include a top case shell and a bottom case shell pivotally connected by a hinge. The two shells are maintained in a closed position by one or more latch mechanisms located along the front and/or the sides of the case. A variety of latch mechanisms have been employed in the past, such as single throw and double throw latches, some of which may be locked with combination locks or key locks.
[0003] Carrying cases intended for the transport of valuable items, and items which are relatively fragile, are preferably rugged in construction and not subject to inadvertent opening. While combination locks or key locks may reduce the incidence of inadvertent opening of a case, such features are more suitable for cases intended for use by one individual, e.g. brief cases and the like. If a carrying case may be used by several people, it is difficult to convey the combination of a lock to a group, whose members may change, and keys are easily lost. Further, security requirements at airports do not permit locking of cases or luggage, and such cases may be inadvertently opened by baggage handlers. There is therefore a need for a carrying case having a rugged construction with a locking feature which substantially prevents inadvertent opening of the case without the use of combination locks, key locks or the like.
SUMMARY OF THE INVENTION
[0004] This invention is directed to a carrying case with a latch mechanism having a locking feature which prevents inadvertent opening of the case.
[0005] In the presently preferred embodiment, the carrying case of this invention includes a top case shell and a bottom case shell pivotally connected by a hinge. A double throw, triple action latch mechanism maintains the case shells in the closed position. The latch mechanism comprises a latch body pivotally mounted to the bottom case shell, a latch locking element pivotally mounted to the latch body and a latch release coupled to the latch body. With the case in the closed position, the latch locking element engages a seat formed in the top case shell and clamps the two shells together. In response to pivotal motion of the latch body, the latch locking element may be disengaged from the top shell allowing the case to be opened.
[0006] The purpose of the latch release is to prevent inadvertent pivotal motion of the latch body, which, in turn, would allow the latch locking element to disengage the top case shell. As described in detail below, the latch release is movable between a locked position and a release position. In the locked position, the latch release engages the front wall of the bottom case shell and prevents pivotal motion of the latch body. In turn, the latch locking element is maintained in position against the seat of the top case shell thus retaining the case in the closed position. Upon movement of the latch release to the release position, the latch body is free to pivot thus allowing the latch locking element to disengage from the top case shell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The structure, operation and advantages of the presently preferred embodiment of this invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings, wherein:
[0008] FIG. 1 is perspective view of the carrying case with the latch mechanism of this invention;
[0009] FIG. 2 is an exploded, disassembled perspective view of the components forming the latch mechanism herein;
[0010] FIG. 3 is view similar to FIG. 2 , except viewing the latch mechanism from the front;
[0011] FIG. 4 is an assembled, rear perspective view of the latch mechanism;
[0012] FIG. 5 is a view similar to FIG. 4 , except viewing the assembled latch mechanism from the front;
[0013] FIG. 6 is a cross sectional view of the latch mechanism mounted to the carrying case with the case closed and the latch release in the locked position;
[0014] FIG. 7 is a view similar to FIG. 6 except with the latch release moved to the release position;
[0015] FIG. 8 is a view similar to FIG. 6 except with the latch release pivoted relative to the bottom shell of the case; and;
[0016] FIG. 9 is view similar to FIG. 8 except with the latch locking member disengaged from the seat formed in the top case shell.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring initially to FIGS. 1 and 6 , a carrying case 10 is depicted having a top case shell 12 pivotally connected to a bottom case shell 14 . Two latch mechanisms 16 and 18 are located along the front wall 20 of shell 12 and front wall 22 of shell 14 on either side of a handle 24 . As best shown in FIG. 6 , the front wall 20 of top case shell 12 is formed with a seat 26 and a downwardly facing slot 28 which receives the upper edge 30 of the front wall 22 of bottom case shell 14 when the case 10 is closed. The front wall 22 of the bottom case shell 14 is formed with a ledge 32 , for purposes to become apparent below. Except as noted above, the detailed construction of the case 10 forms no part of this invention and is not described herein. Additionally, for purposes of the present discussion, the terms “top,” “bottom,” “upper,” “lower,” “downwardly,” “upwardly” and the like refer to the vertical orientation of the case as it is depicted in the Figs.
[0018] With reference to FIGS. 2-5 , the latch mechanism 16 of this invention is shown in detail. It should be understood that the two latch mechanisms 16 , 18 are identical to one another, and therefore only the latch mechanism 16 is discussed herein. The latch mechanism 16 comprises a latch body 34 , a latch locking element 36 and a latch release 38 . The latch body 34 includes a top wall 39 , a front wall 40 , and, a cavity 42 defined by spaced inner side walls 44 and 46 , a bottom wall 48 and a portion of the top wall 39 . An outer side wall 50 is spaced from the inner side wall 44 and an outer side wall 52 is spaced from the other, inner side wall 46 forming a bearing surface 54 between the side walls 44 and 50 and a bearing surface 56 between the side walls 46 and 52 . As best seen in FIG. 3 , the front wall 40 of latch body 34 is formed with a window 58 to provide access to the latch release 38 , as described below. Aligning bores 60 and 62 are formed in the inner side walls 44 and 46 , respectively. Additionally, a bore 64 is formed in each of the inner and outer walls 44 , 50 which aligns with a bore 66 formed in the inner and outer walls 46 and 52 .
[0019] The latch locking element 36 comprises a front wall 68 , spaced pivot arms 70 and 72 and a hook element 74 . The pivot arm 70 is formed by an outer side plate 76 and an inner side plate 78 . Similarly, the pivot arm 72 is formed by an outer side plate 80 and an inner side plate 82 . A cross brace 84 spans the inner side plates 78 and 82 . The front wall 68 has an opening 86 , and the two pivot arms 70 , 72 are formed with a through bore 88 , 90 , respectively.
[0020] The latch release 38 is sized and shaped to fit within the cavity 42 formed in the latch body 34 . It includes a front wall 92 , a back wall 94 , a top wall 96 and a bottom wall 98 which are interconnected and collectively form a hollow interior within which a sleeve 102 is mounted. A button 100 extends from the bottom wall 98 through an opening 101 in the front wall 92 . The top wall 96 has a recess 104 and an upwardly extending locking member 106 with a tapered top surface. As best seen in FIGS. 6-9 , a cylindrical-shaped projection 110 is mounted to the underside of the bottom wall 98 . The projection 110 is located within an opening 112 defined by the lower ends of the front wall 92 and back wall 94 which extend beyond the bottom wall 98 . A coil spring 114 encircles the projection 110 and seats within a spring holder 115 .
[0021] The latch mechanism 16 is assembled by first inserting the latch release 38 within the cavity 42 of the latch body 34 . The lower ends of the front and back walls 92 , 94 of the latch release 38 , and the holder 115 , rest atop the bottom wall 48 of the latch body 34 . The latch locking element 36 is then placed on the latch body 34 so that the pivot arm 70 rests atop the bearing surface 56 of the latch body 34 , and the pivot arm 72 engages the bearing surface 54 . With the latch locking element 36 and the latch release 38 in this position, a latch assembly pin 116 may be inserted through the bore 88 of pivot arm 70 , through the bore 62 in the inner side wall 46 of the latch body 34 , into the sleeve 102 of the latch release 38 , through the bore 60 in the inner side wall 44 of latch body 34 and then into the bore 90 of pivot arm 72 . This secures both the latch locking element 36 and the latch release 38 to the latch body 34 , as depicted in FIGS. 4 and 5 . The assembled latch mechanism 16 is pivotally connected to the bottom case shell 14 of the case 10 by a case mounting pin 118 which extends through the aligning bores 64 and 66 formed in the latch body 34 .
Operation of Latch Mechanism
[0022] Referring now to FIGS. 6-9 , the operation of the latch mechanism 16 of this invention is illustrated. In FIG. 6 , the latch mechanism is shown in a locked position with the hook element 74 of the latch locking element 36 in engagement with the seat 26 in the front wall 20 of the top case shell 12 and the locking member 106 of the latch release 38 contacting the ledge 32 in the front wall 22 of the bottom case shell 14 . The hook element 74 cannot disengage the seat 26 unless the latch body 34 is pivoted in a clockwise direction relative to the front wall 22 of the bottom case shell 14 , as seen in FIGS. 8 and 9 . If one pulls on the tab 120 formed by the downwardly extending end of the front wall 40 of latch body 34 , with the latch mechanism 16 in the position shown in FIG. 6 , the locking member 106 of the latch release 38 bears against the ledge 32 of the bottom case shell 14 , thus preventing such clockwise pivotal motion.
[0023] The latch release 38 is maintained in the locked position by operation of the spring 114 . As seen in FIG. 6 , the spring 114 urges the latch release 38 in an upward direction so that the locking member 106 bears against the ledge 32 . At the same time, the case mounting pin 118 is received within the recess 104 in the top wall 96 of the latch release 38 , and the latch assembly pin 116 is located at the bottom of the sleeve 102 carried by the latch release 38 .
[0024] In order to allow pivotal movement of the latch body 34 , and, in turn, permit disengagement of the hook element 74 of the latch locking element 36 from the seat 26 in the top case shell 12 , the latch release 38 must be moved to a release position shown in FIG. 7 . One may insert his or her finger through the window 58 in the front wall 40 of the latch body 34 and into contact with the button 100 extending through the opening 101 in the front wall 92 of the latch release 38 . The latch release 38 is then pushed downwardly, against the force exerted by the spring 114 , to a release position wherein the locking member 106 formed in the top wall 96 of the latch release 38 disengages the ledge 32 in the front wall 22 of the bottom case shell 14 . The user is provided with an indication of the release position because the latch assembly pin 116 will contact the upper end of the sleeve 102 in the latch release 38 when the latch release 38 is pushed downwardly to the release position.
[0025] With the latch release 38 in the release position, the latch body 34 may be pivoted in a clockwise direction about the case mounting pin 118 by grasping the tab 120 at the bottom of the latch body 34 and pulling outwardly relative to the bottom case shell 14 , as illustrated in FIG. 8 . Such motion is the first “throw” of the latch mechanism 16 . With the latch body 34 in the position depicted in FIG. 8 , the hook element 74 of the latch locking element 36 can begin to disengage from the seat 26 . When the hook element 74 assumes the position shown in FIG. 8 , the latch body 34 may then be pivoted in the opposite, counterclockwise direction, e.g. the second “throw” of the latch mechanism 16 , so that the hook element 74 may completely disengage the seat 26 as shown in FIG. 9 . The top and bottom case shells 12 , 14 may then be opened.
[0026] Closure of the latch mechanism 16 is accomplished by reversing the steps noted above. The latch body 34 is initially pivoted in the clockwise direction to allow the hook member 74 of the latch locking element 36 to assume the position relative to the seat 26 shown in FIG. 8 . The latch body 34 may then be pivoted in the counterclockwise direction so that it rests along the front wall 22 of the bottom case shell 14 as depicted in FIGS. 6 and 7 . The spring 114 urges the locking member 106 of latch release 38 to the locked position, and the case 10 is now locked in such a way that inadvertent contact with the latch body 34 cannot cause the latch mechanism 16 to open without first moving the latch release 38 to the release position.
[0027] While the invention has been described with reference to a preferred embodiment, it should be understood by those skilled in the art that various changes may be made and equivalents substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
|
A carrying case includes a top case shell hinged to a bottom case shell which may be maintained in a closed position by a double throw, triple action latch mechanism comprising a latch body pivotally mounted to the bottom case shell, a latch locking element pivotally mounted to the latch body and a latch release coupled to the latch body. With the case in the closed position, the latch locking element engages a seat formed in the top case shell and clamps the two shells together. After moving the latch release to a release position, the latch body may be pivoted relative to the bottom case shell to permit disengagement of the latch locking mechanism from the top shell allowing the case to be opened.
| 4
|
FIELD OF THE INVENTION
The instant invention relates to optically active uracil compounds and uses thereof.
BACKGROUND ARTS
U.S. Pat. No. 4,859,229 discloses that certain types of uracil compounds have herbicidal activity. However, there is no description concerning whether the herbicidal activities between the optical isomers are the same or different, or which optical isomer is more effective as a herbicidal active ingredient.
Generally speaking, in pesticides field, it is known that some optically active isomers have almost the same activity as their racemic compounds and the other optically active isomers have at most twice activity than their racemic compounds. It seems to be dependent on a structure near the asymmetric carbon in the compound whether the pesticidal activity between the optical isomers is the same or different. However, it is very difficult to estimate a pesticidal activity of an optical isomer without experimentation. When one optical isomer is almost inactive, the other optical isomer is theoretically considered to be effective twice against its racemate, because the racemate contains a half amount of the active optical isomer.
DISCLOSURE OF THE INVENTION
The present invention provides optically active uracil compounds having excellent herbicidal activity. Said uracil compounds are of the formula (I):
wherein, R 1 is C1-C8 alkyl or C3-C8 alkenyl, and * represents an asymmetric carbon atom whose configuration is R, and have excellent herbicidal activity.
DETAILED DESCRIPTION OF THE INVENTION
The present uracil compounds may be essentially pure R isomer in the 2 nd position of the propionate, namely essentially free from S isomer, or R-rich isomers of the absolute configuration in the 2 nd position of the propionate, shown in the above formula [hereinafter referred to as the present compound(s)]. In the present invention, essentially pure R isomer means one containing 95% or more R isomer, and R-rich isomer generally means one containing 80% or more R isomer based on the RS mixture.
In the present invention, examples of the C1-C8 alkyl represented by R 1 include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl, amyl, isoamyl, sec-amyl, tert-amyl and hexyl, and examples of the C3-C 8 alkenyl represented by R 1 include allyl, 1-methyl-2-propenyl, 3-butenyl, 2-butenyl, 3-methyl-2-butenyl and 2-methyl-3-butenyl. Among the present compounds, the compounds wherein R 1 is C1-C6 alkyl or C3-C6 alkenyl are preferable.
The present compounds can be produced by methods, for example, shown in the following.
(Production Method 1)
A method of production by reacting a hydroxy compound of the formula (II):
with an S-lactate of the formula (III):
wherein R 1 represents the same as defined above.
Said reaction is usually performed in the presence of a triarylphosphine or trialkylphosphine such as triphenylphosphine, triethylphosphine, tributylphosphine and the like, in combination with a di(lower alkyl) azodicarboxylate such as diethyl azodicarboxylate, diisopropyl azodicarboxylate, and the like. Said reaction is usually performed within a solvent, and the range of the reaction temperature is usually −20 to 150° C., preferably 0 to 100° C., and the range of the reaction time is instantaneous to 48 hours. The amount of the S-lactate of the formula (III) used in the reaction is generally 1 to 3 moles, preferably 1 to 1.2 moles, based on 1 mole of the hydroxy compound of the formula (II). The amount of the triarylphosphine or trialkylphosphine is generally 1 to 3 moles, preferably 1 to 1.2 moles, and the amount of the di(lower alkyl) azodicarboxylate is generally 1 to 3 moles, preferably 1 to 1.2 moles, based on 1 mole of the hydroxy compound of the formula (II). Examples of the solvent utilized for the reaction include aliphatic hydrocarbons such as hexane, heptane, ligroin, cyclohexane and petroleum ether; aromatic hydrocarbons such as benzene, toluene and xylene; halogenated aromatic hydrocarbons such as chlorobenzene, dichlorobenzene and benzotrifluoride; ethers such as diethyl ether, diisopropyl ether, dioxane, tetrahydrofuran and ethylene glycol dimethyl ether; and the like, and mixtures thereof. After completing the reaction, for example, by the methods shown below, the objective present compounds can be isolated.
1) The reaction solution is poured into water, that is extracted with an organic solvent, said organic layer is dried and concentrated, and the residue is subjected to chromatography.
2) The reaction solution is concentrated as it is, and the residue is subjected to chromatography.
In addition, it is possible to purify the present compounds by operations such as recrystalization.
The hydroxy compound of the formula (II) can be prepared by the method described in U.S. Pat. No. 4,859,229.
(Production Method 2)
A method of production by reacting a hydroxy compound of the formula (II) with an S-2-chloropropionate of the formula (IV):
wherein R 1 represents the same as defined above.
Said reaction is usually performed in the presence of a base within a solvent, and the range of the reaction temperature is usually −20 to 100° C., preferably 0 to 40° C., and the range of the reaction time is instantaneous to 240 hours. The amount of the S-2-chloropropionate of the formula (IV) used in the reaction is generally 1 to 2 moles, preferably 1 to 1.2 moles, based on 1 mole of the hydroxy compound of the formula (II). The amount of the base is generally 1 to 3 moles, preferably 1 to 1.2 moles, based on 1 mole of the hydroxy compound of the formula (II). Examples of the base utilized for the reaction include inorganic bases such as lithium carbonate, sodium carbonate, potassium carbonate, sodium hydride and potassium hydride. Examples of the solvent utilized for the reaction include aliphatic hydrocarbons such as hexane, heptane, ligroin, cyclohexane and petroleum ether; aromatic hydrocarbons such as benzene, toluene and xylene; halogenated aromatic hydrocarbons such as chlorobenzene, dichlorobenzene and benzotrifluoride; ethers such as diethyl ether, diisopropyl ether, dioxane, tetrahydrofuran and ethylene glycol dimethyl ether; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, isophorone and cyclohexanone; esters such as ethyl formate, ethyl acetate, butyl acetate and diethyl carbonate; nitriles such as acetonitrile, propionitrile and butyronitrile; acid amides such as formamide, N,N-dimethylformamide and acetamide; sulfur compounds such as dimethyl sulfoxide and sulfolane; and the like, and mixtures thereof. After completing the reaction, for example, by the methods shown below, the objective present compounds can be isolated.
1) The reaction solution is poured into water, that is extracted with an organic solvent, said organic layer is dried and concentrated, and the residue is subjected to chromatography.
2) The reaction solution is concentrated as it is, and the residue is subjected to chromatography.
(Production Method 3)
A method of producing from a carboxylic acid compound of the formula (V):
and an alcohol compound of the formula (VI):
R 1 OH
wherein R 1 represents the same as defined above.
(Production Method 3-1)
A method of producing by reacting a carboxylic acid compound of the formula (V) with an alcohol compound of the formula (VI) directly.
Said reaction is usually performed in the presence of an acid, without or within a solvent, and the range of the reaction temperature is usually from 20 to 150° C., preferably 50 to 100° C., and the range of the reaction time is usually from instantaneous to 24 hours. The amount of the alcohol compound of the formula (VI) used in the reaction is generally 1 mole to a large excess and the amount of the acid is generally a catalytic amount to 1 mole based on 1 mole of the carboxylic acid compound of the formula (V). Examples of the acid utilized for the reaction include inorganic acid such as sulfuric acid; sulfonic acid such as methanesulfonic acid, trifluoromethanesulfonic acid, p-toluenesulfonic acid, benzenesulfonic acid; ion-exchange resin that is acidic cation resin; and the like. Examples of the solvent utilized for the reaction include aliphatic hydrocarbons such as hexane, heptane, nonane, decane, ligroin, cyclohexane and petroleum ether; halogenated aliphatic hydrocarbons such as methylene chloride, chloroform, carbon tetrachloride, 1,2-dichloroethane and 1,2,3-trichloropropane; aromatic hydrocarbons such as benzene, toluene, xylene and mesitylene; halogenated aromatic hydrocarbons such as chlorobenzene, dichlorobenzene and benzotrifluoride; ethers such as diethyl ether, diisopropyl ether, methyl tert-butyl ether, dioxane, tetrahydrofuran and ethylene glycol dimethyl ether; and the like, and mixtures thereof. After completing the reaction, for example, by the methods shown below, the objective present compounds can be isolated.
1) The reaction solution is poured into water optionally after concentrated, that is extracted with an organic solvent, said organic layer is dried and concentrated, and the residue is subjected to chromatography.
2) The reaction solution is concentrated as it is, and the residue is subjected to chromatography.
The carboxylic acid compound of the formula (V) can be prepared by hydrolysis of the uracil compounds of the formula (I). Therefore, this method serves an ester exchange procedure, and especially it is suitable for the process from methyl or ethyl ester to the other esters.
The hydrolysis may be performed in the presence of an acid and water, and usually within a solvent. The range of the reaction temperature is usually from 20 to 150° C., preferably 70 to 110° C., and the range of the reaction time is usually from instantaneous to 48 hours. The amounts of the acid used in the reaction is generally a catalytic amount to 1 mole, preferably a catalytic amount to 0.2 mole, based on 1 mole of the uracil compound of the formula (I). The amount of the water is generally 1 mole to a large excess, based on 1 mole of the uracil compound of the formula (I). Examples of the acid utilized for the hydrolysis include inorganic acid such as hydrochloric acid and sulfuric acid; sulfonic acid such as methanesulfonic acid, trifluoromethanesulfonic acid, p-toluenesulfonic acid, benzenesulfonic acid; and the like. Examples of the solvent utilized for the reaction include dioxane, tetrahydrofuran and the like. After completing the reaction, for example, by the methods shown below, the objective compound can be isolated.
1) The reaction solution is poured into water optionally after concentrated, that is extracted with an organic solvent, said organic layer is dried and concentrated, and the residue is subjected to chromatography.
2) The reaction solution is concentrated as it is, and the residue is subjected to chromatography.
This method may be modified by known procedures utilizing a dehydration-esterifying agent such as dicyclohexylcarbodiimide.
(Production Method 3-2)
A method of producing by reacting a reactive intermediate such as acid chloride, which can be derived from a carboxylic acid compound of the formula (V), with an alcohol compound of the formula (VI).
Said method may be performed by, after making such into an acid chloride compound by reacting the carboxylic acid compound of the formula (V) with a chlorinating agent (hereinafter referred to as procedure 3-2-1), reacting with the alcohol compound of the formula (VI), in the presence of a base (hereinafter referred to as procedure 3-2-2).
Procedure 3-2-1 is performed without a solvent or within a solvent. The range of the reaction temperature is usually from 0 to 150° C., and the range of the reaction time is usually from instantaneous to 24 hours. The amount of the chlorinating agent offered with the reaction is theoretically 1 mole based on 1 mole of the carboxylic acid compound of the formula (V), but optionally the amount may be changed in the range of 1 mole to an excess as needed with the reaction condition. Examples of the chlorinating agent utilized for the reaction include thionyl chloride, sulfuryl chloride, phosgene, oxalyl chloride, phosphorous trichloride, phosphorous pentachloride and phosphorous oxychloride. Examples of the solvent include aliphatic hydrocarbons such as hexane, heptane, nonane, decane, ligroin, cyclohexane and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and mesitylene; halogenated aliphatic hydrocarbons such as methylene chloride, chloroform, carbon tetrachloride, 1,2-dichloroethane and 1,2,3-trichloropropane; halogenated aromatic hydrocarbons such as chlorobenzene, dichlorobenzene and benzotrifluoride; ethers such as diethyl ether, diisopropyl ether, methyl tert-butyl ether, dioxane, tetrahydrofuran and ethylene glycol dimethyl ether; and the like, and mixtures thereof. After completing the reaction, the reaction solution is usually concentrated under reduced pressure, and the concentrated residue is utilized as it is for procedure 3-2-2.
Procedure 3-2-2 is performed in the presence of a base, and within a solvent or without a solvent. The range of the reaction temperature is usually −20 to 100° C., and the range of the reaction time is usually instantaneous to 24 hours. The amounts of the base and the alcohol compound (VI) used in the reaction are theoretically 1 mole respectively, based on 1 mole of the carboxylic acid compound of the formula (V), but optionally the amounts may be changed in the range of 1 mole to an excess as needed with the reaction condition. Examples of the base utilized for the reaction include inorganic bases such as lithium hydrogencarbonate, sodium hydrogencarbonate, potassium hydrogencarbonate, lithium carbonate, sodium carbonate and potassium carbonate; nitrogen-containing aromatic compounds such as pyridine, quinoline, 4-dimethylaminopyridine, 2-picoline, 3-picoline, 4-picoline, 2,3-lutidine, 2,4-lutidine, 2,5-lutidine, 2,6-lutidine, 3,4-lutidine, 3,5-lutidine, 3-chloropyridine, 2-ethyl-3-methylpyridine and 5-ethyl-2-methylpyridine; tertiary amines such as triethylamine, diisopropylethylamine, tri-n-propylamine, tri-n-butylamine, benzyldimethylamine, phenethyldimethylamine, N-methylmorpholine, 1,8-diazabicyclo[5.4.0]undec-7-ene, 1,5-diazabicyclo[4.3.0]-non-5-ene or 1,4-diazabicyclo[2.2.2]octane. Examples of the solvent include aliphatic hydrocarbons such as hexane, heptane, nonane, decane, ligroin, cyclohexane and petroleum ether; aromatic hydrocarbons such as benzene, toluene, xylene and mesitylene; halogenated aliphatic hydrocarbons such as methylene chloride, chloroform, carbon tetrachloride, 1,2-dichloroethane and 1,2,3-trichloropropane; halogenated aromatic hydrocarbons such as chlorobenzene, dichlorobenzene and benzotrifluoride; ethers such as diethyl ether, diisopropyl ether, methyl tert-butyl ether, dioxane, tetrahydrofuran and ethylene glycol dimethyl ether; and the like, and mixtures. After completing the reaction, for example, by the methods shown below, the objective present compounds can be isolated.
1) The reaction solution is poured into water, that is extracted with an organic solvent, said organic layer is dried and concentrated
2) The reaction solution is concentrated as it is, or as needed, is filtered and the filtrate is concentrated. In addition, it is possible to purify the present compounds by operations such as recrystalization and chromatography.
This method may be modified by known procedures utilizing carbonyldiimidazole in place of the chlorinating agent.
The present compounds have excellent herbicidal activity, and some of them exhibit excellent selectivity between crop plants and unfavorable weeds. The present compounds show a herbicidal efficacy in foliar treatment and soil treatment of fields, for example, against the various kinds of problematic weeds mentioned in the following.
Polygonaceae:
wild buckwheat ( Polygonum convolvulus ), pale smartweed ( Polygonum lapathifolium ), pennsylvania smartweed ( Polygonum pensylvanicum ), ladysthumb ( Polygonum persicaria ), curly dock ( Rumex crispus ), broadleaf dock ( Rumex obtusifolius ), Japanese knotweed ( Polygonum cuspidatum )
Portulacaceae:
common purslane ( Portulaca oleracea )
Caryophyllaceae:
common chickweed ( Stellaria media )
Chenopodiaceae:
common lambsquarters ( Chenopodium album ), kochia ( Kochia scoparia )
Amaranthaceae:
redfoot pigweed ( Amaranthus retroflexus ), smooth pigweed ( Amaranthus hybridus )
Crusiferae:
wild radish ( Raphanus raphanistrum ), wild mustard ( Sinapis arvensis ), shepherdspurse ( Capsella bursapastoris )
Leguminosae:
hemp sesbania ( Sesbania exaltata ), sicklepod ( Cassia obtusifolia ), Florida beggarweed ( Desmodium tortuosum ), white clover ( Trifolium repens )
Malvaceae:
velvet leaf ( Abutilon theophrasti ), prickly sida ( Sida spinosa )
Violaceae:
field pansy ( Viola rafinesquii ), wild pansy ( Viola tricolor )
Rubiaceae:
catchweed bedstraw (cleavers) ( Galium aparine )
Convolvulaceae:
ivyleaf morningglory ( Ipomoea hederacea ), tall morningglory ( Ipomoea purpurea ), entireleaf morningglory ( Ipomoea hederacea var intergriuscula ), pitted morningglory ( Ipomoea lacunosa ), field bindweed ( Convolvulus arvensis )
Labiatae:
purple deadnettle ( Lamium purpureum ), henbit ( Lamium amplexicaule )
Solanaceae:
jimsonweed ( Datura stramonium ), black nightshade ( Solanum nigrum )
Scrophulariaceae:
persian speedwell ( Veronica persica ), ivyleaf speedwell ( Veronica hederaefolia )
Compositae:
common cocklebur ( Xanthium strumarium ), common sunflower ( Helianthus annuus ), scentless chamomile ( Matricaria perforata or inodora ), corn marigold ( Chrysanthemum segetum ), pineappleweed ( Matricaria matricarioides ), common ragweed ( Ambrosia artemisiifolia ), giant ragweed ( Ambrosia trifida ), horseweed ( Erigeron canadensis ), japanese mugwort ( Artemisia princeps ), tall goldenrod ( Solidago altissima )
Boraginaceae:
field forget-me-not ( Myosotis arvensis )
Asclepiadaceae:
common milkweed ( Asclepias syriaca )
Euphorbiaceae:
sun spurge ( Euphorbia helioscopia ), spotted spurge ( Euphorbia maculata )
Gramineae:
barnyardgrass ( Echinochloa crus - galli ), green foxtail ( Setaria viridis ), giant foxtail ( Setaria faberi ), large crabgrass ( Digitaria sanguinalis ), goosegrass ( Eleusine indica ), annual bluegrass ( Poa annua ), blackgrass ( Alopecurus myosuroides ), wild oats ( Avena fatua ), johnsongrass ( Sorghum halepense ), quackgrass ( Elytrigia repens ), downy brome ( Bromus tectorum ), bermudagrass ( Cynodon dactylon ), fall panicum ( Panicum dichotomiflorum ), Texas panicum ( Panicum texanum ), shattercane ( Sorghum bicolor )
Commelinaceae:
common dayflower ( Commelina communis )
Equisetaceae:
field horsetail ( Equisetum arvense )
Cyperaceae:
rice flatsedge ( Cyperus iria ), purple nutsedge ( Cyperus rotundus ), yellow nutsedge ( Cyperus esculentus )
Additionally, some of the present compounds do not show a problematic phytotoxicity against important crops such as corn ( Zea mays ), wheat ( Triticum aestivum ), barley ( Hordeum vulgare ), rice ( Oryza sativa ), sorghum ( Sorghum vulgare ), soybean (Glycine max), cotton (Gossypium spp.), sugar beet ( Beta vulgaris ), peanut ( Arachis hypogaea ), sunflower ( Helianthus annuus ) and canola ( Brassica napus ); gardening plants such as flowering plants and ornamental plants; vegetable crops.
The present compounds can attain effective control of unfavorable weeds in the no-tillage cultivation of crops such as soybean, corn and wheat. Furthermore, some of them do not show a problematic phytotoxicity against crops.
The present compounds have herbicidal activity against various unfavorable weeds as recited below under the flooding treatment on paddy fields.
Gramineae:
early watergrass ( Echinocholoa oryzoides )
Scrophulariaceae:
Common falsepimpernel ( Lindernia procumbens )
Lythraceae:
Indian toothcup ( Rotala inidica ), Ammannia multiflora
Elatinaceae:
water wort ( Elatine triandra )
Cyperaceae:
smallflower umbrellaplant ( Cyperus difformis ), hardstem bulrush ( Scirpus juncoides ), needle spikerush ( Eleocharis acicularis ), water nutgrass ( Cyperus serotinus ), water chesnut ( Eleocharis kuroguwai )
Pontederiaceae:
monochoria ( Monochoria vaginalis )
Alismataceae:
arrowhead ( Sagittaria pygmaea ), Sagittaria trifolia , waterplantain ( Alisma canaliculatum )
Potamogetonaceae:
roundleaf pondweed ( Potamogeton distincutus )
Umbelliferae:
watercelery ( Oenanthe javanica )
Furthermore, some of the present compounds do not show a problematic phytotoxicity against transplanted paddy rice.
The present compounds can attain effective control of various unfavorable weeds in orchards, pastures, lawns, forests, waterways, canals, or other non-cultivated lands.
The present compounds also have herbicidal activity against various aquatic plants such as water hyacinths ( Eichornia crassipes ) which grow in waterways, canals and the like.
The present compounds have substantially the same characteristics as those of the herbicidal compounds described in the publication of International Patent Application, WO95/34659. In the case where crops with tolerance imparted by introducing a herbicide tolerance gene described in the publication are cultivated, the present compounds can be used at greater doses than those used when ordinary crops without tolerance are cultivated, and it is, therefore, possible to attain effective control of other unfavorable plants.
When the present compounds are used as active ingredients of herbicides, they are usually mixed with solid or liquid carriers or diluents, surfactants, and/or other formulation auxiliary agents, and formulated into such as emulsifiable concentrates, wettable powders, flowables, granules, concentrated emulsions, and water-dispersible granules.
These formulations may contain any of the present compounds as an active ingredient at an amount of 0.001% to 80% by weight, preferably 0.005% to 70% by weight, based on the total weight of the formulation.
Example of the solid carrier or diluent may include fine powders or granules of the following materials: mineral matters such as kaolin clay, attapulgite clay, bentonite, terra abla, pyrophyllite, talc, diatomaceous earth and calcite, organic substances such as walnut shell powder, water soluble organic substances such as urea, inorganic salt such as ammonium sulfate, and synthetic hydrated silicon dioxide. Examples of the liquid carrier or diluent may include the following materials:aromatic hydrocarbons including alkylbenzenes such as methylnaphthalene, phenylxylylethane, and xylene alcohols such as isopropyl alcohol, ethylene glycol and 2-ethoxyethanol, esters such as phthalic acid dialkyl ester , ketones such as acetone, cyclohexanone and isophorone, mineral oils such as machine oil, vegetable oils such as soybean oil and cotton seed oil, dimethylsulfoxide, N,N-dimethylformamide, acetonitrile, N-methylpyrrolidone water, and the like.
Examples of the surfactant utilized for emulsification, dispersing or spreading may include the following materials:anionic surfactants such as alkylsulfate ester salts, alkylsulfonate salts, alkylarylsulfonate salts, dialkyl sulfosuccinate salts and polyoxyethylenealkylaryl ether phosphate ester salts, nonionic surfactants such as polyoxyethylenealkyl ethers, polyoxyethylenealkylaryl ethers, polyoxyethylenepolyoxypropylene block copolymers, sorbitan fatty acid esters and polyoxyethylenesorbitan fatty acid esters; and the like.
Examples of the formulation auxiliary agents may include the following materials: ligninsulfonate salts, alginate salts, polyvinyl alcohol, gum arabic, CMC (carboxymethyl cellulose), PAP (acidic isopropylphosphate), and the like.
The present compounds are usually formulated and applied for the pre- or post-emergence soil, foliar, or flooding treatment of unfavorable weeds. The soil treatment may include soil surface treatment and soil incorporation treatment. The foliar treatments may include application over the plants and directed application in which a chemical is applied only to the unfavorable weeds so as to keep off the crops.
When the present compounds are used as active ingredients of herbicides, the application amount is usually in the range of 0.01 to 10,000 g, preferably 1 g to 8,000 g per hectare, although it may vary depending upon the weather conditions, formulation type, application timing, method of application, soil conditions, objective crop and objective unfavorable weed(s). In the case of emulsifiable concentrates, wettable powders, suspensible concentrates, concentrated emulsions, water dispersable granules, or the like, the formulation is usually applied at prescribed amounts after diluted with 10 L to 1,000 L of water (in which an adjuvant such as a spreading agent may be added, if necessary) per hectare. In the case of granules or certain types of suspensions, the formulation is usually applied as such without any dilution.
Example of the adjuvant used, if necessary, may include in addition to the surfactants described above, polyoxyethylene resin acids (esters), ligninsulfonate salts, abietate salts, dinaphthylmethanedisulfonate salts, crop oil concentrate, vegetable oils such as soybean oil, corn oil, cotton seed oil and sunflower oil.
The present compounds may be used in the places such as corn fields, wheat fields, barley fields, rice fields, sorghum fields, soybean fields, cotton fields, sugar beet fields, peanut fields, sunflower fields, rape fields and paddy fields.
The present compounds can also be utilized as active ingredients of harvest-aids such as desiccants and defoliants agents for cottons, desiccants of potatoes ( Solanum tuberosum ). In these cases, the present compounds are usually formulated in the same manner as the case where they are used as active ingredients of herbicides, and used alone or in combination with other harvesting aids for foliar treatment before the harvesting of crops.
EXAMPLES
Hereinafter, the present invention is further explained with the production examples, formulation examples and test examples, but the present invention is not limited such examples.
To begin with, the production examples of the present compounds are explained.
Production Example 1
Seventeen grams (17.0 g) of the hydroxy compound of formula (II), 8.0 g of methyl S-lactate (Merck & Co., Inc.) and 20.0 g of triphenylphosphine were dissolved in 50 mL of tetrahydrofuran. To the solution, a solution which had 13.0 g of diethyl azodicarboxylate dissolved in 15 mL of tetrahydrofuran was added dropwise over 30 minutes while stirring under ice-cooling. At that time, the reaction temperature was kept from 8 to 15° C. Thereafter, and after stirring at room temperature for 30 minutes, the reaction solution was poured into water, and that was extracted with ethyl acetate. The organic layer was washed with saturated sodium chloride solution, and after drying over magnesium sulfate, was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate=3/1), and 18.48 g of methyl (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (hereinafter referred to as the present compound 1) was obtained.
1 H-NMR (CDCl 3 , 300 MHz): δ (ppm) 7.31 (1H, d, J=9.0 Hz), 6.82 (½H, d, J=6.42 Hz), 6.81 (½H, d, J=6.45 Hz), 6.35 (1H, s), 4.68 (1H, q, J=6.9 Hz), 3.74 (3H, s), 3.55 (3H, s, br), 1.66 (3H, d, J=6.9 Hz) [α] D 20 +25.8° (c 1.0, CH 3 OH), the content (R isomer:S isomer)=97.3:2.7 (determined by LC method utilizing optically active column).
Production Example 2
Ten grams (10.0 g) of (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionic acid were dissolved in 150 mL of ethanol. To the solution, 1.0 mL of sulfuric acid was added and refluxed for 3 hours under heating. Thereafter, a part of the reaction solution was collected, concentrated and poured into water, and that was extracted with ethyl acetate. The organic layer was washed with saturated sodium chloride solution, and after drying over anhydrous magnesium sulfate, was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate=3/1), and 7.8 g of ethyl (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (hereinafter referred to as the present compound 2) was obtained.
1 H-NMR (CDCl 3 , 300 MHz): δ (ppm) 7.31 (1H, d, J=9.0 Hz), 6.83 (½H, d, J=6.4 Hz), 6.81 (½H, d, J=6.4 Hz), 6.34 (½H, s), 6.33 (½H, s), 4.67 (1H, q, J=7.0 Hz), 4.25-4.15(2H, m), 3.54 (3H, q, J=1.3 Hz), 1.66 (3H, d, J=7.0 Hz), 1.23 (½×3H, t, J=7.2 Hz), 1.22 (½×3H, t, J=7.1 Hz), R content: 99% or more (determined by LC method utilizing optically active column).
Production Example 3
One and fifty-one hundredths grams (1.51 g) of (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionic acid was dissolved in 10 mL of tetrahydrofuran, and after adding 1.5 mL of thionyl chloride while stirring, that was heated with stirring under reflux for 1 hour. Thereafter, and after allowing the reaction solution to be cooled, and concentrated, that was dissolved in 6 mL of tetrahydrofuran and 1 mL of pyridine was added thereto, and then, 0.5 mL of allylalcohol was added thereto. After stirring at room temperature for 1 hour, ice-water was poured into the reaction solution. After adding ethyl acetate and saturated sodium chloride solution, and phase separating, the organic layer was washed with saturated sodium chloride solution, and after drying over magnesium sulfate, that was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate=3/1), and 1.02 g of allyl (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (hereinafter, referred to as the present compound 3) was obtained.
1 H-NMR (CDCl 3 , 300 MHz): δ (ppm) 7.31 (1H, d, J=8.9 Hz), 6.84 (½H, d, J=6.50 Hz), 6.82 (½H, d, J=6.41 Hz), 6.34 (1H, s), 5.91-5.80 (1H, m), 5.29 (1H, ddd, J=1.1 Hz, 1.1 Hz, 17.1 Hz), 5.22 (1H, dd, J=1.1 Hz, 10.7 Hz), 4.71 (1H, q, J=7.1 Hz), 4.64 (2H, dd, J=1.1 Hz, 5.6 Hz), 3.55 (3H, t, J=1.45 Hz), 1.68 (3H, d, J=7.1 Hz), [α] D 19 +24.70° (c 1.0, CH 3 OH).
Production Example 4
Thirty grams (30.0 g) of the hydroxy compound of formula (II) was dissolved in 360 g of N,N-dimethylformamide, and after adding 36.7 g of potassium carbonate, that was stirred for 100 minutes at room temperature. To the mixture, 18.96 g of isobutyl (S)-2-chloropropionate was added dropwise over 100 minutes, and then the reaction mixture was stirred for 8.75 hours at room temperature. Thereafter, the reaction mixture was poured into ice-water and extracted with ethyl acetate. The organic layer was washed with saturated sodium chloride solution twice, and after drying over magnesium sulfate, that was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate), and 25.28 g of isobutyl (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (hereinafter, referred to as the present compound 4) was obtained.
1 H-NMR (CDCl 3 , 300 MHz): δ (ppm) 7.31 (1H, d, J=8.7 Hz), 6.81 (½H, d, J=6.4 Hz), 6.80 (½H, d, J=6.3 Hz), 4.70 (1H, q, J=6.6 Hz), 3.97-3.86 (2H, m), 3.54 (3H, q, J=1.3 Hz), 1.97-1.82 (1H, m), 1.70 (3H, d, J=6.6 Hz), 0.861 (3H, d, J=6.5 Hz), 0.858 (3H, d, J=6.5 Hz), [α] D 29 +24.50° (c 1.0, CH 3 OH).
Production Example 5
Forty-one and a half grams (41.5 g) of the hydroxy compound of the formula (II), 13.5 g of methyl S-lactate (Merck & Co., Inc.; Lot 42111033) and 35.4 g of triphenylphosphine were dissolved in 350 mL of tetrahydrofuran. To the solution, 67.8 g of a 40% toluene solution containing 13.0 g of diisopropyl azodicarboxylate was added dropwise over 15 minutes under ice-cooling. Thereafter, and after stirring at room temperature for 2.75 hours, the reaction solution was poured into water, and that was extracted with ethyl acetate. The organic layer was washed with saturated sodium chloride solution, and after drying over magnesium sulfate, was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate=3/1), and 40.8 g of methyl (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (hereinafter referred to as the present compound 5) was obtained. R content: 99% or more (determined by LC method utilizing optically active column).
Production Example 6
Five grams (5.0 g) of the present compound 5 was dissolved in tetrahydrofuran to prepare a 100 mL solution (hereinafter referred to as the solution A). On the other hand, 5.0 g of the Compound X, that is methyl (2S)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate, produced by the Reference Production Example 5 below was dissolved in tetrahydrofuran to prepare a 100 mL solution (hereinafter referred to as the solution B).
Nine mililiters (9.0 mL) of the solution A and 1.0 mL of the solution B were combined and then concentrated to give methyl 2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate, the R content of which is 90% (hereinafter referred to as the present compound 6).
Eight mililiters (8.0 mL) of the solution A and 2.0 mL of the solution B were combined and then concentrated to give methyl 2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate, the R content of which is 80% (hereinafter referred to as the present compound 7).
Next, production examples of comparative compounds, which were utilized to compare with the present compounds, are provided as reference production examples.
Reference Production Example 1
Eight and a half grams (8.5 g) of the hydroxy compound of the formula (II), 3.12 g of methyl R-lactate (Tokyo Chemical Industry Co., Ltd.) and 7.9 g of triphenylphosphine were dissolved in 25 mL of tetrahydrofuran. To the solution, a solution which had 5.22 g of diethyl azodicarboxylate dissolved in 5 mL of tetrahydrofuran was added dropwise over 15 minutes under ice-cooling with stirring. At that time, the reaction temperature was kept 8 to 20° C. Thereafter, and after stirring at room temperature for 30 minutes, the reaction solution was poured into water, and that was extracted with ethyl acetate. After the organic layer was dried over magnesium sulfate, such was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate=3/1), and 9.91 g of methyl (2S)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (hereinafter referred to as the comparative compound 1).
1 H-NMR (CDCl 3 , 300 MHz): δ (ppm) 7.31 (1H, d, J=9.0 Hz), 6.82 (½H, d, J=6.42 Hz), 6.81 (½H, d, J=6.45 Hz), 6.35 (1H, s), 4.68 (1H, q, J=6.9 Hz), 3.74 (3H, s), 3.55 (3H, s, br), 1.66 (3H, d, J=6.9 Hz), [α] D 20 −23.5° (c 1.0, CH 3 OH), the content (R isomer: S isomer)=2.9:97.1 (determined by LC method utilizing optically active column).
Reference Production Example 2
Twenty grams (20 g) of the hydroxy compound of the formula (II) was dissolved in 200 mL of N,N-dimethylformamide. To the solution, 10.0 g of potassium carbonate and 12.1 mL of ethyl (RS)-2-bromopropionate were added and stirred for 40 minutes at room temperature. Thereafter, the reaction mixture was poured into water, and that was extracted with ethyl acetate. The organic layer was washed with saturated sodium chloride solution and dried over anhydrous magnesium sulfate, such was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate=3/1), and 23.46 g of ethyl (2RS)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (hereinafter referred to as the comparative compound 2).
Reference Production Example 3
One and thirty-two hundredths grams (1.32 g) of (2RS)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionic acid was dissolved in 15 mL of tetrahydrofuran. To the solution, 1.0 mL of thionyl chloride was added and heated for 70 minutes under reflux. Thereafter, the reaction solution was concentrated to be a volume of 15 mL, to which 1 mL of allyl alcohol and 1 mL of pyridine were added and stirred for 4 hours at room temperature. And then the reaction solution was poured into water, and that was extracted with ethyl acetate. The organic layer was washed with saturated sodium chloride solution and dried over anhydrous magnesium sulfate, such was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate=5/1), and 1.02 g of allyl (2RS)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (hereinafter referred to as the comparative compound 3).
Reference Production Example 4
Five milliliters (5.0 mL) of the solution A above and 5.0 mL of the solution B were combined and then concentrated to give methyl 2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate, the R content of which is 50% (hereinafter referred to as the comparative compound 4).
Reference Production Example 5
One and thirteen hundredths grams (1.13 g) of the hydroxy compound of the formula (II), 0.4 mL of methyl R-lactate (Tokyo Chemical Industry Co., Ltd.) and 1.0 g triphenylphosphine were dissolved in 7.5 mL of tetrahydrofuran. To the solution, 1.9 g of a 40% toluene solution containing diisopropyl azodicarboxylate was added dropwise over 15 minutes under ice-cooling. Thereafter, and after stirring at room temperature for 1.5 hours, the reaction solution was poured into water, and that was extracted with ethyl acetate. After the organic layer was dried over magnesium sulfate, such was concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate=3/1), and 0.91 g of methyl (2S)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (referred to as the Compound X). S content: 99% or more (determined by LC method utilizing optically active column)
Additionally, a production example of a starting material of the present compounds, that is the carboxylic acid compound of the formula (V), is given as reference production example 6.
Reference Production Example 6
Three and one hundredth grams (3.01 g) of methyl (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionate (the present compound 1) was dissolved in 30 mL of dioxane. To the solution, a mixture of 5 mL of conc. hydrochloric acid and 5 mL of water was added with stirring, and then heated for 2.5 hours under reflux with stirring. Thereafter, after allowing the reaction solution to be cooled to room temperature, ice water were poured into the solution, and further ethyl acetate and saturated sodium chloride solution were added. After phase separation, the organic layer was washed with saturated sodium chloride solution, dried over magnesium sulfate and concentrated. The residue was subjected to silica gel column chromatography (eluent, hexane/ethyl acetate), and 2.42 g of (2R)-2-[2-chloro-4-fluoro-5-[3-methyl-2,6-dioxo-4-(trifluoromethyl)-1,2,3,6-tetrahydropyrimidin-1-yl]phenoxy]propionic acid.
Next, the formulation examples of the present compounds are explained.
Formulation Example 1
Fifty (50) parts of each of the present compounds 1 to 7, 3 parts of calcium ligninsulfonate, 2 parts of sodium laurylsulfate, and 45 parts of synthetic hydrated silicon dioxide are well pulverized and mixed, to obtain each of the wettable powders.
Formulation Example 2
Ten (10) parts of each of the present compound 1 to 7, 14 parts of polyoxyethylenestyryl phenyl ether, 6 parts of calcium dodecylbenzenesulfonate, 35 parts of xylene, and 35 parts of cyclohexanone are mixed to obtain each of the emulsifiable concentrates.
Formulation Example 3
Two (2) parts of each of the present compound 1 to 7, 2 parts of synthetic hydrated silica, 2 parts of calcium ligninsulfonate, 30 parts of bentonite, and 64 parts of kaolin clay are well pulverized and mixed, and after adding water and well kneading, that is granulated and dried to achieve each of the granules.
Formulation Example 4
Twenty-five (25) parts of each of the present compound 1 to 7, 50 parts of a 10% aqueous solution of polyvinyl alcohol, and 25 parts of water are mixed, are wet pulverized until the average particle diameter is 5 μm or less, to obtain each of the suspensible concentrates.
Next, test examples are explained to show that the present compounds are effective as an active ingredient of a herbicide.
The herbicidal activity was evaluated at 6 levels with indices of 0 to 5, i.e., designated by the numeral “0”, “1”, “2”, “3”, “4” or “5”, wherein “0” means that there was no or little difference in the degree of germination or growth between the treated and the untreated tested plants at the time of examination, and “5” means that the test plants died complete or their germination or growth was completely inhibited.
Test Example 1
Foliar Treatment on Upland Fields
Plastic pots which have an area of (26.5×19)cm 2 and a depth of 7 cm were filled with upland soil, seeded with common cocklebur ( Xanthium strumarium ) and were given 21 days to grow in a greenhouse. Each of the test compounds was formulated into emulsifiable concentrates according to Formulation Example 2, which was diluted with a designated amount of water containing 1% Agri-Dex (adjuvant produced by Helena Chemical Company), and such was uniformly sprayed over the foliage of the test plants with a sprayer at a volume of 1000 liters per hectare. After the application, the test plants were grown in the greenhouse for 21 days, and the herbicidal activity was examined. Those results are given in Table 1.
TABLE 1
Application Amount
of the Active
Herbicidal
Ingredient
Activity
Test Compound
(g/ha)
Common Cocklebur
Present Compound 1
1
5
Comparative Compound 1
1
0
As shown in the table above, the present compound (methyl ester, R/S=97.3/2.7) is more effective than the comparative compound (methyl ester, R/S=2.9/97.1).
Test Example 2
Soil Surface Treatment on Upland Fields
Plastic pots which have an area of (26.5×19)cm 2 and a depth of 7 cm were filled with upland soil, seeded with johnsongrass ( Sorghum halepense ). Each of the test compounds was formulated into emulsifiable concentrates according to Formulation Example 2, which was diluted with a designated amount of water, and such was uniformly sprayed over the soil surface in the pots with a sprayer at a volume of 1000 liters per hectare. After the application, the test plants were grown in a greenhouse for 25 days, and the herbicidal activity was examined. Those results are given in Table 2.
TABLE 2
Application
Amount of the
Herbicidal
Active Ingredient
Activity
Test Compound
(g/ha)
johnsongrass
Present Compound 5
16
4
32
5
63
5
Present Compound 6
16
4
32
5
63
5
Present Compound 7
16
4
32
5
63
5
Comparative Compound 4
16
1
32
2
63
4
As shown in the table above, the present compounds (methyl ester, the contents of R isomer; 80% or more) are much more effective than the comparative compound (methyl ester, racemic). Especially, a forth dosage (16 g/ha) of the present compound against the dosage of the comparative compound (63 g/ha) showed almost the same effect for controlling the weeds.
Test Example
Soil Incorporation Treatment on Upland Fields
Cylindrical plastic pots of 10 cm in diameter and a 10 cm in depth were filled with upland soil. The soil from the surface to 3 cm in depth was taken and mixed with the dilution which was given by diluting the emulsifiable concentrates of the test compounds, formulated according to Formulation Example 2, with water at a volume of 606 liters per hectare. Thereafter, the treated soil was put back to the pots, in which johnsongrass ( Sorghum halepense ) was sowed at 1.5 cm in depth. The test plants were grown in a greenhouse for 19 days, and the herbicidal activity was examined. Those results are given in Table 3.
TABLE 3
Application
Amount of the
Herbicidal
Active Ingredient
Activity
Test Compound
(g/ha)
johnsongrass
Present Compound 5
20
4
40
5
80
5
Present Compound 6
20
3
40
5
80
5
Present Compound 7
20
2
40
5
80
5
Comparative Compound 4
20
0
40
2
80
4
As shown in the table above, the present compounds (methyl ester, the contents of R isomer; 80% or more) is much more effective than the comparative compound (methyl ester, racemic).
Test Example 4
Soil Surface Treatment on upland fields
Plastic pots which have an area of (26.5×19)cm 2 and a depth of 7 cm were filled with upland soil, seeded with hemp sesbania ( Sesbania exaltata ), barnyardgrass ( Echinochloa crus - gali ) and johnsongrass ( Sorghum halepense ). Each of the test compounds was formulated into emulsifiable concentrates according to Formulation Example 2, which was diluted with a designated amount of water, and such was uniformly sprayed over the soil surface in the pots with a sprayer at a volume of 100 liters per hectare. After the application, the test were grown in a greenhouse for 25 days, and the herbicidal activity was examined. Those results are given in Table 4.
TABLE 4
Application
Amount of the
Active
Herbicidal Activity
Ingredient
hemp
barnyard-
johnson-
Test Compound
(g/ha)
sesbania
grass
grass
Present
16
2
5
3
Compound 2
32
5
5
5
63
5
5
5
Comparative
16
0
0
0
Compound 2
32
2
3
2
63
3
3
3
125
4
5
4
As shown in the table above, the present compounds (ethyl ester, the contents of R isomer; 99% or more) is much more effective than the comparative compound (ethyl ester, racemic). Especially, a forth dosage (32 g/ha) of the present compound against the dosage of the comparative compound (125 g/ha) showed same or more effective for controlling the weed.
Test Example 5
Soil Incorporation Treatment on Upland Fields
Cylindrical plastic pots of 10 cm in diameter and a 10 cm in depth were filled with upland soil. The soil from the surface to 3 cm in depth was taken and mixed with the dilution which was given by diluting the emulsifiable concentrates of the test compounds, formulated according to Formulation Example 2, with water at a volume of 606 liters per hectare. Thereafter, the treated soil was put back to the pots, in which johnsongrass ( Sorghum halepense ) was sowed at 1.5 cm in depth. The test plants were grown in a greenhouse for 19 days, and the herbicidal activity was examined. Those results are given in Table 5.
TABLE 5
Application
Amount of the
Herbicidal
Active Ingredient
Activity
Test Compound
(g/ha)
johnsongrass
Present Compound 2
20
4
40
5
80
5
Comparative Compound 2
20
1
40
2
80
4
As shown in the table above, the present compounds (ethyl ester, the contents of R isomer; 99% or more) is much more effective than the comparative compound (ethyl ester, racemic). Especially, a forth dosage (20 g/ha) of the present compound against the dosage of the comparative compound (80 g/ha) showed almost the same effect for controlling the weed.
Test Example 6
Soil Surface Treatment on Upland Fields
Plastic pots which have an area of (26.5×19)cm 2 and a depth of 7 cm were filled with upland soil, seeded with johnsongrass ( Sorghum halepense ). Each of the test compounds was formulated into emulsifiable concentrates according to Formulation Example 2, which was diluted with a designated amount of water, and such was uniformly sprayed over the soil surface in the pots with a sprayer at a volume of 1000 liters per hectare. After the application, the test plants were placed in a greenhouse for 25 days, and the herbicidal activity was examined. Those results are given in Table 6.
Application
Amount of the
Herbicidal
Active Ingredient
Activity
Test Compound
(g/ha)
johnsongrass
Present Compound 3
16
3
32
5
63
5
Comparative Compound 3
16
0
32
1
63
2
As shown in the table above, the present compound is much more effective than the comparative compound. Especially, even a forth dosage (“3” at 16 g/ha) of the present compound is much more effective than the comparative compound (“2” at 63 g/ha).
|
The present invention relates to an optically active uracil compounds of the formula (I):
wherein, R 1 is C1-C8 alkyl or C3-C8 alkenyl, and * represents an asymmetric carbon atom whose configuration is R. The compounds have excellent herbicidal activity.
| 0
|
This application is a continuation, of application Ser. No. 95,821, filed Nov. 19, 1979 which is in turn a continuation of application Ser. No. 16,633, filed Mar. 1, 1979 which in turn is a continuation of application Ser. No. 915,705, filed June 15, 1978, now all abandoned.
FIELD OF THE INVENTION
This invention relates to high-impact, glass-like plastics alloys of polymethacrylates and aliphatic polyurethane ureas.
BACKGROUND OF THE INVENTION
Processes for the production of glass-clear sheets from thermoplastic plastics by the radical addition polymerization of olefinically unsaturated monomers are known. They are based on the use of monomers which represent a solvent for the polymers thereof. Examples of such monomers are the esters of acrylic acid and methacrylic acid. In particular, processes for the production of glass-clear moldings by the bulk polymerization of methyl methacrylate have acquired commercial significance.
Despite the favorable optical and mechanical properties thereof, these materials are unsatisfactory on account of the brittleness thereof, i.e. the low resistance thereof to impact. Accordingly, there has been no shortage of attempts to produce polymethyl methacrylate moldings having the same favorable optical properties, but considerably improved impact strength and with the level of dimensional stability to heat substantially intact. Of the methods used for the high-impact modification of polymethyl methacrylate or methyl methacrylate copolymers, alloying with polyurethane elastomers is of particular interest because the properties of such combination materials are variable over wide ranges by virtue of the wide range of possible starting materials and variants of the production process.
It is known that cross-linked or linear polyurethane elastomers containing unsaturated or olefinic double bonds on the basis of polyether or polyester polyols and low molecular weight, aliphatic polyhydric alcohols may be produced by polyaddition in solution in vinyl monomers whose polymerization would normally lead to hard polymers having a high glass transition temperature, for example in methyl methacrylate or in monomer mixtures consisting predominantly of methyl methacrylate.
German Patent Publication No. 2,003,365 describes a process for the production of high-impact moldings from thermoplastic polymers, in which a cross-linked polyurethane is synthesized in a vinyl monomer or in a mixture of vinyl monomers by reacting polyisocyanates with polyfunctional compounds containing Zerewitinoff-active hydrogen atoms, after which the vinyl monomer is polymerized. Since, in this process, gels which may neither be cast nor shaped are obtained as an intermediate stage, shaping has to be completed before the polyaddition reaction has advanced to the cross-linked polyurethane stage. Accordingly, such a process may only be combined with difficulty with the now generally accepted process for the production of moldings, particularly sheets, by bulk polymerization.
In the course of further development of the above proposal, it was found that gelation of the polyurethane solutions could be avoided by selecting the polyurethane precursors for the functionality thereof in such a way that the concentration of the branching or cross-linking sites did not exceed a certain limit (German Patent Publication No. 2,312,973). In this process, however, it is not possible to rule out the danger of the formation of gels and other inhomogeneities which adversely affect the quality of the completed polymer products.
German Patent Publication No. 2,033,157 describes a process for the production of high-impact rigid polymers based on acrylic esters in which solutions of linear polyurethanes containing unsaturated groups accessible to copolymerization are produced from diisocyanates, aliphatic diols, relatively high molecular weight aliphatic polyester diols and isocyanate-monofunctional compounds containing an ethylenic double bond in a monomeric acrylic and/or methacrylic ester.
It has been found that the composite materials formed during the bulk polymerization of such solutions are made up of two phases, the polyurethane component representing the continuous phase and the polymethacrylate component the disperse phase, even with relatively low concentrations of polyurethane.
The observed phase structure makes it necessary to use polymers having optimal mechanical properties, particularly with regard to tensile and tear strength, elongation at break and elasticity and in regard to the dependence thereof upon temperature. It is known that these properties and the thermal stability under load of polyurethane elastomers may be improved by incorporating urea groups as so-called "hard segments" into the polymer chain. This may be done by using diamines in the synthesis of the elastomer, aliphatic and cycloaliphatic diamines being particularly suitable on account of the imperative color stability and resistance to weather.
However, methyl methacrylate or even less polar acrylic and methacrylic acid esters are relatively poor solvents for polyurethane urea elastomers of this type, as reflected, for example, in the very steep increase in solution viscosity with increasing content of urea groups in the polyurethane chain. The hard segments of the elastomer chains form crystalline associates which are firmly bound through hydrogen bridges and which cannot be kept in solution by poor solvents. This crystallization of the hard segments frequently results in clouding of the polyurethane monomer solutions and the moldings obtained from them by polymerization. Although the most widely used polyisocyanate for the production of light-stable polyurethanes, namely the readily obtainable hexamethylene diisocyanate, leads to high-quality elastomers, slightly clouded polyurethane urea solutions are formed during chain-extension with diamines in methyl methacrylate as solvent when using this diisocyanate. Although moldings produced from these solutions show excellent mechanical properties, they are unsuitable for the production of glass-clear sheets.
SUMMARY OF THE INVENTION
It has now been found that clear solutions of linear polyurethane-polyurea elastomers in monomeric methacrylic acid esters, above all methyl methacrylate, optionally in combination with small quantities of other copolymerizable monomers, such as acrylonitrile or methacrylonitrile, styrene or vinyl toluene or α-methyl styrene, may be obtained and fully polymerized to form clear sheets or other moldings by reacting aliphatic diisocyanates having a fairly complex, non-linear structure, alicyclic diisocyanates or aliphatic or alicyclic diisocyanates modified by graft polymerization with one or more vinyl monomers with relatively long chain polyester diols and aliphatic or alicyclic diamines as chain-extenders. It has also been found that, by using aromatic polyester diols or by using mixed polyesters of aliphatic and aromatic dicarboxylic acids, the refractive index of the elastomer phase may readily be matched with that of the thermoplastic phase, as a result of which an improvement in weathering resistance is additionally observed. It is possible to obtain a linkage between the polyurethane urea phase and the thermoplast phase in known manner by the incorporation of unsaturated groups which copolymerize with the monomer (mixture) present.
Accordingly, the present invention relates to a process for the production of high-impact polymer alloys by the radically initiated polymerization of homogeneous mixtures of:
(A) from about 40 to 92%, by weight of one or more monomeric esters of methacrylic acid and, optionally, small quantities of one or more copolymerizable vinyl monomers; and
(B) from about 8 to 60%, by weight, of a substantially linear polyurethane urea elastomer; wherein the polyurethane urea elastomer is initially synthesized by polyaddition from:
(1) one or more substantially linear polyester, polyester amide, polyacetal or polycarbonate polyols, preferably a polyester diol based on:
(a) from about 50 to 100 mol %, preferably from about 65 to 95 mol %, of optionally olefinically unsaturated aliphatic dicarboxylic acids; and
(b) from about 0 to 50 mol %, preferably from about 5 to 35 mol %, of cycloaliphatic and/or aromatic dicarboxylic acids,
having a molecular weight of from about 500 to 6000, preferably from about 600 to 4000 and, with particular preference, from about 800 to 2500, preferably having a glass transition temperature of at most about -20° C. and, optionally, from about 0 to 20 mol %, based on the entire polyol component, of diols having a molecular weight of from about 62 to 500;
(2) one or more aliphatic diisocyanates having a branched carbon skeleton of from about 7 to 36 carbon atoms, cycloaliphatic diisocyanates containing from about 5 to 25 carbon atoms and/or aliphatic or alicyclic diisocyanates modified by graft copolymerization with one or more vinyl monomers;
(3) one or more aliphatic or cycloaliphatic diamines; and, optionally,
(4) a saturated or olefinically unsaturated compound with monofunctional reactivity to isocyanates; by preparing a prepolymer containing from about 1 to 5%, by weight, of NCO-groups from component (1) and (2) in a first stage, reacting the prepolymer dissolved in the polymerizable monomeric ester of acrylic acid with component (3) in a second stage in an NCO/NH 2 equivalent ratio of from about 1.01 to 1.5, preferably from about 1.1 to 1.4, optionally in the presence of other copolymerizable vinyl monomers, preferably until an about 20% solution of the polyurethane urea in the monomer has a viscosity of from about 200 to 30,000 cP at 20° C. optionally, reacting the free NCO-groups which may still be present in a third stage by the addition of component (4), adjusting the solids content of the solution to from about 8 to 60%, by weight, optionally by the addition of more vinyl monomers, and finally subjecting the mixture to a radically initiated polymerization reaction in known manner, optionally in molds.
On account of the imperative resistance to weathering, particularly in the case of sheets produced by bulk polymerization, the conventional polyether polyols cannot be used for synthesizing the polymer alloys according to the present invention.
According to the present invention, however, it is possible to use hydroxyl group-containing polycarbonates, polyester amides and polyacetals having a substantially linear structure and the above-mentioned molecular weight range as component (1).
DETAILED DESCRIPTION OF THE INVENTION
The polyesters containing hydroxyl groups which may be used in accordance with the present invention are, for example, reaction products of polyhydric, preferably dihydric and, optionally, also trihydric, alcohols with polybasic, preferably dibasic, carboxylic acids. Instead of using the free polycarboxylic acids, it is also possible to use the corresponding polycarboxylic acid anhydrides or corresponding polycarboxylic acid esters of lower alcohols or mixtures thereof for producing the polyesters. The polycarboxylic acids may be aliphatic, cycloaliphatic, aromatic and/or heterocyclic and may optionally be substituted, for example by halogen atoms, and/or may be unsaturated.
Examples of such polycarboxylic acids include: succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, trimellitic acid, phthalic acid anhydride, tetrahydrophthalic acid anhydride, hexahydrophthalic acid anhydride, tetrachlorophthalic acid anhydride, endomethylene tetrahydrophthalic acid anhydride, glutaric acid anhydride, maleic acid, maleic acid anhydride, fumaric acid, dimeric and trimeric fatty acids, such as oleic acid, optionally in admixture with monomeric fatty acids, terephthalic acid dimethyl ester and terephthalic acid-bis-glycol ester. Suitable polyhydric alcohols are for example, ethylene glycol, 1,2- and 1,3-propylene glycol, 1,4- and 2,3-butylene glycol, 1,6-hexane diol, 1,8-octane diol, neopentyl glycol, cyclohexane dimethanol (1,4-bis-hydroxymethyl-cyclohexane), 2-methyl-1,3-propane diol, also diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycols, dipropylene glycol, polypropylene glycols, dibutylene glycol and polybutylene glycols. Small quantities of higher polyhydric alcohols, such as glycerol, trimethyl propane, etc., are used for introducing a low degree of branching. The polyesters may contain terminal carboxyl groups. Polyesters of lactones, for example ε-caprolactone, or hydroxy carboxylic acids, for example ω-hydroxy caproic acid, may also be used.
Suitable polyacetals are, for example, the compounds obtainable from the reaction of glycols, such as diethylene glycol, triethylene glycol, 4,4'-dioxethoxy diphenyl dimethyl methane and hexane diol, with formaldehyde. Polyacetals suitable for use in accordance with the present invention may also be obtained by the polymerization of cyclic acetals.
Suitable polycarbonates containing hydroxyl groups are known and may be obtained, for example, by reacting diols, such as 1,3-propane diol, 1,4-butane diol and/or 1,6-hexane diol, diethylene glycol, triethylene glycol or tetraethylene glycol, with diaryl carbonates, for example diphenyl carbonate, or with phosgene.
The polyester amides and polyamides include, for example, the predominantly linear condensates obtained from polybasic saturated and unsaturated carboxylic acids or the anhydrides thereof and polyfunctional saturated and unsaturated amino-alcohols, diamines, polyamines and mixtures thereof.
Representatives of these compounds which may be used in accordance with the present invention are described, for example, in High Polymers, Vol. XVI, "Polyurethanes, Chemistry and Technology", by Saunders-Frisch, Interscience Publishers, New York, London, Vol. I, 1962, pages 44 to 54, and Vol II, 1964, pages 5-6 and 198-199, and in Kunststoff-Handbuch, Vol. VII, Vieweg-Hochtlen, Carl-Hanser-Verlag, Munich, 1966, for example on pages 45-71.
It is, of course, also possible to use mixtures of the above-mentioned polyols. According to the present invention, it is preferred to use polyester diols based on ethylene glycol, propylene glycol, 1,4-butane diol, 1,6-hexane diol and/or neopentyl glycol and adipic acid, optionally aromatic dicarboxylic acids, such as phthalic acid, isophthalic acid and terephthalic acid, and/or olefinically unsaturated dicarboxylic acids, such as maleic acid, itaconic acid or fumaric acid. The polyesters are normally produced using an excess of the diol component so that the chain ends contain hydroxyl groups. In order to optimize the properties of the end product, it may be necessary to use a combination of several polyester diols. Reference has been made to the significance of using aromatic polyesters for adjusting the refractive index and for improving weather resistance. It is also possible, to a certain extent, to use branched polyesters produced not only from difunctional components, but also from more highly functional branching agents, best triols, such as glycerol or trimethylol propane. However, the proportion in which these branched polyesters are used should be kept so small that a polyurethane which is homogeneously soluble in the monomer, rather than a cross-linked polyurethane gel, is formed, which may be determined by a simple preliminary test.
Low molecular weight diols which may optionally be used are, for example, the compounds referred to above as starting components for the production of the polyesters.
It has been found that glasses having high stability to light may be obtained in accordance with the present invention by using a diisocyanate having a branched aliphatic carbon skeleton of from about 7 to 36 carbon atoms or a basic alicyclic skeleton containing from about 5 to 25 carbon atoms. Suitable aliphatic diisocyanates are, for example, 2,2,4- or 2,4,4-trimethylhexamethylene diisocyanate or technical mixtures thereof, diisocyanates derived from esters of lysine or diisocyanates based on dimerized fatty acids which are produced in known manner by converting dicarboxylic acids containing up to 36 carbon atoms into the corresponding diamines, followed by phosgenation. Suitable alicyclic diisocyanates are, for example, 1,3-cyclobutane diisocyanate 1,3- and 1,4-cyclohexane diisocyanate, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl cyclohexane (isophorone diisocyanate), 2,4- and/or 2,6-diisocyanato-1-methyl cyclohexane or 4,4'-diisocyanatodicyclohexyl methane in the form of the pure geometric isomers or the isomer mixtures. According to the present invention, it is particularly preferred to use isophorone diisocyanate. Preadducts of the above-mentioned diisocyanates with the above-mentioned low molecular weight diols may also be used.
Other suitable diisocyanates are obtained by the radical graft copolymerization of aliphatic or cycloaliphatic diisocyanates with one or more of the vinyl monomers described below, preferably methyl methacrylate, in quantities of from about 10 to 100%, by weight, preferably from about 20 to 75%, by weight based on the diisocyanate used. As a result of this pretreatment, the hexamethylene diisocyanate which, as such, is unsuitable for the process according to the present invention may also be converted into a suitable isocyanate which gives clear polyurethane solutions. These modified polyisocyanates may be obtained by mixing the diisocyanate, the vinyl monomer and optionally an inert solvent and initiating radical polymerization in a manner known per se e.g. by adding an initiator. Processes of this kind are described e.g. in British Pat. No. 1,354,783, in U.S. patent application Ser. Nos. 277,804 and 765,172 and in U.S. Pat. Nos. 3,654;106 and 3,943,159, herein incorporated by reference.
Diamines suitable for use in accordance with the present invention are alkylene diamines containing from 2 to 36 carbon atoms, for example hexamethylene diamine, undecamethylene diamine, 2,2,4- and/or 2,4,4-trimethyl hexamethylene diamine or diamines derived from dimeric fatty acids, also cyclic aliphatic diamines containing from 5 to 25 carbon atoms, for example the various diaminocyclohexanes, diaminomethyl cyclohexanes and diaminodicyclohexyl methanes in the form of the pure position and geometric isomers or isomer mixtures, bis-aminomethyl cyclohexanes and 1-amino-3,3,5-trimethyl-5-aminomethyl cyclohexane (isophorone diamine). The preferred diamine is isophorone diamine whose use in combination with isophorone diisocyanate or aliphatic or alicyclic diisocyanates modified by graft polymerization leads to the formation of completely clear elastomer solutions in methyl methacrylate.
In order to avoid an excessive increase in viscosity during preparation of the elastomer solution, which would complicate processing, the isocyanate component (2) and the sum of components (1) and (3) containing active hydrogen are not used in an equimolar ratio, but instead in a molar ratio which, on completion of the reaction, gives a polyurethane urea containing residual NCO-groups. The unreacted isocyanate groups of the polyurethane urea may be closed by means of an excess of diamine or by means of a monofunctional NCO-reactive compound. For this purpose, it is possible to use, for example, aliphatic alcohols, such as methanol, ethanol, octanol, sec.-butanol stearyl alcohol, etc., or aliphatic monoamines, for example n-butylamine, stearylamine, di-n-butylamine, cyclohexylamine, etc. In addition, polymerizable groups may be introduced by means of the residual NCO-groups by reacting them with a compound containing an olefinic double bond and having monofunctional reactivity to isocyanates. Such compounds are, for example, the hydroxy alkyl esters of acrylic acid or methacrylic acid, such as β-hydroxyethyl methacrylate. The elastomer phase may be linked to the thermoplast phase through the thus introduced polymerizable double bonds.
The polyurethane urea elastomer is synthesized in the monomeric methacrylic ester by a two-stage or prepolymer process, in which the relatively high molecular weight polyol component is initially reacted with a polyisocyanate to form a prepolymer containing NCO-groups, after which the high molecular weight polyurethane urea is synthesized by adding the chain-extender. After the required molecular weight has been reached, the reaction may be stopped by the addition of a monofunctional chain-terminator.
The prepolymer is preferably produced by reacting the selected polyol(s) under anhydrous conditions and after dehydration in vacuo with a calculated excess of the diisocyanate and following the progress of the reaction by titrimetric determination of the NCO-content. Normally, there is no need to add catalysts. In the interests of acceleration, however, the conventional polyurethane catalysts, particularly organo-tin compounds, such as tin dioctoate or di-n-butyl tin dilaurate, may be added in small quantities, for example from 0.0005 to 0.5%, based on the quantity of the reaction mixture. The reaction is over when the NCO-concentration has reached the value calculated beforehand from the molar ratio of the starting materials. The reaction temperature is limited at the lower end of the range by the consistency of the reactants used, above all the polyester diol which is generally highly viscous to wax-like or resin-like to solid at room temperature, so that a reaction temperature of at least about 50°to 60° C. is preferably applied in the interests of thorough admixture. At the upper end of the range, the reaction temperature is limited by the possibility of undesirable secondary reactions which increase in extent with increasing temperature and may lead to losses of isocyanates and to cross-linking reactions and also to the formation of clouded or colored products. It is not advisable significantly to exceed a reaction temperature of about 120° C. A particularly preferred range for the reaction temperature is from about 80 to 110° C. It is, of course, also possible directly to prepare the prepolymer in the monomer, although the concentrations of the inter-reacting groups are reduced in this way, the reaction thereby slowing down.
The highly viscous melt of the prepolymer is best taken up in an organic solvent for further processing. The organic solvent preferably used for this purpose is the monomer which, in order to inhibit premature polymerization, should preferably be stabilized by the addition of a standard inhibitor, such as hydroquinone, hydroquinone monomethyl ether or phenothiazine.
The necessary quantity of chain-extender may be calculated from the NCO-number of the prepolymer in accordance with the following equation: ##EQU1## wherein W D : quantity of diamine to be used (in g)
W P : quantity of the prepolymer (in g)
M D : molecular weight of the diamine
α: degree of extension
NCO-number: %, by weight, of NCO.
The degree of extension is defined as the percentage quantity of chain-extender used based on the amount of chain extender equivalent to the NCO-content. The degree of extension applied in practice is selected in such a way that the viscosity of a 20% solution of the elastomer in the monomer assumes a value of from about 200 to 30 000 cP, as measured at 20° C.
As mentioned above, the prepolymer is dissolved in the vinyl monomer selected either at room temperature or at moderately elevated temperature before the chain-extending reaction. The chain-extender is then added continuously or in portions and the increase in the viscosity of the solution is followed. The extending reaction takes place smoothly at sufficient velocity at temperatures as low as room temperature, although in the interests of acceleration it may also be carried out at moderately elevated temperatures, for example up to 40° C. In the interests of better admixture during introduction and hence better control of the reaction, the chain-extender is preferably also dissolved in the vinyl monomer used. The quantity of the vinyl monomer used as solvent is selected in such a way that the solids content of the end product does not fall below the required limit. Once the required end viscosity or rather the preselected degree of extension has been reached and a residual NCO-content may still be detected, the reaction is stopped. This is done by reacting the residual NCO-groups with the monofunctional chain-terminator, of which the necessary quantity may be calculated in accordance with the following formula: ##EQU2## wherein: W T : quantity of chain-terminator (in g)
M T : molecular weight of the chain-terminator.
Due to inevitable side reactions, in practice part of the NCO-groups of the prepolymer are consumed by reactions other than chain extension so that NCO-free polyurethane ureas are obtained even if a subequivalent amount of chain extending agent is used. In cases, where the elastomer still contains free NCO-groups, however, after the desired viscosity (or degree of extension) has been reached, these residual NCO-groups may be removed, as explained above, by adding a monofunctional compound or a further portion of diamine in excess to the residual NCO-content.
Unless the reaction by which the prepolymer is formed has already been catalyzed, a conventional catalyst, for example an organo-tin compound, such as di-n-butyl tin dilaurate, may optionally be added in a small quantity, for example from 0.0005 to 0.5%, based on the solids content of the solution, in order to accelerate chain-termination. The reaction may also be carried out at room temperature or at moderately elevated temperature. The final elastomer solution may be stored for prolonged periods under the conventional precautionary measures, such as cooling and saturation with atmospheric oxygen, optionally in the presence of standard commercial-grade phenolic or aminic stabilizers, until it is required for processing.
The polymerizable monomer or monomer mixture consists predominantly of esters of methacrylic acid, the principal monomer, generally methyl methacrylate, best being used as solvent during production of the polyurethane.
Just as in the production of unmodified polymethylmethacrylate, additions of from about 0 to 20 mol % of other (meth)acrylic acid esters are possible in order to produce materials having the required properties. For example, acrylic and methacrylic acid esters of C 4 -C 8 alcohols may improve the processing properties of the polymer, whereas short-chain acrylates, such as methyl or ethyl acrylate, increase thermal stability. In order to improve phase compatibility (for example by the development of hydrogen bridge bonds), it may be advantageous to add unsaturated acids, such as acrylic or methacrylic acids or the nitriles thereof or hydroxyalkyl(meth)acrylates, such as β-hydroxyethyl methacrylate.
Monomers having a high refractive index, such as styrene and its derivatives, and also phenyl or benzyl(meth) acrylate, may be used for matching the refractive index of the hard phase with the polyurethane phase.
According to the present invention, the following quantities are generally used:
(a) from about 80 to 100 mol %, preferably from about 90 to 100 mol %, (based on the total quantity of polymerizable monomers) of methyl methacrylate;
(b) from about 0 to 20 mol %, preferably from about 0 to 10 mol %, of other esters of acrylic and/or methacrylic acids;
(c) from about 0 to 20 mol %, preferably from about 0 to 10 mol %, of acrylic acid and/or methacrylic acid; and
(d) from about 0 to 20 mol %, preferably from about 0 to 10 mol %, of other olefinically unsaturated monomers.
By using molecular weight regulators, such as alkyl mercaptans or esters of thioglycolic or thiopropionic acid, it is also possible to improve the processibility of the polymer and to increase its thermal stability by the reduction in molecular weight. On the other hand, it may be necessary, in order to prevent corrosion and solubility, to add cross-linking agents, for example glycol dimethacrylate, allyl or vinyl(meth)acrylate, triallyl cyanurate, etc., which leads to products having good properties, above all in the event of modification with small quantities of polyurethane urea. It is also possible to add agents which suppress gel effects, such as terpinols (German Pat. No. 1,795,395), UV- and heat-stabilizers, plasticizers, coupling agents and release agents, etc.
In order to produce high-impact, rigid acrylic glass, elastomer solutions having PUR-contents of from about 10 to 25%, by weight, are generally used. Higher PUR-contents within the claimed range lead to soft, flexible products on completion of polymerization.
Polymerization of the unsaturated monomers is carried out radically in known manner in the presence of peroxides or azo compounds which have suitable decomposition rates at the polymerization temperature selected, although photochemical polymerization by UV-rays or other high-energy rays, optionally in the presence of photoinitiators, is also possible.
The polymerization reaction is preferably carried out in known manner between two plates of glass and an elastic sealing cord encircling them at the edges thereof. This process is described, inter alia, in U.S. Pat. No. 2,091,615, incorporated herein by reference.
In addition, however, other polymerization processes known from the production of acrylic glass, such as polymerization between two endless steel belts (U.S. Pat. No. 3,371,383, incorporated herein by reference), may also be used.
The polyurethane-modified methacrylate-based plastics produced in accordance with the present invention represent an enrichment of the art, in particular when, as mentioned above, the polymerization reaction is carried out in a mold, for example between glass plates or steel belts.
The process according to the present invention is illustrated by the following Examples. (Unless otherwise indicated, the quantities quoted represent parts, by weight, or percent, by weight).
The following abbreviations are used for the various starting materials in the following Examples:
Polyester A: Linear polyester diol of adipic acid, 1,6-hexane diol and neopentyl glycol having an OH-number of 66 and an average molecular weight of 1700.
Glass transition temperature: -60° C.
Polyester B: A linear polyester diol of adipic acid, phthalic acid anhydride and ethylene glycol having an OH-number of 64 and an average molecular weight of 1750.
Molar ratio of the dicarboxylic acids: 1:1
Glass transition temperature: -20° C.
Polyester C: A linear polyester diol of adipic acid and 1,6-hexane diol having an OH-number of 134 and an average molecular weight of 835.
Glass transition temperature: -30° C.
Polyester D: A linear polyester diol similar to polyester A having an OH-number of 55 and an average molecular weight of 2000.
Glass transition temperature: -60° C.
Polyester E: A linear, unsaturated polyester diol of phthalic acid anhydride, maleic acid anhydride and 1,2-propylene glycol having an average molecular weight of 2000.
Molar ratio of the acid components: 1.08:1.
Glass transition temperature: +32° C.
IPDI: 3-isocyanatomethyl-3,5,5-trimethyl cyclohexyl-isocyanate (isophorone diisocyanate).
IPDA: 3-aminomethyl-3,5,5-trimethyl cyclohexylamine (isophorone diamine).
Solution viscosity was measured by means of a Haake Viskotester VT 02, bell number 1.
Production of the polyurethane urea solutions:
Solution 1
1680 g (2 mols) of polyester C are dehydrated in a water jet vacuum at 110° C. 666 g (3 mols) of IPDI are then added at 100° C. After heating for 2 hours to 100° C., an NCO-group content of 3.6% is determined. 2000 g of this product are dissolved in 8000 g of monomeric methyl methacrylate. An NCO-group content of 0.59 is determined in the solution. 111 g (0.654 mol) of isophorone diamine, divided into 3 portions, are then introduced at room temperature. This corresponds to 92.5% of the quantity equivalent to the NCO-content. An increase in viscosity is observed. Finally, 10 ml of methanol are added to react off residual NCO-groups. The solution has a viscosity at room temperature of 5500 cP, as measured using a Haake Viskotester, and a refractive index n D 20 of 1.4925.
Solution 2
A prepolymer having an NCO-content of 2.81% is prepared from 2.1 mols of polyester C and 3 mols of IPDI in the same way as described in Example 1. 850 g of this prepolymer are reacted for 3 hours at 100° C. with 17 g (0.189 mol) of 1,4-butane diol, after which the NCO-content has fallen to 0.71%. This viscous melt is dissolved in methyl methacrylate (solids content 30%), followed by the addition of 10.0 g (0.059 mol) of IPDA. A highly viscous solution is formed which is diluted to 20% with more methyl methacrylate. 2 g of di-n-butylamine are added to close the remaining NCO-groups. The solution has a viscosity of 2650 cP at room temperature.
Solution 3
A polyurethane urea solution is prepared in the same way as described in Example 2, starting with 1313 g of a prepolymer of 1.05 mol of polyester D and 1.5 mol of IPDI which has an NCO-content of 1.5%. The initial chain-extending reaction is carried out using 10.5 g (0.117 mol) of 1,4-butane diol in the melt at 100° C. The prepolymer is dissolved in methyl methacrylate to form a 30% solution which is reacted with 14 g of IPDA (0.082 mol). The resulting highly viscous solution is diluted to a solids content of 20% and then stirred for 1 hour with 4 g of di-n-butylamine (0.031 mol). The fully reacted solution has a viscosity at room temperature of 1000 cP.
Solution 4
1050 g of a prepolymer which has been produced by reacting 1.2 mols of polyester A and 0.2 mol of polyester B with 2 mols of IPDI and which has an NCO-content of 2.0% are taken up in 1575 g of methyl methacrylate. 30.6 g of IPDA are initially added to the resulting solution. During the chain-extending reaction, the viscosity of the solution rises steeply so that the solution is diluted to a solids content of 20% using 2625 g of methyl methacrylate, after which another 3.4 g of IPDA are added. The total quantity of IPDA corresponds to 0.2 mol. No more NCO-groups may be detected in the solution. The solution has a final viscosity of 3400 cP at 20° C.
Solution 5
1160 g (2 equivalents) of a graft polymer which has been produced by the radical polymerization of 30 parts of methyl methacrylate in the presence of 100 parts of polyester A with azoisobutyronitrile as initiator and which has an OH-number of 95 are reacted with 333 g (1.5 mols)of IPDI to form an NCO-prepolymer having an NCO-content of 2.4%. This prepolymer is subjected to initial chain-extension using 22.5 g (0.25 mol) of 1,4-butane diol and the product is dissolved in 3535 g of methyl methacrylate. The resulting solution has an NCO-group content of 0.23%. For further chain-extension, 21.3 g (0.125 mol) of IPDA are then added to the mixture, corresponding to 80% of the quantity of isocyanate present in the solution. After a short time, the viscosity of the solution rises steeply so that the solution is diluted to a solids content of 20% using another 2550 g of methyl methacrylate. Following the addition of 1 g of IPDA (0.006 mol), a further increase in viscosity is observed. The final viscosity is measured at 650 cP/20° C. and the refractive index n D 20 at 1. 4912.
Solution 6
595 g (0.35 mol) of polyester A and 131 g (0.15 mol) of polyester B are dehydrated in vacuo for 30 minutes at 110° C. 166.5 g (0.75 mol) of IPDI are added to the melt at 100° C., followed by stirring for 2 hours at that temperature. The product is then left standing for another 20 hours at room temperature. Thereafter, the NCO-group content amounts to 1.89%. The prepolymer is dissolved in 3900 g of methyl methacrylate at 40° C. 90% of the equivalent quantity of 38.2 g (0.224 mol) of IPDA, dissolved in 196 g of methyl methacrylate, are added in portions to the resulting solution. Thereafter, the viscosity of the solution has increased to 21,000 cP and the reaction is stopped by the addition of 6 g of β-hydroxyethyl methacrylate and 0.5 g of dibutyl tin dilaurate dissolved in 20 g of methyl methacrylate. The water-clear, colorless solution has a refractive index of 1.4928.
Solution 7
A prepolymer having an NCO-content of 2.03% is prepared in the same way as described in Example 6 using 0.1 g of dibutyl tin dilaurate. Further processing is also carried out in the same way as described in Example 6, except that the chain-extending reaction is stopped after only 80% of the calculated quantity of amine has been added. The product has a viscosity of 3800 cP.
Solution 8
A mixture of 382 g (0.225 mol) of polyester A and 50 g (0.025 mol) of polyester E is reacted without preliminary dehydration with 83.3 g (0.375 mol) of IPDI to form a prepolymer having an NCO-content of 1.85%. The product is taken up in 1885 g of methyl methacrylate and a solution of 17.4 g of IPDA in 85 g of methyl methacrylate is added dropwise at room temperature. After 90% of the amine solution has been added dropwise, the viscosity reaches a value of 2800 cP. The reaction is stopped by the addition of 1.95 g of β-hydroxyethyl methacrylate and 1 g of dibutyl tin dilaurate dissolved in a little methyl methacrylate. The solids content amounts to 20% and the viscosity to 2800 cP.
Solution 9
The procedure is as in Example 8, except that the chain-extending reaction is carried out at 35° C. The solution obtained has a viscosity of 3400 cP at 20° C.
Solution 10
The procedure is as in Example 8, except that the starting prepolymer has an NCO-content of 2.07%. A polyurethane urea solution in methyl methacrylate having a solids content of 20%, a viscosity of 2400 cP/20° C. and a refractive index of 1.4862 is obtained.
Solution 11
A mixture of 305 g (0.175 mol) of polyester A and 127.5 g (0.075 mol) of polyester B is reacted without preliminary dehydration with 78.2 g (0.75 equivalent) of a graft polymer which has been produced by the radically initiated polymerization of 20 parts of methyl methacrylate in 80 parts of hexamethylene diisocyanate with 0.1 part of azoisobutyronitrile as initiator and which has an NCO-content of 40.5%, corresponding to an NCO-equivalent weight of 107. The reaction is continued at 100° C. until an NCO-content of 1.92% is reached. The prepolymer is taken up in 2040 g of methyl methacrylate. The equivalent quantity of IPDA calculated from the NCO-number, namely 19.85 g, is dissolved in methyl methacrylate to form a solution having a total volume of 100 ml. The solution is added dropwise with stirring at room temperature to the prepolymer solution. After 90% of the solution has been added, a viscosity of 4200 cP is reached and the chain-extending reaction is terminated. The remaining NCO-groups are closed by the addition of 1.5 g of methanol. The product is completely clear and colorless.
Solution 12
A prepolymer is prepared in the same way as described in Example 11, starting from a graft polymer having an NCO-content of 39.5% produced in the same way with tert.-butyl peroctoate as polymerization initiator. The prepolymer has an NCO-content of 2.1%. This corresponds to an IPDA demand of 21.5 g. The chain-extending reaction is carried out at 40° C. in the same way as described in Example 11, except that it is stopped after only 80% of the diamine solution has been added and the residual NCO-content is reacted with 3 g of β-hydroxyethyl methacrylate. The solution has a final viscosity at room temperature of 3100 cP.
EXAMPLES
Example 1
Following the addition of 0.2 part, by weight, of t-butyl-perpivalate, an elastomer solution consisting of 96 parts, by weight, of polyurethane urea solution 6 and 4 parts, by weight, of styrene is briefly evacuated in order to remove dissolved gases, introduced into a chamber consisting of two plates of glass and an elastic spacing and sealing cord encircling them at the edges thereof and polymerized in this chamber in a water bath at 50° C. for 15 hours. Polymerization is completed in a drying cabinet over a period of 2 hours at 110° C.
Test specimens are cut from the resulting clear, colorless 4 mm acrylic glass plate for measuring impact and notched impact strength in accordance with DIN 53 453 and the Vicat softening temperature in accordance with DIN 54 460.
Testing in comparison with unmodified acrylic glass (values in brackets) gives the following mechanical properties:
Impact strength: 94 (12) mmN/mm 2
Notched impact strength: 8 (2) mmN/mm 2
Vicat softening temperature: 91 (112)° C.
Example 2
Polyurethane urea solution 10 is polymerized by the polymerization process described in Example 1 in the presence of 0.2%, by weight, of dilauroyl peroxide as initiator.
The following properties are measured on the colorless clear plate:
Impact strength: 107 mmN/mm 2
Notched impact strength: 8 mmN/mm 2
Vicat softening temperature: 89° C.
Example 3
An elastomer solution of 97 parts, by weight, of polyurethane urea solution 11 and 3 parts, by weight, of benzyl methacrylate is polymerized with 0.15%, by weight, of azoisobutyronitrile by the process described in Example 1 and tested. The resulting plate has the following properties:
Impact strength: no breakage
Notched impact strength: 10 mmN/mm 2
Vicat softening temperature: 81° C.
Example 4
The following elastomer solution is polymerized in accordance with Example 1 and the colorless, clear acrylic glass plate obtained tested in the same way:
97 parts, by weight, of polyurethane urea solution 12
3 parts, by weight, of styrene
Impact strength: no breakage
Notched impact strength: 9 mmN/mm 2
Vicat softening temperature: 95° C.
Examples 5 to 7
In order to test the effect of the PUR-content upon the properties of acrylic glass plates, solution 1 is adjusted by the addition of styrene and, optionally, by dilution with methyl methacrylate to solids contents of 10, 15 and 20% by weight, and to a ratio, by weight, of methyl methacrylate to styrene of 97.8:2.2. The solution is polymerized in accordance with Example 1.
______________________________________ VicatPUR- softening Impact strength Notched impactcontent %, tempera- at 23° C. strength at 23° C.by weight ture °C. (mmN/mm.sup.2)-20° C. (mmN/mm.sup.2)-20° C.______________________________________10 105 48 13 4.0 2.115 99 75 15 5.3 2.320 91 no break- 33 10 3.0 age______________________________________
Example 8
A hemi-spherical dome 200 mm in diameter is deep drawn at 160° C. from a 6 mm acrylic glass plate produced in accordance with Example 1 in order to test the thermoelastic shaping properties.
Re-formability is good and the optical quality of the dome is satisfactory.
The orientation present at the zenith of the dome corresponds to that of a flat, 45% biaxially stretched plate on which the following values were determined:
Impact strength: no breakage
Notched impact strength: 52 mmN/mm 2
This means that a considerable increase in toughness in relation to the measured values of Example is obtained by the biaxial stretching.
Example 9
An elastomer solution of 97.2 parts, by weight, of polyurethane urea solution 2 and 2.8 parts, by weight, of styrene is polymerized as in Example 1 in the presence of 0.2 parts, by weight, of t-butyl perpivalate, 0.4 part, by weight, of a UV-stabilizer (Tinuvin® 327, a product of Ciba-Geigy), 0.6 part, by weight, of an oxidation stabilizer (Irganox® 101, a product of Ciba-Geigy) and 0.25 part, by weight, of a hydrolysis stabilizer (Stabaxol® I, a product of Bayer AG), and the resulting acrylic glass plate was weathered in the open for 2 years.
After this weathering period, the plate, which was originally glass clear, is slightly clouded and its notched impact strength has fallen from 10 to 9 mmN/mm 2 , i.e. only slightly.
Example 10
Polyurethane urea solution 4 is concentrated by distilling off part of the monomer. By adding methyl methacrylate and different quantities of methyl acrylate, the solids content is adjusted to 20%, by weight, and the ratio, by weight, of methyl methacrylate (MMA) to methyl acrylate (MA) to the values shown in the following Table. The solutions are polymerized in accordance with Example 1 and the resulting colorless acrylic glass plates tested in the same way:
______________________________________Ex-ample Vicat softeningNo. MMA/MA temperature (°C.) IS NIS Clarity______________________________________ 100/0 89 no 12 clouded break- age 90/10 85 no 11 slight break- clouding age10 85/15 82 no 12 clear break- age 80/20 80 no 12 slight break- clouding age______________________________________ IS = impact strength NIS = notched impact strength (mmN/mm.sup.2)
Example 11
The polyurethane urea solution (solution 4) used in Example 10 is polymerized in the presence of 1% of glycol dimethacrylate.
The acrylic glass plate obtained is insoluble in organic solvents and its thermoelastic shaping properties are substantially unchanged.
Notched impact strength: 8 mmN/mm 2
Vicat softening temperature: 105° C.
Although the invention has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
|
A process of making radically polymerizable compositions suitable for the production of impact resistant optically clear glass like plastic and forming the glass from such compositions is disclosed. Also taught are the polymerizable compositions and the final glass produced. An isocyanate terminated prepolymer based upon a polyol selected from polyesters, polyester amides, polycarbonates and polyacetals and diisocyanates selected from branched aliphatic isocyanates, cycloaliphatic isocyanates and aliphatic or cycloaliphatic isocyanates graft polymerized with vinyl monomers is chain extended with aliphatic or cyloaliphatic diamines while in solution in vinyl monomers consisting mainly of methacrylic acid esters. The chain extension is carried out with a deficit of amine and preferably to a viscosity at 20% solids in the vinyl monomers of between 200 and 30,000 cP at 20° C. The composition is then radically polymerized to form the high impact glass like plastic alloy.
| 2
|
BACKGROUND OF THE INVENTION
This relates generally to a device for heating articles and organisms and in particular to a device for rendering harmless or destroying organisms containing nucleic acids and/or proteins by transmission of microwaves radiation into a chamber containing the articles and/or organisms wherein such radiation is generated by a plurality of magnetrons configured to avoid cold spots.
It is known that living cells and organisms as well as small viruses and other organisms containing proteins and nucleic acids can be destroyed or rendered harmless by the action of chemical or physical substances, whereby they lose their toxicity. Infected material may be sterilized by physical methods, such as exposure to heat, radiation (beta rays, X-rays, gamma rays, UV radiation) chemical methods and special filtration, in which the organisms are physically retained. Exposure to a sufficient amount of heat for a sufficient time irreversibly damages and renders harmless the proteins and/or nucleic acid contained within the infected material. Thus, all growth and reproductive functions of the organism exposed to such heat are destroyed. Devices for exposing material to heat for sterilization purposes are presently routinely used worldwide in the medical and industrial fields. Such devices are also frequently employed for destroying a wide variety of infectious waste prior to final disposal and for preventing harm to disposal personnel as well as to the general public.
Known devices which expose infected material to heat typically operate either by the method of hot air sterilization or by autoclaving. In these methods, heat (hot air sterilization), or steam under pressure (autoclaving) must be supplied from an external environment to the infected material to be sterilized, so that successful sterilization may only be attained by precisely following exacting procedures.
Although these two methods of heat sterilization are generally considered reliable and result in relatively complete sterilization of the infected material, an enormously high outlay of energy and time is required in order to adequately sterilize the infected material. Furthermore, a most unpleasant and unavoidable odor is generally produced by these methods.
Exposure of the infected material to radiation, and in particular to radioactivity, may render the infected material harmless but is hardly practicable for sterilization of infected material because of high industrial and safety engineering costs associated with use of sufficiently radioactive substances.
Filtration of the infected material, in which the organisms must be physically collected in a filter in especially high concentration is not a complete nor adequate solution as the collected organisms must still be disposed of. Apart from this, the method is largely limited to liquids, and possibly gases, but cannot be employed for organisms found on solid carriers.
In addition to these methods and devices, chemical methods in which disinfectant chemicals are employed for sterilizing infected material may be used. However, chemical methods are suitable primarily for surface disinfection and for disinfecting of interior walls of hollow chambers into which the disinfectants can be introduced in a controlled manner.
A final method of destroying or rendering harmless organisms containing nucleic acids and/or proteins comprises exposing such organisms or articles infected with such organisms to microwave radiation.
Living structures exposed to microwave radiation undergo a heating of fluids from within the structure, such heating exceeding the boiling point of the fluids and resulting in death or destruction of the organism. A requirement of microwave sterilization is that all organisms present in the sterilization chamber be exposed to sufficient microwave energy. In conventional devices, precautions have not been taken to avoid the occurrence of the so-called "cold spots." The avoidance of such cold spots is essential when infected articles are placed in the sterilization chamber to be uniformly exposed to microwave radiation and thus sterilized. Since the microwave radiation is transmitted for a relatively short time only, any heating by heat conduction in the infected material itself is without practical significance and will not significantly aid in the sterilization of the material.
In addition to problems associated with supplying inadequate microwave radiation to certain areas of the sterilization chamber, known microwave devices often leak microwave radiation to the environment external to the device.
More particularly, known microwave devices will in general exhibit scattering radiation, i.e. a portion of the high frequency radiation generated by the device will leave the system at points not completely impervious to high frequency radiation. Most of this leakage radiation is typically given off through door crevices and seals. Furthermore, such leakage radiation is not limited to microwave devices for performing sterilization but exists in practically all microwave generating devices.
The high-frequency leakage radiation represents a potential hazard to the operator of the device as well as others in close vicinity. For this reason, there are internationally set standards on maximum allowable peak limits of radiation emitted from microwave devices. Thus a device when sold must not emit to the environment more than a prescribed output density of microwave radiation.
It is known, however, that leakage of microwave radiation may be minimized through utilization of suitable materials and constructing the device in accordance with proper specification. However, regardless of the quality of materials or construction or even the initial minimization of microwave radiation, the materials and components constructed therefrom are all subject to aging and/or wear resulting in increased microwave radiation leakage. Moreover, such increased microwave leakage typically occurs without the knowledge of the operator, thereby potentially exposing the operator or other personnel to increasingly severe levels of radiation resulting in irreversible harm.
In particular, known devices and methods exist whereby the amount of leakage of microwave radiation may be tested. Unfortunately, such devices are not generally available to the operator, nor are there generally any statutory provisions calling for periodic inspection of a microwave device including measurement of leakage radiation. Furthermore, the cost of such an output density measuring system is often prohibitive and thus such devices are generally not owned by most microwave device owners. Even if microwave devices are repeatedly subjected to testing, during operation of the device, such as in the period between two successive tests, the operator can have no complete assurance that prior leakage levels accurately reflect present microwave leakage levels. For example, rubber gaskets may become damaged and indeed do generally degrade with time. Such damage may not become apparent until the next inspection of the device. In the interval, the operator of the device would have been exposed to the microwave radiation without protection.
Illustrative of prior art sterilization methods is German Patent 3430673 which discloses a sterilization process in which the material to be sterilized is passed through a hollow conductor between two synchronously running conveyor belts. Unfortunately, what is generally referred to as "cold spots", i.e., portions of the hollow conductor not receiving sufficient sterilizing radiation, are often developed in such a hollow conductor. Such cold spots prevent complete sterilization of the material in practice and lead to an increased risk of infection and the like. Furthermore, this device is complicated in structure and involves problems associated with shielding the outside environment from the microwave radiation.
European Patent Application 0 116 921 discloses a sterilization system for infusion of a liquid from an external closed container into a patient. More specifically, the external closed container is provided with a first conduit connected to a coupling which is also connected to the patient by way of a second conduit. A small volume of liquid is permitted to flow to the coupling whereupon a guided wave member is then placed over the coupling and emits radiation to destroy any bacteria present in the coupling. Unfortunately, this device is limited to sterilizing liquid contained within a coupling connecting two conduits. It is often desirable to sterilize other materials and in fact it is generally necessary to sterilize medical wastes in order to destroy organisms such as bacteria, viruses and spores contained therein. However, known devices and methods are not capable of adequately disinfecting or sterilizing medical waste and the like prior to disposal in a land fill or combustion facility so as to avoid endangering disposal personnel as well as the general public.
U.S. Pat. No. 2,550,584 discloses a milk pasteurization system in which milk continuously flows through a heat exchanger and through a fluid cooled high frequency electronic tube heater. The high frequency heater comprises a cylindrical member having an input end and an output end. Heat from the high frequency heater is used to preheat the milk in the heat exchanger. However, this device is limited to pasteurizing milk.
SUMMARY OF THE INVENTION
The present invention comprises a sterilization chamber and a plurality of microwave emitting means configured so as to avoid so-called cold spots, thereby providing for reliable sterilization of the entire infected material present in the sterilization chamber. Advantageously, the microwave emitting means preferably comprises a plurality of microwave emitting devices configured such that any one of the microwave emitting devices radiates into a space defined by the sterilization chamber free from microwaves emitted from the other microwave emitting devices. As a result, it is ensured that no cold spots will form in the sterilization chamber.
The present invention is thus especially suitable for sterilizing medical appliances, for sterilizing infectious medical waste to be properly disposed and for sterilizing surgical linen or dressing materials. In addition, liquids or gases continuously passing through hoses in the sterilization chamber may also be sterilized.
In a preferred embodiment of the invention, three microwave emitting devices are provided, two of which are located in one side wall of the sterilization chamber and the third is located in a wall of the sterilization chamber opposite to the one side wall. This arrangement of the microwave emitting devices is especially advantageous in the avoidance of cold spots.
The microwave emitting devices which supply microwave radiation to the interior of the sterilization chamber generate heat during typical use. Thus, a cooling arrangement is desirable. The microwave emitting devices of the present invention are advantageously arranged outside of the sterilization chamber in a cooling chamber capable of being ventilated by way of cooling fans which are readily accessible to inspection.
Cooling fans may also be utilized for circulation of air in the interior of the sterilization chamber. This is accomplished by openings near a floor member of the sterilization chamber, such openings providing air flow between the cooling chamber(s) and the sterilization chamber.
The electrical field strength E-vectors of the microwave radiation emitted by the magnetrons are oriented orthogonally or approximately orthhogonally with respect to each other, the direction of each of these three E-vectors of the microwaves being offset from the direction of the axes of the cartesian coordinate system formed by the three mutually perpendicular edges of the rectangular sterilization chamber. The three magnetrons and their configuration ensure an output density uniformly distributed over the interior of the sterilization chamber, thus enabling the infected material to be uniformly and completely sterilized.
The present invention advantageously includes a thermal relay associated with the sterilization chamber for protection against overheating. It is thus ensured that neither the equipment nor the articles placed in it will suffer heat damage, since the heat will act only to destroy the organisms. Furthermore, if steam is generated in the sterilization chamber, a safety valve is preferably provided from the interior of the sterilization chamber to exhaust excessive pressure and render the sterilization chamber safe from excessive internal pressure. Destruction of the sterilization chamber and associated equipment accompanied by the emergence of potentially harmful organisms, as well as emission of microwave radiation into the surrounding space is thus advantageously prevented.
In a further embodiment of the invention, a flap valve is provided in a wall of the sterilization chamber and serves as an outlet passage from the interior of the sterilization chamber to an exhaust duct preferably opening into a sewer system. In this way, all fumes and odors arising in the course of sterilization can be carried off, preferably into the sewer system, so that there will be no objectionable odors creating a nuisance or hazard to operating personnel or the surroundings.
The present invention preferably includes means to measure the sterilizability of material, such means comprising a test passage leading from the interior of the sterilization chamber to the exterior, a suction fan for aspirating air from the interior of the sterilization chamber, heating means for heating the aspirated air to a predetermined temperature and a humidity sensor to determine the humidity level of the heated air. The heating means and the humidity sensor may be positioned within the test passage.
This configuration advantageously permits measurement of the atmospheric humidity in the sterilization chamber continuously during the sterilization process and thus enables one to determine whether particular material is sterilizable and operate the device accordingly. Material not sterilizable by way of microwave radiation, for example, dry material, can easily and automatically be identified as such. More specifically, as soon as the moisture content rises to a value significantly different from the initial moisture content prior to energization of the microwave emitter means, it may be concluded that the material to be sterilized has attained at least the boiling temperature of water. Thus it is possible to automatically determine whether any sterilizable material is present in the sterilization chamber. If the heating means and humidity sensor are arranged in the test passage, a compact design results which advantageously permits determining moisture content at its place of origin, as close as possible to the interior of the sterilization chamber.
The test passage employed for determining moisture content preferably opens into the exhaust duct which leads into a sewer system or the like. Thus it is ensured that even the small quantity of air from the interior of the sterilization chamber that is required for determination of the humidity from time to time will not leak into the air surrounding the sterilization system.
The humidity sensor is preferably coupled to a means for shutting off the energy supply of the microwave emitting means. It is thereby possible to switch the device off when the material contained in it is not sterilizable by way of microwave radiation. In the presence of sterilizable material in the sterilization chamber, the humidity sensor should register a rise in humidity after the system has been started and microwave radiation emitted. If no such rise is registered, the device switches off. A visible and/or audible indicating means is preferably provided with the present invention to automatically indicate that non-sterilizable material is present in the sterilization chamber.
In addition to the sterilization of infected material by microwaves, an independent source of liquid may be arranged in the interior of the sterilization chamber, such as a receptacle filled with water and/or disinfectants and/or deodorants. The receptacle for the liquid need not be sealed and preferably exposes the liquid which vaporizes during operation of the device, thereby disinfecting, deodorizing or further heating the infected material.
In a further embodiment of the invention, microwave radiation leakage is advantageously continuously monitored so that in case of excessive leakage steps may immediately be taken for the safety of the operator as well as others in the environment. This is accomplished by protection and/or monitoring means located in the regions of typical areas of leakage such as a door. Additionally, such means may be located for monitoring microwave radiation levels in or within the vicinity of test passages, valves and the like. Preferably, the perimeter of any opening or potential source of leakage is lined with an antenna fitted to the opening. This arrangement permits constant monitoring of the opening for detecting the leakage of hazardous microwave radiation. Advantageously, such an arrangement may be applied to any microwave emitting means, independently of the number of individual microwave emitting devices including, for example, so-called microwave ovens, widely employed in households and commercial food establishments for the heating and/or cooking of food.
Signals received by and transmitted along the antenna, illustratively a wire loop, are supplied to a threshold detection circuit to determine whether the radiation received by the antenna is greater than a maximum prescribed safety limit of radiation. The threshold detection circuit is preferably coupled to a shut-off means for disconnecting the electric supply from the microwave emitting means. Additionally, a visual or audible signal may be provided to indicate surpassion of the threshold value thereby warning personnel of a potentially hazardous situation and enabling proper precautions to be taken. In this way it can be ensured that when the threshold value (which should be close to the allowable dosage limit) is reached, a visual or audible alarm signal will be produced, and/or the device will be automatically switched off.
The antenna is preferably arranged on a perimeter of a frame around the opening in the region of scattered radiation potentially passing through cracks, crevices or areas partially transparent to microwave radiation. The antenna is connected to a diode which rectifies the AC signal present on the antenna. A comparator circuit compares the voltage after the diode to a predetermined voltage corresponding to the maximum prescribed safety limit of radiation, i.e. the threshold voltage. If the rectified voltage exceeds the threshold voltage, the visual and/or audible alarm will be activated.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the invention will be more readily apparent from the following detailed description of the drawings in which;
FIG. 1 depicts a front view of a first embodiment of the invention;
FIG. 2 depicts a front view of a second embodiment of the invention;
FIGS. 3A and 3B depict sections at lines A--A and B--B, respectively in the second embodiment shown in FIG. 2; and
FIG. 4 depicts means for protecting and/or monitoring microwave radiation leakage in the region of a door of a microwave emitting unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, a device for heating articles and organisms comprises a heating cavity 1, a plurality of microwave emitting means 2, thermal relay 13, atomizer 14, pressure relief valve 15 and drain valve 16.
Heating cavity 1 may take on a wide variety of forms and preferably is an approximately rectangular sterilization chamber having four side walls, a ceiling member and a floor member. Sterilization chamber 1 is provided with an opening (not shown) for insertion and removal of material to be sterilized. The opening preferably is through one of the side walls and is closable by way of a door member. Such a closable structure is well known in the art and need not be detailed further.
Microwave emitting means 2 may also take on a wide variety of forms. Illustratively, microwave emitting means 2 is a magnetron or, alternatively, a klystron. Microwave emitting means 2, upon application of an electric power supply, emits high frequency radiation, and more specifically, microwave radiation, into sterilization chamber 1 for heating material therein. Microwave emitting means 2 preferably comprises three magnetrons each of which emits microwave radiation into the interior space defined by sterilization chamber 1. Magnetrons 2 are physically arranged with respect to each other and with respect to the sterilization chamber such that they emit radiation which uniformly sweeps and fills sterilization chamber 1 thereby preventing cold spots. Such a physical arrangement of the magnetrons advantageously permits infected material and the like which is enclosed by the sterilization chamber to be wholly exposed to a sufficient amount of microwave radiation so as to completely sterilize the infected material contained therein.
The effectiveness of the microwave radiation in sterilizing the infected material is preferably increased by introducing cold water vapor into the sterilization chamber. Such cold water vapor is generated by an external atomizer 14, illustratively an ultrasonic atomizer which introduces the cold water vapor into the sterilization chamber for subsequent heating by the magnetrons. The cold water vapor is heated and increases the temperature to which the infected material is exposed thereby increasing the efficiency and effectiveness of the sterilization process.
Pressure relief valve 15 provides a conduit from the interior of sterilization chamber 1 to the exterior environment upon an increase in pressure within the sterilization chamber beyond a tolerable limit.
Thermal relay 13 is also preferably provided as protection against overheating and shuts off the power supply to the magnetrons in the event of excessive temperature. Either or both of pressure relief valve 15 and thermal relay 13 may shut off the magnetron and/or provide a visual and/or audible alarm to an operator to indicate that excessive pressure or temperature has been reached.
Drain valve 16 is provided at the bottom of sterilization chamber 1 for the removal of liquid waste, condensed steam and to facilitate cleaning of the chamber. The entire sterilization process may be controlled by way of an electronic control unit (not shown). A grating 17 is preferably provided above the floor member of the sterilization chamber on which a receptacle containing the infected material to be sterilized may be placed.
Referring now to FIGS. 2 and 3, there is depicted another embodiment of the invention in which similar elements are labelled similiarly. Microwave emitting means 2 comprises, illustratively, three magnetrons arranged on the side walls at an angle alpha, illustratively 45°, in the top view of FIG. 3 and at an angle beta, illustratively 65°, from the vertical in the front view of FIG. 2. Any suitable angles which result in the uniform emission of microwave radiation throughout the interior of sterilization chamber 1 may be utilized. As will be apparent, the electrical field strength vectors E of the microwave radiation emitted by the magnetrons are oriented orthogonally or approximately orthogonally with respect to each other, the direction of each of these three E-vectors of the microwaves being offset from the direction of the axes of the cartesian coordinate system formed by the three mutually perpendicular edges of the rectangular sterilization chamber. The three magnetrons 2 ensure an output density uniformly distributed over the interior of the sterilization chamber 1, thus enabling the infected material to be uniformly and completely sterilized. The three magnetrons are mounted within enclosed chambers 8 and are cooled by fans 3. Fans 3 also perform the function of circulating air through the interior of the sterilization chamber as shown in FIG. 2, so that the water vapor formed in the interior may be expelled. The fans 3 discharge into cooling chambers 8 in which the magnetrons are located. Cooling chambers 8 communicate with the interior of the sterilization chamber by way of openings located near a floor member 9 of the sterilization chamber. Furthermore, the interior of the sterilization chamber is connectable by way of a flap valve 7 located in an outlet passage 10 of the sterilization chamber into an exhaust duct opening and then into a sewer system. If the flap valve 7 is open, the air delivered into the sterilization chamber by fans 3 may be vented to the sewer system by way of the outlet passage 10 and exhaust duct 11.
Further, a test passage 12 is provided to communicate with the interior of the sterilization chamber. This test passage 12 can be supplied with air from the interior of the sterilization chamber by means of a small suction fan 4. The test passage 12 carries the air from the interior of the sterilization chamber through a heating means 5 and a humidity sensor 6. The heating means 5 and the humidity sensor 6 in the embodiment depicted in FIG. 2 are located in the test passage 12. The air entering the test passage 12 by suction fan 4 is thus preheated to a constant predetermined temperature by the heating means 5 and its humidity level determined by humidity sensor 6. The test passage 12 then opens into the exhaust passage 11, so that air removed from the interior of the sterilization chamber for test purposes and the like will also enter into the exhaust duct 11.
The humidity sensor 6 may be coupled, in a known manner not shown, with means for shutting off the power supply to magnetrons 2 as well as means for providing visual and/or audible indication of humidity level below a threshold level. The power supply to the magnetrons is advantageously shut off if the humidity sensor does not detect a significant increase in humidity after a predetermined amount of time as would be the situation if dry material were to be placed in the sterilization chamber and attempted to be sterilized.
In addition, the interior of the sterilization chamber 1 may be provided with a source of liquid independent of any outside supply, for example, a recepticle or bag filled with water, disinfectants or deodorants.
In operation of the device depicted in FIGS. 2 and 3, the material to be sterilized is placed in the interior of the sterilization chamber with the door open, in a receptacle transparent to microwave radiation and which is not sealed. At the beginning of the sterilizing operation, fans 3 are switched on and valve 7 is opened. By way of the small fan 4, air is removed from the interior of the sterilization chamber and heated to the predetermined constant temperature by heating means 5, and its moisture content determined at that predetermined temperature by humidity sensor 6. The valve 7 is then closed, and the magnetrons 2 are switched on. The small fan 4 continuously withdraws a certain flow of air from the interior of the sterilization chamber and its humidity is measured at constant temperature. As soon as the moisture content rises to a value differing significantly from the initial moisture content before the magnetrons 2 were switched on, it may be concluded from this rise that the material to be sterilized has reached at least the boiling temperature of water. This makes it possible to determine whether any sterilizable material is present inside the sterilization chamber. The microwave radiation is now allowed to act on the infected material for a predetermined period of time, so as to ensure destroying the organisms through sterilization. In the last phase of this sterilization process, the valve 7 is opened again, so that the moisture formed in the interior of the sterilization chamber may be blown out. The magnetrons 2 are switched off and the two fans 3 are allowed to continue in operation for a time to blow the residual moisture out of the interior of the sterilization chamber and to continue cooling the magnetrons. The door of the sterilization chamber can then be opened and the sterilized material as well as the recepticle may be removed from the sterilization chamber. If no significant rise in humidity is observed during the emission of the microwave radiation, the magnetrons 2 will be shut off after a predetermined time period, indicating that no material sterilizable by microwave radiation is present.
FIG. 4 depicts a means for monitoring the level of microwave radiation leakage and is positioned in the vicinity of the closure member, i.e., the door. This monitoring means indicates when a threshold level of radiation has leaked from the sterilization chamber. Such a monitoring means may be provided for microwave emission devices in general, and is not limited to microwave devices serving to sterilize infected material. The perimeter of the sterilization chamber opening as indicated in FIG. 4 is lined in its entirety by an antenna 18 fitted to the opening. This antenna 18 is fixedly connected to a frame 19 surrounding the opening. The antenna is thus located in the region of the scattered radiation passing through the crack of the door.
The antenna is connected to a demodulator, i.e., rectifying, diode 20. The voltage U across the rectifier diode 20 is input to a comparator means (not shown). This comparator means is also input with a predetermined voltage level which corresponds to a threshold microwave radiation level beyond which it is desired to signal an alarm or shut off the magnetrons. The comparator means outputs an alarm signal if an excessive amount of radiation is detected, preferably shutting off the power supply to the magnetrons and/or providing a visual or audible signal. This visual or audible signal indicates that the threshold value has been exceeded. The monitoring means thus serves to monitor the amount of microwave radiation leakage associated with potential areas of leakage such as the door and may be employed for any microwave device such as those typically employed in households, institutional kitchens as well as microwave devices for special applications.
|
A device is disclosed for heating of articles and organisms, and in particular for destroying or rendering harmless organisms containing nucleic acids and/or proteins by action of microwave radiation generated by a microwave emission device. The microwave emission device illustratively comprises a plurality of magnetrons emitting microwave radiation into a sterilization chamber and configured such that cold spots are avoided. The invention further relates to a microwave radiation level monitoring device positioned in the vicinity of areas of likely microwave leakage such as a door to the sterilization chamber.
| 7
|
BACKGROUND OF THE INVENTION
[0001] This invention relates in general to methods, systems, and apparatuses for processing signals for vehicle monitoring and specifically to methods, systems, and apparatuses for real-time processing of sensor signals for vehicle tire load monitoring.
[0002] A typical automotive vehicle may include many monitoring and control systems, for example, a cruise assist system (cruise control), an Anti-Lock Braking System (ABS), an Anti-Theft Vehicle Protection System (AVP), a Global Positioning System (GPS), and a variety of lighting, safety, climate control, and audio systems, just to name a few. These systems include many different components; including, for example, sensors, processors, transmitters, receivers, memory devices, etc. There are many varieties of each component device, for example, the sensors in an automotive vehicle may include tachometers, accelerometers, thermostats, pressure gauges, photo-electric sensors, angle sensors, yaw-rate sensors, etc.
[0003] One type of automotive vehicle system is a Tire Load Monitoring System (TLMS) disclosed in, for example, U.S. patent application Pub. No. US 2003/0058118 A1 published Mar. 27, 2003 in the name of Kitchener C. Wilson (herein after, “the Wilson application”), the disclosures of which are incorporated herein by reference. The Wilson application discloses an accelerometer-based TLMS that estimates tire load information based upon tire contact patch length. The tire contact patch length is calculated from the time period during which a point on the tire circumference stays in contact with the ground. In order to accomplish tire load monitoring in typical dynamic driving situations, the rate of data acquisition typically needs to be at least about 10 kHz to capture the signal from an accelerometer placed in the tire with sufficient resolution and accuracy in order to be useful in determining the tire load.
[0004] FIG. 1 is a simplified block diagram of the known real-time tire monitoring system of the Wilson application, shown generally at 30 . The system 30 is incorporated in a vehicle 32 having a plurality of wheels 34 each carrying a tire 36 mounted on a rim 38 . The tires 36 are shown in their loaded condition, and accordingly each has a flattened deflection contact region 40 in contact with a load-bearing surface (ground), such as a road 42 .
[0005] The tire monitoring system 30 generally includes a contact region detector 50 and an associated receiver-transmitter 52 within each tire 36 ; a tire identifying plaque 54 attached to the sidewall of each tire; and a receiver 56 , data processor 58 , a distributed control subsystem 60 , a data storage unit 62 , an operator display 64 , a remote receiver-transmitter 66 and a data bus 68 within the vehicle 32 . The monitoring system 30 further includes, remote from the vehicle, a remote monitor receiver-transmitter 70 for communicating information to and from the vehicle 32 ; a console 72 through which a technician interacts with the vehicle 32 ; a magnetic wand 74 to identify the physical locations of the tires; and a tire identifying plaque scanner 76 to read the parameter information on the tire identifying plaque 54 .
[0006] Generally, the contact region detector 50 functions to detect tire load-induced deflections, to time the load-induced tire deflection duration and periodicity, and to reduce signal noise. The receiver-transmitter 52 serves to receive the timing information from the contact detector 50 , measure tire pressure and temperature, and transmit these data to the vehicle receiver 56 . The tire identifying plaque 54 on each tire 36 carries machine-readable data relating to parameter values specific to the tire model. The in-vehicle receiver 56 is adapted to receive data transmissions from all tires 36 . The data processor 58 determines tire deformation, tire load, tire molar (air) content, vehicle mass, and the distribution of vehicle mass. The distributed control system 60 includes adaptive vehicle subsystems such as brakes 60 a, steering 60 b, suspension 60 c, engine 60 d, transmission 60 e, and so forth, that respond in predetermined fashions to the load, the vehicle mass and the distribution of the vehicle mass. The data storage unit 62 stores the values of parameters and of interim calculations while the operator display 64 provides status information and warnings. The remote receiver-transmitter 66 sends information to the remote monitor receiver-transmitter 70 . The data bus 68 interconnects the system components.
[0007] The known approach taken to the detection of the deflection region of a loaded tire is to sense the acceleration of the rotating tire by means of an accelerometer mounted on the tire, preferably within the tire and more preferably on the inner tread lining of the tire. As the tire rotates and the accelerometer is off the flat deflection region, a high centripetal acceleration is sensed. Conversely, when the accelerometer is on the flat deflection region and not rotating, a low acceleration is sensed. The deflection points are determined at the points where the acceleration transitions between the high and low values.
SUMMARY OF THE INVENTION
[0008] This invention relates to methods, systems, and apparatuses for real-time vehicle monitoring signal processing. In one embodiment, a method includes separating processing tasks into a fast task portion and a slow task portion. The fast task portion and slow task portion are performed at different rates. Optionally, the fast task portion and the slow task portion may be coordinated with the transmission of coordination flags. Further, information relating to the tasks may also be transmitted in relation to the flags.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a simplified block diagram of a known real-time tire monitoring system.
[0010] FIG. 2 is a flowchart of a process for real-time tire load monitoring.
[0011] FIG. 3 is a simplified block diagram of a real-time tire monitoring system in accordance with the present invention.
[0012] FIG. 4 is a flowchart of a fast task portion of a process for real-time tire load monitoring in accordance with the present invention.
[0013] FIG. 5 is a flowchart of a slow task portion of a process for real-time tire load monitoring in accordance with the present invention.
[0014] FIG. 6 is a schematic of a Serial Processing Scheme in accordance with the present invention.
[0015] FIG. 7 is a schematic of a Parallel Processing Scheme in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] FIG. 2 is a flowchart of a process for real-time tire load monitoring 210 , which, for example, may be used in the system 30 of the Wilson application. The process 210 begins in functional block 215 where a set of default internal variables are loaded into a real-time tire monitoring system, for example the system 30 of FIG. 1 . The set of variables preferably includes a signal filter frequency value and an expected edge threshold value.
[0017] The process 210 proceeds to functional block 220 where the system 30 acquires data from a contact patch sensor, such as the contact patch region detector 50 . Preferably, the data is acquired by receiving a data signal from a transmitter associated with an accelerometer based contact patch sensor, such as the receiver-transmitter 52 .
[0018] The process 210 then proceeds to functional block 225 where the system 30 filters the data signal. The system 30 sets a frequency range for allowable data signal in order to reduce false data signals. Preferably, the system 30 sets the frequency range as a function of the signal filter frequency value.
[0019] In decision block 230 , the system 30 detects for a rising pulse edge in the allowable data signal. If the rising pulse edge is not detected then the process 210 returns to functional block 220 and proceeds as before. If the rising pulse edge is detected then the process 210 proceeds to functional block 235 where the system 30 measures the duration of a pulse in the allowable data signal to generate a pulse duration value.
[0020] In decision block 240 , the system 30 analyzes the pulse duration value for validity. If the pulse duration value is not valid then the process 210 returns to functional block 220 and proceeds as before. If the pulse duration value is valid then the process 210 proceeds to functional block 245 where the system 30 calculates a tire load value, as least partially based upon the pulse duration value.
[0021] The process 210 proceeds to functional block 250 where the tire load value calculated is used to update a tire load value stored in the system 30 .
[0022] The process 210 then proceeds to functional block 255 where the system 30 calculates an updated signal filter frequency value.
[0023] The process 210 then proceeds to functional block 260 where the system 30 calculates an updated expected edge threshold value.
[0024] The process then proceeds to functional block 265 where the updated internal variables are loaded in place of the internal variables previously used in the calculations in the system 30 .
[0025] The process 210 then returns to functional block 220 , continues through as before, and runs until stopped by some outside interrupt, such as the system 30 being turned off or as will be described below.
[0026] The Process 210 for real-time tire load monitoring consists of a signal processing portion, as generally indicated by a dashed line 270 , and a values calculation portion, as generally indicated by a dashed line 275 . The process 210 continually proceeds though the signal processing and then the value calculations, both portions occurring once per a single processing period.
[0027] In order to accomplish tire load monitoring in dynamic driving situations, the signal processing portion needs to run at about 10 kHz (kilohertz) or faster; thus, typically the process 210 is running at least at about 10 kHz or faster.
[0028] FIG. 3 is a simplified block diagram of a real-time tire monitoring system in accordance with the present invention, shown generally at 130 . The system 130 is entirely incorporated in a vehicle 132 having a plurality of wheels 134 each carrying a tire 136 mounted on a rim 138 . The tires 136 are shown in their loaded condition, and accordingly each has a flattened deflection contact region 140 in contact with a load-bearing surface (ground), such as a road 142 .
[0029] The tire monitoring system 130 generally includes a contact region detector 150 , including, for example, an accelerometer, a microprocessor, and an associated receiver-transmitter 152 within each tire 136 . Preferably, the contact region detector 150 and the associated receiver-transmitter 152 are integrated and mounted on the tire 136 . However, the contact region detector 150 and the associated receiver-transmitter 152 may be separated, for example as the contact region detector 50 and the associated receiver-transmitter 52 are in the Wilson application. Further, the contact region detector 150 and the associated receiver-transmitter 152 may be connected by any suitable manner, such as electrical wiring, RF transmission, or optical interface. The system 130 further generally includes a vehicle receiver-transmitter 156 , a data processor 158 , a distributed control subsystem 160 , a data storage unit 162 , an operator display 164 , and a data bus 168 within the vehicle 132 .
[0030] Generally, the contact region detector 150 functions to detect tire load-induced deflections, to time the load-induced tire deflection duration and periodicity, and to reduce signal noise. The associated receiver-transmitter 152 serves to receive and transmit information to and from the contact detector 150 , and the vehicle receiver-transmitter 156 . The associated receiver-transmitter 152 may also receive and transmit additional information, such as tire pressure and temperature, which may be received from a pressure sensor (not shown) and a temperature sensor (not shown), within each tire 136 . The in-vehicle vehicle receiver-transmitter 156 is adapted to receive and transmit data transmissions to and from all tires 136 . The data processor 158 determines tire deformation, and tire load. Additionally, the data processor may also determine the amount of air in the tire (i.e. the tire molar air content), vehicle mass, and the distribution of vehicle mass. The distributed control system 160 includes adaptive vehicle subsystems such as brakes 160 a, steering 160 b, suspension 160 c, engine 160 d, transmission 160 e, and so forth, that may respond in predetermined fashions to the load, the vehicle mass and the distribution of the vehicle mass. The data storage unit 162 , preferably a RAM module, stores the values of parameters and of interim calculations while the operator display 164 provides status information and warnings. The data bus 168 interconnects the system components.
[0031] The approach of the present invention taken to the detection of the deflection region of a loaded tire is to sense the acceleration of the rotating tire by means of the accelerometer of the detector 150 mounted on the tire 136 , preferably on the interior surface of the tire 136 and more preferably on the inner tread lining of the tire 136 . As the tire 136 rotates and the accelerometer is off the flat deflection region, a high centripetal acceleration is sensed. Conversely, when the accelerometer is on the flat deflection region and not rotating, a low acceleration is sensed. The deflection points are determined at the points where the acceleration transitions between the high and low values.
[0032] In one embodiment of the present invention, a process for real-time tire load monitoring, which, for example, may be used in the system 130 , the signal processing and values calculation processes are broken down to two sub-task portions, i.e. a fast task portion 211 , as shown in FIG. 4 , and a slow task portion 212 , as shown in FIG. 5 .
[0033] FIG. 4 is a flowchart of the fast task portion 211 of a process for real-time tire load monitoring in accordance with the present invention. Preferably, the fast task portion 211 is running at the same sample rate as data acquisition, typically about 10 kHz. However, the fast task portion 211 may be running at a rate faster or slower than the sample rate of data acquisition.
[0034] Preferably the fast task portion 211 has access to a common data storage, such as the common data storage 162 of the system 130 , where the fast task portion 211 can, for example, access default internal variables and updated internal variables, and store values, for example, a pulse duration value. The fast task portion 211 may have direct access to the common data storage, such as through a wired or wireless interface, or the fast task portion 211 may have indirect access to the common data storage, such as through a command processor. For example, the data processor 158 of the system 130 may act as such a command processor.
[0035] The fast task portion 211 begins in functional block 215 where a set of default internal variables is loaded into the real-time tire monitoring system 130 . The set of variables preferably includes a signal filter frequency value and an expected edge threshold value.
[0036] The fast task portion 211 proceeds to functional block 220 where the system 130 acquires data from the contact patch sensor 150 . Preferably, the data is acquired by receiving a data signal from the receiver-transmitter 152 associated with the accelerometer based contact patch sensor 150 .
[0037] The fast task portion 211 then proceeds to functional block 225 where the system 130 filters the data signal. Preferably, the system 130 uses the signal filter frequency value to filter the data signal.
[0038] In decision block 230 , the system 130 detects for a rising pulse edge in the data signal. If the rising pulse edge is not detected then the fast task portion 211 returns to functional block 220 and proceeds as before. If the rising pulse edge is detected then the fast task portion 211 proceeds to functional block 235 where the system 130 measures the duration of a pulse in the data signal to generate a pulse duration value.
[0039] The fast task portion 211 proceeds to functional block 236 where the system 130 stores the pulse duration value, preferably in the common data storage 162 . It must be understood, however, that the fast task portion 211 may store the pulse duration value in any suitable module. For example, in an alternative embodiment of the invention, the fast task portion 211 stores the pulse duration value in a command processor. In one embodiment of the invention, the data processor 158 of the system 130 acts as such a command processor.
[0040] The fast task portion 211 then proceeds to functional block 265 where updated internal variables are loaded in place of the internal variables currently being used in the system 130 , preferably retrieved from the common data storage 162 .
[0041] The fast task portion 211 then returns to functional block 220 and continues through as before and runs until stopped by some outside interrupt, such as, the system 130 being turned off or as will be described below.
[0042] FIG. 5 is a flowchart of the slow task portion 212 of a process for real-time tire load monitoring in accordance with the present invention. Preferably, the slow task portion 212 is running at a sample rate as slower than the rate of data acquisition, i.e. slower than the rate of the fast task portion 211 . Typically, the sample rate of the slow task portion 212 is greater than the duration of one wheel rotation. For example, at 80 mph (miles per hour) a typical vehicle wheel is rotating at about 15 Hz (hertz). The typical rate of data acquisition is about 10 kHz. As discussed above the fast task portion 211 would preferably be running at least at about the same rate as the rate of data acquisition, and thus the fast task portion typically would be running at about 10 kHz. Thus, in this example the slow task portion would be preferably running at a rate between about 15 Hz and about 10 kHz. Generally, the slow task portion 212 performs updated filter frequency calculation, updated expected edge threshold calculation, and tire load calculation, as will be described below.
[0043] Preferably, the slow task portion 212 has access to the common data storage, such as the common data storage 162 of the system 130 , where the slow task portion 212 can, for example, access vehicle sensor data, such as wheel speed and tire inflation. The slow task portion 212 may have direct access to the common data storage, such as through a wired or wireless interface, or the slow task portion 212 may have indirect access to the common data storage, such as through a command processor. For example, the data processor 158 of the system 130 may act as such a command processor.
[0044] Preferably, the slow task portion 212 will use instantaneous wheel speed information to calculate a contact patch length from a contact time period and in turn calculate tire load. Further, the slow task portion 212 will preferably use instantaneous wheel speed information to calculate an updated filter frequency, and an updated expected edge threshold in order to deal with dynamic driving situations when wheel speeds change significantly between two adjacent pulses in the acceleration signal.
[0045] The slow task portion 212 begins in decision block 239 where a real-time tire monitoring system 130 queries for a new pulse duration value. If the new pulse duration value is available then the slow task portion 212 proceeds to decision block 240 .
[0046] In decision block 240 , the system 130 analyzes the pulse duration value for validity. If the pulse duration value is not valid then the slow task portion 212 returns to decision block 239 and proceeds as before. If the pulse duration value is valid then the slow task portion 212 proceeds to functional block 245 where the system 130 calculates a tire load value, as least partially based upon the pulse duration value.
[0047] The slow task portion 212 proceeds to functional block 250 where the tire load value calculated is used to update a tire load value stored in the system 130 . The slow task portion 212 then returns to decision block 239 and proceeds as before.
[0048] If in decision block 239 the new pulse duration value is not available then the slow task portion 212 proceeds to functional block 255 where the system 130 calculates an updated signal filter frequency value. The slow task then proceeds to functional block 256 where the system 130 stores the updated signal filter frequency value.
[0049] The slow task portion 212 then proceeds to functional block 260 where the system 130 calculates an updated expected edge threshold value. The slow task then proceeds to functional block 261 where the system 130 stores the updated expected edge threshold value.
[0050] The slow task portion 212 then returns to decision block 239 and continues through as before and runs until stopped by some outside interrupt, such as, the system 130 being turned off or as will be described below.
[0051] In one embodiment of the present invention, a process for real-time tire load monitoring consists of the fast task portion 211 , as generally exemplified in FIG. 4 , and the slow task portion 212 , as generally exemplified in FIG. 5 . The fast task portion 211 preferably continually proceeds though signal processing and the slow task portion 212 preferably continually proceeds through value calculation, both portions cycle once per a respective processing period. Preferably, each respective period is less than the duration of one wheel rotation. However, the cycle of each portion is independent of the other, and may run asynchronously, i.e. without temporal concurrence, and/or asequentially, i.e. run without succeeding or following in order.
[0052] Further, in one embodiment of the present invention execution of a fast task portion and a slow task portion of a process for real-time tire load monitoring is not scheduled in a conventional process time-sharing way, i.e. where a fast task portion takes priority over a slow task portion. Two exemplary schemes are described as follows.
[0053] Referring again to the drawings, FIG. 6 schematically illustrates a serial-processing scheme, indicated generally at 310 . The serial-processing scheme 310 includes a single microprocessing system 314 . The fast task portion 211 and the slow task portion 212 of a process for real-time tire load monitoring in accordance with a first embodiment of the present invention are programmed into the single microprocessing system 314 . The fast task portion 211 is communicatively connected to the slow task portion 212 by a first communications pathway 330 . The slow task portion 212 is communicatively connected to the fast task portion 212 by a second communications pathway 334 . The fast task portion 211 and the slow task portion 212 are executed during different portions of a processing cycle, as will be described below. The processing cycle corresponds to a sensor data signal period, preferably a signal period of a transmitter associated with an accelerometer based contact patch sensor, preferably, the contact region detector 150 of the tire monitoring system 130 .
[0054] The fast task portion 211 is further communicatively connected to a task scheduler process 346 by a third communications pathway 350 . The task scheduler process 346 is communicatively connected to the fast task portion 211 by a fourth communications pathway 354 . The task scheduler process 346 is further communicatively connected to the slow task portion 212 by a fifth communications pathway 358 . The slow task portion 212 is communicatively connected to the task scheduler process 346 by a sixth communications pathway 362 .
[0055] The single microprocessing system 314 is preferably placed with the accelerometer of the detector 150 , embedded inside the tire 136 . For example, the single microprocessing system 314 may be the microprocessor included in the detector 150 . However, it will be appreciated that the single microprocessing system 314 may be placed in any appropriate location within a vehicle. For example, the single microprocessing system 314 may be the data processor 158 included in the system 130 . In an alternate embodiment of the invention where the single microprocessing system 314 is the data processor 158 , the detector 150 does not include a microprocessor.
[0056] For practical application, signal processing and value calculation processes are broken down into the two sub-tasks portion, the fast task portion 211 , and the slow task portion 212 . The fast task portion 211 performs loading of internal variables 366 , acquisition of an acceleration signal, filtering of the signal, detection of a rising pulse edge, measurement of a pulse duration, and transmission of a pulse duration value 370 . Preferably, the fast task portion 211 performs all functions at the same rate as the sample data acquisition rate, i.e. within the processing cycle corresponding to the sensor data signal period. The pulse duration value 370 is transmitted from the fast task portion 211 to the slow task portion 212 via the first communications pathway 330 , preferably through a common data storage module, such as a RAM module. A first coordination flag 374 is transmitted from the fast task portion 211 to the task scheduler process 346 via the third communications pathway 350 to indicate that the fast task portion 211 has fully performed one of its functions.
[0057] The task scheduler process 346 transmits a second coordination flag 378 to the slow task portion 212 via the fifth communication pathway 358 to enable the slow task portion 212 to execute. The slow task portion 212 calculates updated filter frequency value and expected edge threshold value, transmits the updated filter frequency value and expected edge threshold value as internal variables 366 , performs duration value validity analysis, and calculation of tire load. Preferably, the slow task portion 212 is running at a slower sample rate than the fast task portion 211 . Additionally, the slow task portion 212 has access to wheel speed sensor data and tire inflation sensor data. In order to deal with dynamic driving situations, such as when wheel speeds change significantly between two adjacent pulses in the acceleration signal, instantaneous wheel speed information is used to assist in calculating contact patch length, updated filter frequency value, and expected edge threshold value. The internal variables 366 , the updated filter frequency value, and the updated expected edge threshold value, are transmitted from the slow task portion 212 to the fast task portion 211 via the second communications pathway 334 . A third coordination flag 382 is transmitted from the slow task portion 212 to the task scheduler process 346 via the sixth communications pathway 362 to indicate that the slow task process 322 has fully performed one of its functions.
[0058] The task scheduler process 346 transmits a fourth coordination flag 386 to the fast task portion 211 via the fourth communication pathway 354 to enable the fast task portion 211 to execute. The fast task portion 211 loads the internal variables 366 . The fast task portion 211 then performs acquisition of the acceleration signal, filtering of the signal, detection of the rising pulse edge, measurement of the pulse duration, and transmission of the pulse duration value 370 and the process continues through the cycle as before.
[0059] Although the fast task portion 211 may be executed to perform different functions during the processing cycle, it is preferred that the slow task portion 212 is executed only once during the processing cycle. The invention contemplates loading the internal variables, i.e. updating the signal filter frequency value and expected edge threshold value, within the cycle in the acceleration signal. However, the fast task portion 211 would be executed as a time-sharing multi-rate task and the slow task portion 212 would be executed once within the cycle following the completion of detecting a rising pulse edge and the fast task portion 211 would be executed subsequently to finish.
[0060] FIG. 7 illustrates a Parallel Processing Scheme indicated generally at 390 . The Parallel Processing Scheme 390 includes a dual microprocessing system 392 . The fast task portion 211 and the slow task portion 212 of a process for real-time tire load monitoring in accordance with a second embodiment of the present invention are executed in two separate microprocessors, a first microprocessor 394 and a second microprocessor 398 , respectively.
[0061] In the dual microprocessing system 392 , the first microprocessor 394 containing the fast task portion 211 is preferably placed with the accelerometer of the detector 150 , embedded inside the tire 136 , and the second microprocessor 398 is preferably placed elsewhere in the vehicle 132 . For example, while the first microprocessor 394 may be the microprocessor included in the detector 150 , the second microprocessor 398 may be the data processor 158 included in the system 130 . However, it will be appreciated that the first microprocessor 394 and the second microprocessor 398 may be placed in any appropriate location within a vehicle.
[0062] The fast task portion 211 performs loading of internal variables 366 , acquisition of an acceleration signal, filtering of the signal, detection of a rising pulse edge, measurement of a pulse duration, and transmission of a pulse duration value 370 .
[0063] The pulse duration value 370 is transmitted from the fast task portion 211 to the slow task portion 212 via a first communications pathway 398 , through a common data storage module, such as a RAM module, preferably the data storage unit 162 of the system 130 .
[0064] The slow task portion 212 calculates updated filter frequency value and expected edge threshold value, transmits the updated filter frequency value and expected edge threshold value as the internal variables 366 , performs duration value validity analysis, and calculation of tire load
[0065] The internal variables 366 , i.e. the updated filter frequency value and expected edge threshold value, are transmitted from the slow task portion 212 to the fast task portion 211 via a second communications pathway 399 .
[0066] Preferably, the fast task portion 211 loads the internal variables and then performs acquisition of the acceleration signal, filtering of the signal, detection of the rising pulse edge, measurement of the pulse duration, and transmission of the pulse duration value 370 and then continues through the cycle until stopped by some outside interrupt, such as the system being turned off or input of a stop command from elsewhere in the system 130 .
[0067] Although, the Parallel Processing Scheme 390 has been described for use with one wheel, the invention contemplates a scheme where the first microprocessor 394 , embedded in one or more wheels, performs the fast task portion 211 for each the wheels in which the first microprocessor 394 is embedded, and where the second microprocessor 396 performs the slow task portion 212 for all of the wheels in which a first microprocessor 394 is embedded.
[0068] In summary, the invention may include various aspects, which differ from the prior art and provide advantages over the prior art. While the principal and mode of operation of this invention have been explained and illustrated in its preferred embodiment, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
|
A system for real-time signal processing for vehicle monitoring, including a first device disposed in a tire of a vehicle and producing a signal that is a function of a tire contact time period, during which a point at the tire circumference stays in contact with the ground, and a second device operative to repetitively perform a first task of processing the signal to calculate the tire contact time period at a first predetermined rate, and to repetitively perform a second task of calculating a tire load based at least in part upon the calculated tire contact time period at a second predetermined rate, wherein said second predetermined rate is less than said first predetermined rate.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns an improved nuclear steam generator having an auxiliary recirculation path in its upper shell region for facilitating the prompt and uniform mixing of wet lay-up chemicals in its water inventory.
2. Description of the Prior Art
Various techniques for mixing wet-layup chemicals in nuclear steam generators are known in the prior art. The mixing of such chemicals within the water inventory contained within the secondary sides of such generators is necessary whenever the manways of the secondary side are opened, and ambient air is allowed to flow into the interior of the generator. Such an opening of the manways is necessary from time to time so that repairmen can perform routine inspections and maintenance operations within the generator. The air that flows into the generator from the manways air contains oxygen, some of which becomes dissolved in the water present within the shell of the secondary side of the generator. If left unchecked, this dissolved oxygen can substantially accelerate the corrosion deterioration of the heat exchanger tubes contained within the secondary shell. The purpose of the wet lay-up chemicals is to remove the dissolved oxygen within the water inventory, and to render the water slightly basic in order to retard the corrosion that occurs to the tubes within the generator. The introduction and mixing of these chemicals into the water of the secondary side of the generator is often accompanied by a nitrogen sparging process, wherein pressurized nitrogen is used to displace the oxygen-containing air within the secondary shell.
In order for the wet lay-up chemicals to be effective, they must be thoroughly mixed into all portions of the water inventory of the generator. To this end, prior art mixing techniques have introduced the sparging gas through the blow-down line located at the bottom of the secondary side so that the resulting bubble agitation of the water would mix the water and chemicals. To further effect the desired mixing, recirculation pumps have been used within the secondary shell. Unfortunately, none of these techniques has succeeded in thoroughly mixing the wet lay-up chemicals with the water in the generator in a short amount of time. This is a significant shortcoming since generator down-time is very expensive. However, before one can fully understand the deficiencies of prior art mixing techniques, some basic understanding of the structure of nuclear steam generators is necessary.
Nuclear steam generators of the Westinghouse design are comprised of three principal parts, including the aforementioned secondary side, a tubesheet in which a bundle of U-shaped heat exchanger tubes are mounted, and a primary side. The primary side receives hot, radioactive water heated by the nuclear reactor. The primary side conducts this water to the inlets of the U-shaped tubes that are mounted in the tubesheet. The tubesheet and the U-shaped tubes hydraulically isolate the primary from the secondary sides of the steam generator while thermally connecting them together, so that heat from the radioactive water in the primary side is transferred to the non-radioactive water in the secondary side. The hot, radioactive water transfers its heat through the walls of the bundle of U-shaped heat exchanger tubes contained within the secondary side to non-radioactive feedwater present in the shell of the secondary side of the generator, thereby converting this feedwater into non-radioactive steam.
Structurally, the nuclear steam generator resembles a vertically oriented cylindrical shell having an enlarged portion at its upper end (see FIGS. 1A and 1B). The primary side of the generator is a bowl-shaped vessel located at the bottom portion of the shell, while the secondary side is formed from the middle and enlarged upper portion of the shell. The middle portion of the cylindrical shell contains the previously mentioned bundle of U-shaped heat exchanger tubes, while the upper shell region encloses a bank of water separators that separate water droplets entrained in the steam generated by the tube bundle. In order to uniformly recirculate the water that is removed from the steam by the steam separators, the bundle of U-shaped tubes is surrounded by a generally cylindrically shaped tube wrapper that is concentrically spaced from the shell of the secondary side of the generator. The annular space between the inner surface of the shell and the outer surface of the tube wrapper forms a downcomer path for the water droplets that collect the stream down the inner walls of the shell from the water separators. The bottom edge of the tube wrapper is spaced a short distance from the tubesheet so that the water that flows down the downcomer path will be conducted into the water that surrounds the bundle of heat exchanger tubes.
Under normal operating conditions, the water level within the secondary side of the generator is always higher than the upper edge of the tube wrapper, but lower than the upper portion of the separators contained within the upper shell region. At such a level, the water contained in the interior of the tube wrapper is free to circulate through the tube bundle, over the upper edge of the tube wrapper, through the primary separators, and down the downcomer path defined between the outer wall of the tube wrapper and the inner wall of the secondary shell. From there, the water flows downwardly until it reaches the gap between the bottom edge of the tube wrapper and the upper surface of the tubesheet, where it flows back to the bottom of the tube bundle.
Unfortunately, the aforementioned recirculation path is broken whenever the level of the water within the secondary shell is brought down to a point near or below the upper edge of the tube wrapper. Such a lowering of the water level is necessary to afford repairmen access to the upper shell region of the generator so that they can perform maintenance operations. The lowering of the water, and the consequent breaking of the recirculation path between the tube bundle and the downcomer path makes it very difficult to quickly and uniformly mix the wet lay-up chemicals into the water inventory contained within the secondary side while the maintenance operations are in progress. The time required to complete the mixing not only increases generator down-time, but also increases the amount of radiation that the repairmen are exposed to while working within the secondary side of the generator.
In order to overcome the non-uniform mixing of these chemicals within the secondary side of the generator, two different mixing techniques were developed in the prior art. The first of these techniques was the injection of the sparging gas (which was normally nitrogen) into the bottom of the secondary side of the generator through the blow-down line. The small bubbles of nitrogen served to agitate the water surrounding the tube bundle, and to effectively mix the anti-corrosion wet lay-up chemicals injected into this region of the generator. However, because the recirculation path between the interior of the tube wrapper and the downcomer path was broken, the water held within the downcomer path would not readily circulate with the water surrounding the heat exchanger tubes. The end result was that a large amount of generator down time passed before the anti-corrosive wet lay-up chemicals were uniformly mixed throughout all parts of the water inventory contained in the secondary side. The second prior art technique employed was the installation of a pump and a plurality of hoses for forcing a circulation between the water in the downcomer path and the water surrounding the tube bundle while sparging gas bubbles were admitted through the blow-down line. While this pump and bubble agitation technique mixed the wet lay-up chemicals throughout the secondary side in a somewhat shorter period of time than bubble-agitation technique alone, it has proved to be expensive and cumbersome since a substantial amount of effort is required by the maintenance personnel to install, operate and remove the pump and various hoses. It has been found that the pump recirculation technique is of such limited effectiveness due to the phenomena known as "streaming" in the art of fluidics. The practical effect of such streaming is that the jet of pressurized water created by the pump passes through the rest of the water largely intact, without mixing. While the effect of such streaming can be counteracted by the installation of a multiplicity of hoses and nozzles, the time loss associated with the installation and removal of additional hoses would more than offset any time gain realized as a result of an increased mixing rate. The pump circulation technique has the additional drawback of increasing the amount of radiation exposure of the maintenance personnel, since they must install and remove the hoses and pump.
Clearly, a new technique for the rapid and uniform mixing of anti-corrosive wet lay-up chemicals within the secondary side of a nuclear steam generator is needed that minimizes both the downtime of the steam generator and the radiation exposure of the maintenance personnel. Ideally, such a technique should be highly reliable, inexpensive, and readily applicable to all models of nuclear steam generators now in existence.
SUMMARY OF THE INVENTION
In its broadest sense, the invention is an improved steam generator having an auxiliary flowpath means for conducting water between the interior of the tube wrapper to the downcomer path when the water level within the secondary shell is too low to allow recirculation between these two regions of the generator. The auxiliary flowpath is selectively operable, so that the normal recirculation path of the water is not interfered with during the normal operation of the generator.
The auxiliary flowpath may include a fitting mounted onto the lower portion of one or more of the water separators enclosed within the upper shell region. The auxiliary flowpath may further include an elbow joint that is detachably connectable onto the fitting for directing a flow of water from the interior of the separator downwardly into the downcomer path defined between the outer surface of the tube wrapper, and the inner surface of the secondary shell. In this embodiment, the auxiliary flowpath may also include a sealing plate that is detachably mountable over the fitting for blocking the flow of water through the fitting when the auxiliary flowpath is not in use. Nuts and bolts secured by fillet welds may be used to secure both the elbow joint and the plate. Alternatively, a manually operable gate valve may be provided between the fitting and the elbow joint for selectively opening the auxiliary flowpath.
In another embodiment of the invention, the auxiliary flowpath may be formed from one or more openings located around the upper edge of the tube wrapper. Each of these openings may be circumscribed by a flange that projects toward the inner surface of the secondary shell. The auxiliary flowpath may further include one or more closure plates that are detachably mountable over the flanges that circumscribe each of the openings in the upper portion of the tube wrapper so that these openings may be closed when the auxiliary flowpath is not in use. In the preferred embodiment, each of these plates is secured onto their respective flanges by means of a plurality of bolts uniformly spaced around the circumference of the flange. In order to ensure that these bolts will not come off, each may be secured by a fillet weld.
The invention further encompasses a method of mixing wet layup chemicals within a steam generator that generally comprises the steps of lowering the level of the water in the secondary shell to a point that breaks the recirculation path within the generator, providing an auxiliary flowpath means within the shell so that water may be circulated from the interior of the tube wrapper to the downcomer path at the reduced water level, injecting wet layup chemicals into the water within the shell, and then simultaneously introducing gas bubbles into the water while circulating water through the auxiliary flowpath until the wet layup chemicals are thoroughly and uniformly mixed throughout all portions of the water inventory within the secondary shell.
The auxiliary flowpath and improved mixing method of the invention provides a greatly improved technique for uniformly mixing anti-corrosion wet lay-up chemicals within the water inventory of a nuclear steam generator in a minimum amount of time. It is readily applicable to all models of nuclear steam generators now in service, and substantially reduces both the downtime of these generators and the amount of radiation exposure incurred by maintenance personnel.
BRIEF DESCRIPTION OF THE SEVERAL FIGURES
FIG. 1A and 1B form a cross-sectional side view of a nuclear steam generator improved in accordance with the invention;
FIG. 1C is a plan view of the nuclear steam generator of FIG. 1A along the line 1C--1C;
FIG. 2A is an enlarged view of the circled region of FIG. 1A;
FIG. 2B is a plan view of the portion of the generator illustrated in FIG. 2A along the line 2B--2B, showing one embodiment of the auxiliary flowpath of the invention;
FIG. 2C is a side view of the auxiliary flowpath illustrated in FIG. 2B along the line 2C--2C with the elbow joints removed and a valve installed in phantom;
FIG. 3 is a side view of the auxiliary flowpath illustrated in FIG. 2B with the elbow joint removed and a closure plate secured thereon, and
FIG. 4 is a side, cross-sectional view of an alternative embodiment of the auxiliary flowpath of the invention as it appears installed in the upper portion of the tube wrapper of the generator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to FIGS. 1A, 1B, and 1C, wherein like numerals designate like components throughout all of the several figures, the improved nuclear steam generator 1 of the invention includes a primary side 3 in the form of a bowl-shaped vessel 5 that forms the bottom of the generator, and a secondary side 7 in the form of a generally cylindrical shell 9 that forms the middle and top portions of the generator. The upper portion of the cylindrical shell 9 of the secondary side 7 flares out into a conical skirt 10 that melds in with an enlarged portion 11 which forms the upper end of the generator 1. The enlarged portion 11 and its contents form what are known as the upper shell region 13 in the art.
A tubesheet 15 is disposed between the primary side 3 and the secondary side 7, and serves to hydraulically isolate the two sides of the generator 1 from one another. The lower portion of the cylindrical shell 9 of the secondary side 7 houses a bundle 17 of U-shaped heat exchanger tubes 19, as shown. The right-hand legs and the left-hand legs of the U-shaped tubes 19 terminate in open inlet ends 21 and outlet ends 22, each of which may protrude downwardly from the lower surface of the tubesheet 15. The bowl-shaped vessel 5 of the primary side 3, in turn, includes a divider plate 27 for hydraulically isolating the inlet ends 21 of the tubes 19 from their outlet ends 22. This vessel 5 further includes an inlet 23 for admitting hot, radioactive water from the reactor core (not shown) into the inlet ends 21 of the tubes 19, as well as an outlet 25 for discharging this water from the bowl-shaped vessel 5 after it has completely circulated around the U-shaped tubes 19 of the tube bundle 17 and out of the outlet ends 22.
In operation, the shell 9 of the secondary side 7 contains an inventory of water 29 that completely immenses the bundle 17 of U-shaped heat exchanger tubes 19, and the hot, radioactive water that circulates through the interior of these tubes 19 transfers sufficient heat to the water 29 within the shell 9 to cause it to boil and to generate a substantial quantity of usable, non-radioactive steam. The steam generated within the shell 9 of the secondary side rises and ultimately flows out of a steam nozzle 30 located at the top of the upper shell region 13. However, before this steam ultimately flows out of the nozzle 30, it must be dried in order to remove any significant amounts of water droplets that may be entrained in the steam flow. To this end, a secondary and a primary separator bank 32 and 34 are provided at the top and bottom ends of the upper shell region 13, respectively. These separator banks 32, 34 serve two important purposes. First, since the steam produced by such nuclear steam generators 1 is ultimately directed against the turbine of an electric generator at pressures ranging between 900 and 1000 pounds per square inch, any residual water droplets in the steam can cause a significant amount of erosion in the blades of the turbine. Secondly, the water losses that occur as a result of such wet steam increase the amount of water that must be supplied to the steam generator 1, which in turn accelerates the creation of sludge deposits within the secondary side 7. Since such sludge deposits are responsible for much of the corrosion that attacks the heat exchange tubes 19 of the steam generator 1, it is desirable that such water losses through the steam be reduced as much as possible.
The secondary separator bank 32 is generally formed from an array of blades that form a tortuous path which the steam must cross before reaching outlet nozzle 30. A drainpipe 33 centrally disposed throughout the secondary separator bank 32 drains some of the water captured by the blades (not shown) of the secondary separator bank 32, and directs this water back into the water inventory 29. The rest of the water captured by the secondary separator 32 drips down to the primary separator bank 34, where it in turn ultimately flows down an annular downcomer path 54 to be described in more detail hereinafter.
The primary separator bank 34 is formed from a plurality of swirl vane separators 36. Each of the separators 36 includes a generally cylindrical riser barrel 38 that is circumscribed around its uppermost portion by a downcomer barrel 40. A set of pitched blades 42 is mounted within the upper end of each of the riser barrels 38. A helical component of motion is imparted to any stream of wet steam that flows through the riser barrel 38 and on through the blade set 42. This helical component of motion slings out water droplets entrained in the steam flow into an opening (not shown) located at the upper end of each of the riser barrels 38. The resulting separated liquid flows downwardly between the outer surface of the riser barrel 38 and the inner surface of the downcomer barrel 40, and ultimately flows into the previously mentioned annular downcomer path 54 of the generator 1. Each of the swirl vane separators 36 that forms the primary separator bank 34 is secured within the upper shell portion 13 of the secondary side 7 by an upper deck plate 44 that supports the tops of each of the separators 36, a center deck plate 46 that circumscribes the center portions of each of these separators 36, and a lower deck plate 48 that supports the bottoms of each of the downcomer barrels 40 of the separators 36. The lower deck plate 48 includes a plurality of gussets 49 in order to structurally stiffen it, while the upper and center deck plates 46 include a plurality of vent holes 50 for conducting droplets of separated water back to the previously mentioned annular downcomer path 54.
Circumscribing both tube bundle 17 and the inner surface of the shell 9 of the secondary side 7 is a tube wrapper 52. The previously mentioned annular downcomer path 54 of the steam generator 1 is defined between the outer surface of this tube wrapper 52, and the inner surface of the shell 9 and conical skirt 10 of the secondary side 7. As is shown in FIG. 1B, the bottom edge of the tube wrapper 52 is spaced from the top surface of the tubesheet 15. Such spacing allows any water that flows down the annular downcomer path 54 to circulate into the water inventory 29 that immerses the tube bundle 17.
In order to replenish the water inventory 29 in the secondary side 7 that is constantly being converted into steam, the upper shell region 13 includes a feed nozzle 56. The feed nozzle 56 is in turn hydraulically connected to a distributing ring 58 that includes a plurality of J-tubes 60 spaced around its circumference. The J-tubes 60 resemble open elbow joints, which are pointed downwardly toward the upper end of the annular downcomer path 54. Hence, when pressurized feedwater is introduced into the feed nozzle 56, this feedwater is uniformly distributed around the open end of the annular downcomer path 54. Finally, in order to clean sludge deposits that accumulate on top of the tubesheet 15 as a result of the constant boiling away of the water 29, a blow-down line 62 is provided between the upper surface of the tubesheet 15 and the lower edge of the tube wrapper 52. Normally, the function of the blow-down line 62 is to direct a plurality of jets of pressurized water onto the top surface of the tubesheet 15 in order to remove the sludge. However, this blow-down line 62 may also perform the useful function of providing a sparging line during maintenance operations, as will be presently described.
Under normal operating conditions, the level of the water within the shell 9 of the secondary side 7 is at line 64. At such a level, water is free to circulate from the water inventory 29 that surrounds the tube bundle 17 upwardly through the primary separator bank 34 and downwardly into the upper open end of the annular downcomer path 54, as indicated by the flow arrows 66. From thence, the water flows all the way down the annular downcomer path 54 and into the space between the lower edge of the tube wrapper 52, and the upper surface of the tubesheet 15. Because the steam bubbles created around the tube bundle 17 have the effect of lowering the average density of the water inventory 29 contained within the interior of the tube wrapper 52, a positive pressure differential exists between water inventory 29 and the water flowing down through the annular downcomer path 54. This positive pressure differential, in turn, forces a flow of water along the previously described recirculation path 66.
It has been discovered that the aforementioned recirculation path becomes substantially broken whenever the water level within the shell 9 of the secondary side 7 is brought down to a level 68 that allows maintenance operations to be performed within the upper shell region 13. In such maintenance operations, the manways 14A, 14B are typically opened in order to allow service personnel into the upper shell region 13. The ambient air that fills the upper shell region 13 contains oxygen, a significant amount of which becomes dissolved in the water contained within the secondary side 7. If not removed, this dissolved oxygen can either initiate corrosion within the tubes 19 contained within the secondary side 7, or accelerate the production of corrosion at pre-existing corrosion sites. To remove this oxygen, the service personnel typically add wet layup chemicals, such as ammonia and hydrazine, to the water. The ammonia ensures that the pH of the water will not be acidic, and the hydrazine acts as an oxygen scavenger. As a further precautionary measure, pressurized nitrogen gas is introduced through the blow-down line 62 after the service personnel are evacuated from the generator in order to displace all of the oxygen from the upper shell region 13. It has been found that the introduction of pressurized nitrogen through the blow-down line 62 has the further beneficial effect of agitating the water inventory 29 that surrounds the tube bundle 19, which helps to uniformly mix the wet layup chemicals which are injected through the feed nozzle 56, where they ultimately flow through the J-tubes 60 of the distributing ring 58, down the annular downcomer path 54, and out through the space between the lower edge of the tube wrapper 52 and the bottom surface of the tubesheet 15.
Unfortunately, in prior art nuclear steam generators, the uniform admixing of such wet layup chemicals within the secondary side 7 is greatly impeded due to the lack of free circulation between the water within the annular downcomer path 54, and the water inventory 29 surrounding the tube bundle 17. The instant invention solves this problem by the provision of an auxiliary recirculation path 70 located at either the bottom portion of the riser barrels 38 of one or more of the separators 36 (see FIGS. 2A and 2B), or at the upper portion of the tube wrapper 52 (see FIG. 4).
FIG. 2A and 2B illustrate the first preferred embodiment of the recirculation assembly 72 of the invention. The assembly 72 includes a fitting 74 welded onto the lower portion of the riser barrel 38 of four of the swirl vane separators 36 spaced 90° from one another. Sealingly attached to the fitting 74 is an elbow joint 76. To facilitate the interconnection of the fitting 74 and the joint 76, flanges 78 and 80 are provided on each of these components. The flanges 78 and 80 include bolt holes 79 which are mutually registrable for receiving the shanks of a plurality of bolts 82 which are bound thereon by nuts 84. In the preferred embodiment, both the fitting 74 and the elbow joint 76 are elongated with respect to the circumference of the riser barrel 38 in order to provide a maximum flow of water through the auxiliary circulation path 70. Additionally, each of the elbow joints 76 is directed downwardly toward the open end of the downcomer path 54. Finally, each of the bolts 82 and nuts 84 are preferably secured in place by means of small fillet welds 86 to ensure that no loose components will inadvertently fall into the downcomer path 54, where the recirculating water would sweep and rattle them against the heat exchanger tubes 19.
In order to render the auxiliary circulation path 70 selectively operable, the recirculation assembly 72 may include a gate valve 88 disposed between the flanges 78 and 80 as shown in FIG. 2C. This gate valve 88 would preferably include a handle 89 that opened or closed a conventional fluid gate mechanism 90. Alternatively, the recirculation assembly might be selectively closed by cutting the bolts 82, removing the elbow joint 76, and bolting a closure plate 92 over the flange 78 of the fitting 74, as is illustrated in FIG. 3.
FIG. 4 illustrates a second embodiment of the recirculation assembly 72 of the invention. In this embodiment, the fitting 74 is placed at an upper portion of the tube wrapper 52. Because the opening in the fitting 74 directly contacts the annular downcomer path 54, no elbow joint is necessary. Like the previously described embodiment, this second embodiment also includes a closure plate 92 that is sealingly mountable around the flange 78 of the fitting 74 by means of bolts 82 and nuts 84. These bolts 82 and nuts 84 are again preferably secured around the closure plate 92 by fillet welds 86 to prevent any of these parts from loosening and inadvertently falling into the downcomer path 54.
During periods of non-use, the closure plate 92 is mounted over the path of the fitting 74, whether the fitting 74 is located on the riser barrel 38 of one of the primary separators 36, or on an upper portion of the tube wrapper 52. In both embodiments, at least four such fittings 74 are provided, each of which is uniformly spaced 90° from its neighbors in order to facilitate a uniform recirculating flow through the downcomer path 54 (see FIG. 1C). During periods of use, the bolts 82 and nuts 84 are first removed by either grinding away the fillet welds 86, or by cutting the bolts 82. In the case of the first embodiment, the previously mentioned elbow joint 76 is next installed by placing new bolts 82 through the holes 79 in the flanges 78 and 80, and by ringing new nuts 84 on the ends of the shanks of these bolts 82. In the second embodiment, no such installation of an elbow joint 76 is necessary. In all cases, the bolts and nuts 82, 84 are secured by the previously mentioned fillet welds 86.
The improved method of the invention is applicable to both of the preferred embodiments of the improved generator 1 of the invention. In the first step of this method, the water level is lowered within the upper shell region 13 of the generator 1 to level 68 (shown in FIG. 2A and FIG. 4) in order to allow maintenance personnel access to this region 13. If the first embodiment of the invention is used, the water level 68 during sparging is somewhere between the upper edge of the tube wrapper 52 and the ring 58 of the feed nozzle 56 (see FIG. 2A). If the second embodiment of the invention is used, this water level 68 is just below the upper edge of the tube wrapper 52 (see FIG. 4).
After the maintenance operation has been performed, the auxiliary recirculation path 70 is opened by removing the closure plate 92 from the fitting, and by further installing the elbow joints 76 at each of the four recirculation path locations indicated in FIG. 1C if the first embodiment of the invention is used. The repairmen are then evacuated from the upper shell region 13, but the manways 14a, 14b are left open to allow for depressurization during sparging. Next, pressurized nitrogen is conducted into the secondary shell 9 by introducing it through the blow-down line 62. As soon as the atmosphere in the upper shell region 13 has been substantially replaced with nitrogen, the wet lay-up chemicals are introduced into the secondary shell by conducting them through the distribution ring 58 of the feed nozzle 56. The J-tubes 60 of the ring 58 distribute these chemicals at uniformly spaced points around the circumference of the ring 58, where they ultimately flow into the annular downcomer path 54. Because the nitrogen bubbles have caused the water on the inside of the tube wrapper 52 to be less dense than the water in the downcomer path 54, and because the auxiliary recirculation path 70 is below the level 68 of this water, the water within the secondary shell 9 freely circulates through the tube bundle 17, over the upper portion of the tube wrapper 52, through the downcomer path 54, and back through the bottom of the tube bundle 17. While this recirculation is occurring, the nitrogen bubbles agitate and thoroughly mix the water inventory 29 around the tube bundle 17 as it passes through the inside of the wrapper 52.
After the mixing has been completed, one of the manways 14a, 14b is opened briefly to allow a repairman to re-install the closure plate 92 over the fitting 74 at each of the four locations shown in FIG. 2C. The positive pressure of the nitrogen within the secondary shell 9 prevents any significant amount of atmospheric oxygen from re-entering the upper shell region 13. To compensate for the lack of oxygen, the repairman carries his own supply by way of a scuba-like mechanism. After the closure plates 92 are reinstalled, the repairman leaves the upper shell region 13, and the generator is brought back on line. In all cases of removal and installation, bolts 82, nuts 84 and fillet welds 86 are preferably used to secure the plates 92 or elbows 76 into position. However, it should be noted that the apparatus of the invention is not confined to the use of such bolt and nut securing means, and that other forms of detachable mountings, such as rail-and-track "windowpane" type mountings between the plates 92 and fittings 74 are also contemplated. With respect to the method of the invention, it should be noted that the wet lay-up chemicals may alternatively be added at more than one time during the maintenance operation.
|
An improved steam generator having an auxiliary recirculation path in its secondary side is disclosed herein, as well as an improved method for mixing wet lay-up chemicals therein. The invention is particularly applicable to nuclear steam generators of the type including a secondary shell that contains a quantity of water, a bundle of heat exchange tubes, and a tube wrapper that concentrically surrounds the tube bundle for defining a downcomer path. The auxiliary recirculation path allows the water present within the tube wrapper to circulate through the downcomer path when the water level within the secondary shell is lowered below the upper edge of the tube wrapper during maintenance operations. The auxiliary flowpath, when used in combination with nitrogen sparging, allows wet layup chemicals injected into the downcomer path of the generator to be rapidly and uniformly mixed throughout the entire water inventory in the secondary shell, thereby minimizing generator downtime and radiation exposure to maintenance personnel.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/008,978, filed on Jun. 5, 2014. The entire disclosure of the above application is incorporated herein by reference.
GOVERNMENT INTEREST
[0002] This invention was made with government support under CMM11350202, awarded by the National Science Foundation. The Government has certain rights in the invention.
FIELD
[0003] The present disclosure relates to an active assist stage for scanning applications and, more particularly, to a magnet assisted stage for vibration and heat reduction in wafer scanning.
BACKGROUND AND SUMMARY
[0004] This section provides background information related to the present disclosure which is not necessarily prior art. This section also provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
[0005] Scanning stages are used for precise positioning in a variety of advanced manufacturing processes, such as laser patterning, 3-D printing, and pick-and-place type applications for hard drive manufacturing. In particular, they are used for precise positioning at various stages of silicon wafer processing, such as optical lithography and inspection.
[0006] In response to increased throughput demands, wafer scanning stages must deliver high accelerations/decelerations (acc/dec) at motion reversals. The resulting high inertial forces that are borne by the linear motor actuators cause Joule heating proportional to the square of the motor current, leading to increased thermal errors. Various methods such as forced cooling, thermal error compensation, light-weighting and optimal control of the motor drives can be used to mitigate thermal errors. Unfortunately, forced cooling requires cooling circuits and external heat exchangers, which add to design complexities and raise costs. Effective thermal error compensation requires reliable thermal models and temperature sensor networks. Light-weighting could reduce structural stiffness and introduce unwanted vibrations. Control techniques can only offer incremental benefits for a given motor design.
[0007] In addition to generating excessive heat, the high inertial forces in scanning stages cause residual vibration of the machine frame, which adversely affects positioning speed and precision. Various methods such as tuned mass dampers, input shaping and counter motion devices can be employed to mitigate residual vibration. Tuned mass dampers and input shapers lose effectiveness when operating conditions change. Counter motion devices are bulky, expensive and energy intensive.
[0008] A passive assist device (PAD) is a spring mounted in series or parallel with an active element (e.g., motor). A passive assist device consisting of a torsional spring in parallel with a rotary motor has been illustrated to significantly reduce motor currents and power, when properly tuned for a family of motion trajectories. However, the passive assist device could increase motor currents/heat for operating conditions other than the ones for which it was tuned, making it limited in versatility.
[0009] According to the principles of the present teachings, a passive assist device is provided that uses magnetic repulsion to simultaneously reduce vibration and heat during motion reversals in wafer scanning. In some embodiments, a pair of repelling permanent magnets is used to store and release the stage's kinetic energy during deceleration and acceleration, respectively, to alleviate motor force requirements thereby reducing heat. In some embodiments, residual vibrations are lessened by channeling the assistive forces provided by the magnets to the ground, instead of to the vibration-sensitive machine base. The magnets can be automatically positioned to provide optimal assist for a given scan trajectory, thus enhancing the versatility of the passive assist device. The following discussion describes the magnet-based passive assist device in greater detail, including the design, sizing and control of a prototype magnet assisted stage. Experimental results obtained from an exemplary stage are presented and discussed.
[0010] Furthermore, in some embodiments, a magnet assisted stage system is provided for scanning applications having a scanning table being moveable from a first position to a second position, a scanning actuator operably associated with the scanning table to move the scanning table along a scanning direction from the first position to the second position, and an actively variable magnetic spring system being operably augmented to the scanning table to exert a magnetic repulsion force upon the scanning table in the scanning direction.
[0011] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0012] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
[0013] FIG. 1A illustrates regions of a silicon wafer scanning profile;
[0014] FIG. 1B illustrates a schematic view, along an x-axis, of a silicon wafer scanning stage;
[0015] FIG. 1C illustrates a schematic view, along an x-axis, of a silicon wafer scanning stage including passive assist devices (PAD);
[0016] FIG. 2A illustrates a portion of a schematic view of a scanning stage having a passive assist device employing magnetic repulsion according to the principles of the present teachings;
[0017] FIG. 2B is a graph illustrating characteristic force vs. distance curve of a pair of repelling permanent magnets;
[0018] FIG. 3 illustrates a perspective view of a magnet assisted stage system according to some embodiments of the present teachings;
[0019] FIG. 4A illustrates a schematic view of a simplified Coulombian magnetic force model for determining force between two magnetized surfaces;
[0020] FIG. 4B illustrates a magnetic pole arrangement of 2-D Halbach array, with arrows indicating North pole direction and gray spaces indicating absence of magnets;
[0021] FIG. 5 illustrates a control scheme of the magnet assisted stage system, with P, V, and A denoting position, velocity, and acceleration, respectively;
[0022] FIG. 6A is a photograph of the magnet assisted stage system;
[0023] FIG. 6B is a graph illustrating the predicted and measured F PM (d) curves of each passive assist device;
[0024] FIG. 7A is a graph illustrating reference trajectory used in experiments for a reference velocity trajectory for 0.5 m/s scan speed;
[0025] FIG. 7B is a graph illustrating the measured system response for a linear motor force applied to a moving table;
[0026] FIG. 7C is a graph illustrating the measured system response for position error; and
[0027] FIG. 7D is a graph illustrating the measured system response for horizontal (x-axis) vibration of the isolated base.
[0028] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0029] Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
[0030] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
[0031] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0032] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
[0033] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0034] Magnet Assisted Stage Device
[0035] Combined vibration and heat reduction using passive assist devices
[0036] FIG. 1A illustrates the conventional scanning profile for a silicon wafer. The y-axis advances in successive steps while the x-axis shuttles back and forth (i.e., scans) repeatedly. The scanning motion of the x-axis is the main focus of the present teachings. It consists of a constant velocity (CV) and motion reversal (motion reversal) regions. The constant velocity region of each scan is where the actual manufacturing process (e.g., lithography or inspection) takes place, so positioning must be extremely precise. The motion reversal regions are not useful to the actual manufacturing process; they must therefore be executed as fast as possible (i.e., with high acceleration/deceleration) to boost throughput while ensuring that the precision of the constant velocity regions is not compromised.
[0037] A schematic of the x-axis of a conventional wafer scanning stage 100 is illustrated in FIG. 1B . The scanning table 104 , actuated by motor force F M , is mounted on a rigid base 106 . The base 106 is isolated from ground vibration using very soft springs 108 (conventionally pneumatic isolators) in order to achieve the desired precision in the constant velocity regions. However, when the table 104 is in the motion reversal regions, the presence of the soft springs causes unwanted horizontal and rocking (i.e., θ) vibration of the base 106 due to the large inertial forces present during acceleration/deceleration. Upon arriving at the next constant velocity region, the stage 100 must wait for the residual vibration to settle before the manufacturing process resumes, thus slowing down the process. Moreover, large inertial forces draw high electric currents from the motors, causing unwanted heat that compromises accuracy in the constant velocity regions.
[0038] The present teaching provides an approach for simultaneously reducing vibration and heat using passive assist devices. As illustrated in FIG. 1C , the passive assist devices 102 are designed to store and release some of the table's kinetic energy when the table is in the motion reversal regions, thus reducing heat by lowering the magnitude of F M needed for acceleration/deceleration. Vibrations are reduced by transmitting the reaction forces from the passive assist devices 102 directly to the ground 110 so that they do not disturb the vibration-sensitive base 106 of the machine. An ideal passive assist device 102 would store and release all of the stage's kinetic energy. Additionally, it would disengage completely from the scanning table upon entering the constant velocity regions to stop the transmission of ground vibrations to the table, and to prevent the actuators (F M ) from doing unnecessary work against the passive assist device 102 to maintain the stage at constant velocity.
[0039] Approximation of ideal passive assist device by magnets with tunable stiffness
[0040] According to the principles of the present teachings, the ideal passive assist device 102 described herein can be substantially achieved using a pair of repelling permanent magnets (PMs); one mounted to the moving table and the other fixed just outside the motion reversal region (as illustrated in FIG. 2A ). Magnetic repulsion provides a nonlinear stiffness relationship as illustrated in FIG. 2B , which is almost zero when the distance d between the magnets is large, but grows exponentially as d decreases. The effective stiffness of the device is made tunable by allowing x PM , the position of the permanent magnets just outside the motion reversal region, to be adjustable. Therefore, an optimal x PM value can be determined for any desired motion profile x ref (t) of the stage (t denotes time). For instance, to minimize heat, x PM can be selected to minimize the resistive losses in the motor, represented by the objective function f H given by
[0000]
f
H
=
∫
0
T
(
F
M
(
t
)
K
M
)
2
t
≈
∫
0
T
(
m
x
¨
ref
(
t
)
-
F
PM
(
t
)
K
M
)
2
t
(
1
)
[0041] where K M is the motor constant and m is the moving mass of the stage. T is the time period of one scan cycle (consisting of 1 constant velocity and 2 motion reversal regions). F PM (t) can be calculated from the known F PM (d) curve of the permanent magnet pair making up a passive assist device according to the expression
[0000] F PM ( t )= F PM ( d ( t ))= F PM ( x ref ( t )− x PM ) (2)
[0042] The minimization of residual vibration can be realized approximately by selecting x PM to minimize the peak motor force represented by the objective function f V expressed as
[0000]
f
v
=
max
t
∈
[
0
,
T
]
(
F
M
(
t
)
)
≈
max
t
∈
[
0
,
T
]
(
m
x
¨
ref
(
t
)
-
F
PM
(
t
)
)
(
3
)
[0043] Note that, with x PM determined using Eq. (1) or (3), d min , the minimum gap between a permanent magnet pair for a given scan trajectory, can be determined as
[0000]
d
min
=
max
[
min
t
∈
[
0
,
T
]
(
x
ref
(
t
)
-
x
PM
)
,
δ
]
(
4
)
[0044] where δ represents a safe gap between the magnets to prevent them from colliding.
[0045] Design, Sizing and Control
[0046] Design
[0047] Accordingly, a magnet assisted stage 10 is provided according to the principles of the present teachings. Although the present stage 10 will be described in connection with a specific embodiment of the present teachings, it should be understood that the principles of the present teachings can find utility in a wide variety of embodiments. By way of non-limiting example, it should be understood that the present teachings can find utility in scanning stages having different dimensions, velocities, accelerations, weights, and/or uses. Therefore, the present discussion should not be regarded as limiting the present invention and scope of the associated claims.
[0048] Therefore, by way of non-limiting example, Table 1 summarizes the design targets for the stage of the present embodiment and FIG. 3 illustrates an exemplary scanning stage 10 according to the present teachings.
[0000]
TABLE 1
Design target of magnet assisted stage prototype.
Specification
Design target
Travel
300
mm
Max. acceleration
35 m/s 2
(3.5 g)
Max. scan speed
1
m/s
Table size
360 mm × 360 mm
Moving mass
~15
kg
[0049] With particular reference to FIG. 3 , in some embodiments, magnet assisted stage system 10 of the present teachings can comprise a base structure 12 being coupled to or otherwise functionally equivalent to ground. An isolated base 14 , such as a granite base, is operably coupled to base structure/ground 12 via a plurality of isolators 16 , such as pneumatic isolators. A scanning table 18 is movably coupled relative to isolated base 14 via a support system 20 . In some embodiments, support system 20 can comprise one or more guiding elements 22 being operably coupled to isolated base 14 to provide a support to permit guided movement of scanning table 18 relative to isolated base 14 . Guiding elements 22 can be sized and shaped to complementarily engage a corresponding feature of scanning table 18 to provide smooth articulation. Scanning table 18 can be supported by air bushings or other reduced friction supports 24 . Magnet assisted stage system 10 can further comprise a drive mechanism 26 for “scanning” movement of scanning table 18 .
[0050] By way of non-limiting example, in some embodiments, scanning table 18 is guided by a set of air bushings 24 riding on a set of 25 mm precision ground shafts 22 . A pair of linear shaft motors 26 with 600 N peak and 150 N continuous force (combined) is selected to drive scanning table 18 . The position of scanning table 18 can be measured using linear encoders 28 with 4.88 nm resolution post-interpolation. The scanning table 18 can sit on a 900 mm×600 mm×100 mm granite base 14 suspended by four pneumatic isolators 16 .
[0051] Still further, magnet assisted stage system 10 can comprise a magnetic spring system 50 for use in the stepping direction, the scanning direction, and/or the stepping and scanning directions. Magnetic spring system 50 can comprise a bridge system 52 having upright support members 54 and a support member 56 extending therebetween. Support member 56 can be disposed between isolated base 14 and scanning table 18 , yet physically isolated therefrom to prevent transmission of vibration and/or heat to scanning table 18 . Magnet spring system 50 can comprise one or more permanent magnets 58 installed on opposing sides of scanning stage 18 (only one illustrated; a second one is obscured by scanning table 18 in FIG. 3 ). The particular design, size, and configuration of permanent magnets 58 will be described herein.
[0052] In some embodiments, the position and, thus, the magnetic force exerted by permanent magnet 58 can be varied and/or adjusted by use of a magnet drive system 60 having a motor 62 operably coupled to at least one of permanent magnets 58 to vary a distance between permanent magnet 58 and scanning table 18 . In some embodiments, a servo having a single linear guide and a 10 mm-diameter rolled ball screw driven by a stepper motor can be employed to automatically adjust the position of one or more permanent magnets 58 on the motion reversal side of scanning table 18 . It should be noted that magnet drive system 60 can be mounted upon bridge system 52 , thus allowing the assistive forces to be conducted to the ground without disturbing scanning table 18 and/or isolated base 14 .
[0053] Sizing of Magnets
[0054] In some embodiments, magnet assisted stage system 10 can be compact yet provide assistive forces of at least 525 N (the maximum inertial force requirement) to scanning table 18 at the minimum gap allowed between permanent magnets 58 . Therefore, in some embodiments, a 2-D Halbach arrangement, which is well-known to provide high force densities, can be employed.
[0055] A simplified Coulombian model is used to estimate the magnetic force between the two Halbach arrays for sizing purposes. FIG. 4A depicts the interaction between the surfaces (of dimension a x a) of two magnets, based on the Coulombian model. cx i , cy i , and cz i are respectively the x, y and z coordinates of the center of each surface (i=1, 2). The equation describing the force F between the two magnetized surfaces is given by
[0000]
F
=
σ
1
σ
2
a
2
4
πμ
0
∫
cy
1
-
a
/
2
cy
1
+
a
/
2
∫
cx
1
-
a
/
2
cx
1
+
a
/
2
p
1
,
2
p
1
,
2
3
x
1
y
1
(
5
)
[0056] with position vector p 1,2 expressed as
[0000] p 1,2 =( cx 2 −x 1 ) i +( cy 2 −y 1 ) j +( cz 2 −cz 1 ) k (6)
[0057] where μ 0 =4π×10 −7 H/m is the permeability of free space and σ is magnetic flux density of each surface. In some embodiments, 21 N42 grade NdFeB PM cubes with |σ|=1.32 T are used to construct each Halbach array (permanent magnet 58), as illustrated in FIG. 4B . The net force between the two arrays at a given distance can be found by summing the forces between all the magnetized surfaces of the two arrays. Permanent magnet dimension a=7.9375 mm ( 5/16 in.) is predicted to meet the assistive force requirements of the stage using two identical Halbach arrays for each permanent magnet (i.e., there are a total of four arrays for each passive assist device).
[0058] Controller Design
[0059] In some embodiments, a cascaded P/P| feedback (FB) controller with velocity and acceleration feed forward (FF) is used to control the position of scanning table 18 . It can be implemented using a real time controller running at 10 kHz sampling frequency to achieve a closed loop bandwidth of about 290 Hz. Additional feed forward permanent magnet force and disturbance compensators are implemented to reject known disturbances as illustrated in the block diagram of FIG. 5 . The role of the permanent magnet force compensator is to cancel the spill-over assistive forces in the constant velocity region of each scan, based on the measured F PM (d) curve of the permanent magnets. The disturbance force compensator cancels out the position and velocity dependent disturbance force ripples associated with the linear motor.
EXPERIMENTAL RESULTS
[0060] FIG. 6A illustrates an in-house-built prototype of magnet assisted stage system 10 as described herein. The predicted and experimentally measured F PM (d) curves of each passive assist device are illustrated in FIG. 6B . They are in good agreement and confirm that the stage is capable of providing the needed maximum assistive force (525 N) at a gap of 3.2 mm between the magnets while providing less than 4 N of assistive force at a gap of 30 mm.
[0061] The trapezoidal acceleration scan trajectory whose velocity profile is illustrated in FIG. 7A is used to demonstrate the performance of the stage. The parameters of the trajectory are summarized in Table 2. The minimum distance between the permanent magnets of the passive assist device is determined as 3.3 mm based on minimizing heat using the method discussed herein.
[0000]
TABLE 2
Parameters used in reference trajectory generation
Parameter
Value
Max. jerk
500
m/s 3
Max. acceleration
25 m/s 2
(2.5 g)
Scan speed
0.5
m/s
Scan stroke
200
mm
d min
3.3
mm
[0062] FIGS. 7B, 7C, and 7D , respectively, show the measured motor force F M , position tracking error, and residual vibration of the isolated base 14 in the horizontal direction (x-axis). High frequency contents of the position error signal have been filtered using a 10 ms-window moving average filter, as is customary in wafer scanning applications. When there is no passive assist device, F M equals 123 N RMS . However, when using magnet assisted stage system 10 located at the calculated optimal location, F M drops to 63 N RMS (i.e., 49% reduction). Consequently, using K M =15.13 NW −0.5 , the Joule heating of the linear motors is calculated from Eq. (1) to decrease from 48.4 J to 21.8 J (i.e., 55% reduction), per scan period, with the help of the proposed passive assist devices. By the same token, the RMS value of a B,x , the residual vibration of the base in the x-direction, drops from 0.492 m/s 2 to 0.169 m/s 2 (i.e., 66% reduction). This leads to a 55% decrease in settling time from 290 ms to 130 ms, using a 50 nm position error window.
[0063] Conclusions
[0064] Accordingly, magnet assisted stage system 10 has been shown to reduce motor heat and residual vibration for scanning applications. Assistive forces are applied to the scanning table during motion reversal (MR) regions using a pair of repelling permanent magnets (PMs) at each end of the stage. The assistive forces provided by the PMs are channeled to the ground, rather than to the vibration-sensitive machine base, thus reducing residual vibration and enhancing scanning speed. The position of the PMs relative to each other is designed to be adjustable so that they can be configured to minimize heat or vibration. Using PMs to provide assistive forces has the added advantage of reducing the ground vibration transmitted to the scanning table during high precision constant velocity scanning, because of the nonlinear force-distance curve of PMs. Experiments conducted on a prototype stage constructed based on the present invention demonstrate excellent results with regard to both vibration and heat reduction.
[0065] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically illustrated or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
|
A magnet assisted stage system for scanning applications having a scanning table being moveable from a first position to a second position, a scanning actuator operably associated with the scanning table to move the scanning table along a scanning direction from the first position to the second position, and an actively variable magnetic spring system being operably augmented to the scanning table to exert a magnetic repulsion force upon the scanning table in the scanning direction.
| 5
|
FIELD OF THE INVENTION
The present invention relates to a system for sensing and automatically controlling the orientation of a work tool pivotally attached to an extendable dipperstick of a backhoe, such as a backhoe bucket having telehandler tool features.
BACKGROUND OF THE INVENTION
A variety of work machines can be equipped with tools for performing a work function. Examples of such machines include a wide variety of loaders, excavators, telehandlers, and aerial lifts. A work vehicle such as a backhoe loader with an extendable dipperstick may be equipped with a tool, such as a backhoe bucket having telehandler tool features, for material handling functions. A swing frame pivotally attaches to the frame of the vehicle, a boom pivotally attaches to the swing frame, an extendable dipperstick pivotally attaches to the boom, and the tool pivotally attaches to the extendable dipperstick about a bucket pivot. A vehicle operator controls the orientation of the tool relative to the dipperstick by a tool actuator. The operator also controls the rotational position of the boom and dipperstick, as well as the translational extension of the dipperstick, by corresponding actuators. The aforementioned actuators are typically comprised of one or more double acting hydraulic cylinders and a corresponding hydraulic circuit.
During a work operation with a telehandler tool, such as lifting and moving baled material or palettes, it is desirable to maintain an initial tool orientation relative to gravity as the items are moved from one location to another. To maintain the initial tool orientation relative to gravity, where the tool is a backhoe bucket having telehandler tool features, the operator is required to continually manipulate a backhoe bucket command input device to adjust the tool as the backhoe boom and dipperstick are moved during the work operation. The continual adjustment of the tool orientation, combined with the simultaneous manipulation of a backhoe boom command input device, a dipperstick extension command input device, and a dipperstick command input device inherent in movement of the backhoe boom and dipperstick, requires a degree of operator attention and manual effort that diminishes overall work efficiency and increases operator fatigue.
A number of mechanism and systems have been used to automatically control the orientation of a tool such as a backhoe bucket. Various examples of electronic sensing and control systems are disclosed in U.S. Pat. Nos. 4,923,326, 4,844,685, 5,356,260, and 6,233,511. Control systems typical of the prior art utilize position sensors attached at various locations on the work vehicle to sense and control tool orientation relative to the vehicle frame.
A number of angular velocity sensors suitable for use in the present invention are commercially available. Examples of these types of angular velocity sensor are disclosed in U.S. Pat. Nos. 4,628,734, 5,850,035, 6,003,373. One example of such an angular velocity sensors is the BEI GYROCHIP® Model AQRS, marketed by the Systron Donner Internal Division of BEI Technologies of California.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved system for sensing and automatically controlling the orientation of a tool pivotally attached to an extendable dipperstick of a backhoe or excavator.
The system automatically controls work tool orientation by making use of an angular velocity sensor attached to the tool to sense angular velocity of the tool about its pivot. The present invention comprises a backhoe, a swing frame pivotally attached to the frame of the backhoe, a boom pivotally attached to the swing frame, an extendable dipperstick pivotally attached to the boom, a tool pivotally attached to the extendable dipperstick, an actuator for controllably moving the tool about its pivot, and the aforementioned angular velocity sensor. A controller processes data from the angular velocity sensor and commands movement of the tool actuator in response. The preferred embodiment also includes a tool command input device to affect movement of tool actuator, and a tool auto-hold command input device to enable a tool auto-hold function for maintaining the tool in an initial orientation.
When the tool auto-hold function is enabled, the controller maintains the tool orientation by commanding the tool actuator to move the tool such that the angular velocity sensed about the tool pivot is zero. The controller is adapted to discontinue the tool auto-hold function when the operator manipulates the tool command input device to affect tool movement. The controller resumes tool auto-hold function once the operator discontinues manipulation of the tool command input device, reestablishing the initial tool orientation at the new orientation affected by the operator. Additionally, the operator may manipulate an auto-hold command input device to selectively enable and disable the tool auto-hold function.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a backhoe loader.
FIG. 2 is a schematic diagram of a loader bucket orientation sensing and automatic control system.
FIG. 3 is a schematic diagram of a backhoe bucket orientation sensing and automatic control system for a backhoe with an extendable dipperstick.
DETAILED DESCRIPTION
FIG. 1 illustrates a self-propelled work vehicle, such as a backhoe loader 10 . A backhoe loader 10 has a frame 12 , to which are attached ground engaging wheels 14 for supporting and propelling the vehicle. Attached to the front of the vehicle is a loader assembly 16 , and attached to the rear of the vehicle is a backhoe assembly 18 . Both the loader assembly 16 and backhoe assembly 18 each perform a variety of excavating and material handling functions. An operator controls the functions of the vehicle from an operator's station 20 .
The loader assembly 16 comprises a loader boom 22 and a tool such as a loader bucket or other structure 24 . The loader boom 22 has a first end 26 pivotally attached to the frame 12 about a horizontal loader boom pivot 28 , and a second end 30 to which the loader bucket 24 pivotally attaches about a horizontal loader bucket pivot 32 .
A loader boom actuator, having a loader boom hydraulic cylinder 36 extending between the vehicle frame 12 and the loader boom 22 , controllably moves the loader boom 22 about the loader boom pivot 28 . A loader bucket actuator 38 , having a loader bucket hydraulic cylinder 40 extending between the loader boom 22 and the loader bucket 24 , controllably moves the loader bucket 24 about the loader bucket pivot 32 . In the illustrated embodiment, the loader bucket actuator 38 comprises a loader bucket electro-hydraulic circuit 42 hydraulically coupled to the loader bucket hydraulic cylinder 40 . The loader bucket electro-hydraulic circuit 42 supplies and controls the flow of hydraulic fluid to the loader bucket hydraulic cylinder 40 .
The operator commands movement of the loader assembly 16 by manipulating a loader bucket command input device 44 and a loader boom command input device 46 . The loader bucket command input device 44 is adapted to generate a loader bucket command signal 48 in response to manipulation by the operator, proportional to a desired loader bucket movement. A controller 50 , in communication with the loader bucket command input device 44 and loader bucket actuator 38 , receives the loader bucket command signal 48 and responds by generating a loader bucket control signal 52 , which is received by the loader bucket electro-hydraulic circuit 42 . The loader bucket electro-hydraulic circuit 42 responds to the loader bucket control signal 52 by directing hydraulic fluid to the loader bucket hydraulic cylinder 40 , causing the hydraulic cylinder 40 to move the loader bucket 24 accordingly.
During a work operation with the loader bucket 24 , such as lifting or transporting material, it is desirable to maintain an initial loader bucket orientation relative to gravity to prevent premature dumping of material. To maintain the initial loader bucket orientation as the loader boom 22 is moved relative to the frame 12 during a lifting operation, and as the vehicle frame 12 changes pitch when moving over uneven terrain during a transport operation, the operator is required to continually manipulate the loader bucket command input device 44 to adjust the loader bucket orientation. The continual adjustment of the loader bucket orientation requires a degree of operator attention and manual effort that diminishes overall work efficiency and increases operator fatigue.
FIG. 2 illustrates an improved actuator control system adapted to automatically maintain an initial loader bucket orientation. The present invention makes use of an angular velocity sensor 54 attached to the loader bucket 24 , in communication with the controller 50 . The loader bucket angular velocity sensor 54 is adapted to sense angular loader bucket velocity relative to the loader bucket pivot 32 and to continuously generate a corresponding angular velocity signal 56 . The controller 50 is adapted to receive the angular loader bucket velocity signal 56 and to generate a loader bucket control signal 52 in response, causing the loader bucket actuator 38 to move the loader bucket 24 to achieve a desired loader bucket angular velocity. Where the object of the invention is an auto-hold function to maintain the initial loader bucket orientation set by the operator, relative to gravity, the desired angular loader bucket velocity is zero. Additionally, the controller 50 is adapted to suspend the auto-hold function when the operator commands movement of the loader bucket 24 when receiving the loader bucket command signal 48 , and reestablishing the initial loader bucket orientation as the orientation of the loader bucket 24 immediately after the loader bucket command signal 48 terminates.
In applications requiring greater precision in maintaining the initial loader bucket orientation, the controller 50 , having computational and time keeping capabilities, is adapted to solve the integral for the loader bucket angular velocity as a function of time to determine deviation from the initial loader bucket orientation. The controller 50 is adapted to generate a loader bucket control signal 52 in response to deviation exceeding a desired loader bucket orientation deviation, causing the loader bucket actuator 38 to move the loader bucket 24 to achieve the desired loader bucket orientation deviation. Where the object of the invention is an auto-hold function to maintain the initial loader bucket orientation set by the operator, relative to gravity, the desired loader bucket orientation deviation is approximately zero. Additionally, the controller 50 is adapted to discontinue responding for the desired angular loader bucket velocity when responding for the desired loader bucket orientation deviation.
In the illustrated embodiment, the present invention also utilizes a loader auto-hold command switch 58 in communication with the controller 50 . The loader auto-hold command switch 58 is adapted to generate a loader auto-hold command signal 60 corresponding to a manipulation of the loader auto-hold command switch 58 by the operator to enable operation of the auto-hold function for the loader bucket 24 . The controller 50 is adapted to ignore the angular loader bucket velocity signal 56 unless receiving the loader auto-hold command signal 60 from the loader auto-hold command switch 58 .
The backhoe assembly 18 comprises a swing frame 62 , a backhoe boom 64 , an extendable dipperstick 66 , and a tool such as a backhoe bucket 68 having telehandler tool features. The swing frame 62 has a first end 70 pivotally attached to the frame 12 about a vertical pivot 72 , and a second end 74 . The backhoe boom 64 has a first end 76 pivotally attached to the second end 74 of the swing frame 62 about a horizontal backhoe boom pivot 78 , and a second end 80 . The extendable dipperstick 66 has a first end 82 pivotally attached to the second end 80 of the backhoe boom 64 about a horizontal dipperstick pivot 84 , and a second end 86 translationally extendable relative the first end 82 , to which the backhoe bucket 68 pivotally attaches about a horizontal backhoe bucket pivot 88 .
A swing frame actuator, having a swing frame hydraulic cylinder 90 extending between the vehicle frame 12 and the swing frame 62 , controllably moves the swing frame 62 about the vertical pivot 72 . A backhoe boom actuator, having a backhoe boom hydraulic cylinder 92 extending between the swing frame 62 and the backhoe boom 64 , controllably moves the backhoe boom 64 about the backhoe boom pivot 78 . A dipperstick actuator, having a dipperstick hydraulic cylinder 94 extending between the backhoe boom 64 and the dipperstick 66 , controllably moves the dipperstick 66 about the dipperstick pivot 84 . A dipperstick extension actuator, having a dipperstick extension hydraulic cylinder 95 extending between the first end 82 of the dipperstick and the second end 86 of the dipperstick, controllably extends the second end 86 of the dipperstick relative to the first end 82 . A backhoe bucket actuator 96 , having a backhoe bucket hydraulic cylinder 98 extending between the dipperstick 66 and the backhoe bucket 68 , controllably moves the backhoe bucket 68 about the backhoe bucket pivot 88 . In the illustrated embodiment, the backhoe bucket actuator 96 comprises a backhoe bucket electro-hydraulic circuit 100 , in connection the backhoe bucket hydraulic cylinder 98 , which supplies and controls the flow of hydraulic fluid to the backhoe bucket hydraulic cylinder 98 .
The operator commands movement of the backhoe assembly 18 by manipulating a backhoe bucket command input device 102 , a dipperstick command input device 104 , a dipperstick extension command input device 105 , a backhoe boom command input device 106 , and a swing frame command input device. The backhoe bucket command input device 102 is adapted to generate a backhoe bucket command signal 108 in response to manipulation by the operator, proportional to a desired backhoe bucket movement. The controller 50 , in communication with the backhoe bucket command input device 102 , dipperstick command input device 104 , dipperstick extension command input device 105 , backhoe boom command input device 106 , and backhoe bucket actuator 96 , receives the backhoe bucket command signal 108 and responds by generating a backhoe bucket control signal 110 , which is received by the backhoe bucket electro-hydraulic circuit 100 . The backhoe bucket electro-hydraulic circuit 100 responds to the backhoe bucket control signal 110 by directing hydraulic fluid to the backhoe bucket hydraulic cylinder 98 , causing the hydraulic cylinder 98 to move the backhoe bucket 68 accordingly.
During a telehandler work operation with a backhoe bucket 68 having telehandler tool features 150 for lifting and moving baled material or palettes, it is desirable to maintain an initial tool orientation relative to gravity as the items are moved from one location to another. To maintain the initial backhoe bucket orientation relative to gravity, the operator is required to continually manipulate the backhoe bucket command input device 102 to adjust the backhoe bucket orientation as the backhoe boom 64 and dipperstick 66 are moved during the work operation. The continual adjustment of the backhoe bucket orientation, combined with the simultaneous manipulation of the backhoe boom command input device 106 , the dipperstick extension command input device 105 , and the dipperstick command input device 104 inherent in movement of the backhoe boom 64 and dipperstick 66 , requires a degree of operator attention and manual effort that diminishes overall work efficiency and increases operator fatigue.
FIG. 3 illustrates an actuator control system adapted to automatically maintain an initial orientation backhoe bucket having telehandler tool features 150 . The present invention makes use of an angular velocity sensor 112 attached to the backhoe bucket 68 , in communication with the controller 50 . The backhoe bucket angular velocity sensor 112 is adapted to sense angular backhoe bucket velocity relative to the backhoe bucket pivot 88 and to continuously generate a corresponding angular velocity signal 114 . The controller 50 is adapted to receive the angular backhoe bucket velocity signal 114 and to generate a backhoe bucket control signal 110 in response, causing the backhoe bucket actuator 96 to move the backhoe bucket 68 to achieve a desired angular backhoe bucket velocity. Where the object of the invention is an auto-hold function to maintain the initial backhoe bucket orientation set by the operator, relative to gravity, the desired angular backhoe bucket velocity is zero. Additionally, the controller 50 suspends the auto-hold function while the operator commands movement of the backhoe bucket 68 when receiving the backhoe bucket command signal 108 , and reestablishes the initial backhoe bucket orientation as the orientation of the backhoe bucket 68 immediately after the backhoe bucket command signal 108 terminates.
The present invention also utilizes a backhoe auto-hold command switch 116 in communication with the controller 50 . The backhoe auto-hold command switch 116 is adapted to generate a backhoe auto-hold command signal 118 corresponding to a manipulation of the backhoe auto-hold command switch 116 by the operator to enable operation of the auto-hold function for the backhoe bucket 68 . The controller 50 is adapted to ignore the angular backhoe bucket velocity signal 114 unless receiving the backhoe auto-hold command signal 118 from the backhoe auto-hold command switch 116 .
Having described the illustrated embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims.
Assignment
The entire right, title and interest in and to this application and all subject matter disclosed and/or claimed therein, including any and all divisions, continuations, reissues, etc., thereof are, effective as of the date of execution of this application, assigned, transferred, sold and set over by the applicant(s) named herein to Deere & Company, a Delaware corporation having offices at Moline, Ill. 61265, U.S.A., together with all rights to file, and to claim priorities in connection with, corresponding patent applications in any and all foreign countries in the name of Deere & Company or otherwise.
|
The invention comprises a backhoe with a tool pivotally attached to an extendable dipperstick, an actuator for controllably moving the tool about its pivot, and an angular velocity sensor for sensing the angular velocity of the tool about its pivot. A controller is adapted to perform a tool auto-hold function, automatically maintaining an initial tool orientation by processing the angular velocity data and commanding movement of the tool actuator to hold the angular velocity at zero. The controller is adapted to discontinue the tool auto-hold function when the operator manipulates a tool command input device affecting tool actuator movement, and resume the tool auto-hold function at the new orientation affected by the operator. Manipulation of an auto-hold command input device allows the operator to selectively enable and disable the tool auto-hold function.
| 4
|
DESCRIPTION
The present invention relates especially to a method for creating an ice slab for ice skating, curling or sliding wherein the outdoor ambient conditions of temperature and humidity exist over the entire rink site even though the ice slab is covered to protect it from direct sun, snow and rain.
It has always been found that to hold ice all year around in a covered outdoor environment of this type is virtually impossible and certainly impractical (a) because the amount of refrigeration tonnage required goes way up as warmer, more humid weather arrives, (b) because dripping from the ceiling becomes very annoying building lumps on the ice surface where it lands on the ice, and (c) because on warm days of high humidity fog covers the ice floor and the air becomes uncomfortably clammy. Therefore such ice skating rinks, curling rinks, or refrigerated toboggan slides have always been seasonal in operation.
Today the demand for ice has become a year-round thing largely because of summer ice hockey and figure skating schools and practice sessions, and it is much easier to keep good operating personnel if they are given year-round jobs instead of only for part of a year. Time is rented out by the hour and frequently such rinks are busy 24 hours per day even in the summer.
The cost of totally enclosing a covered ice area, providing heating and dehumidification, adding refrigeration tonnage and extra lighting, and the general sprucing up to be competitive with indoor arena, has been found to be very expensive. Furthermore, there may be zoning restriction, requirements for more parking space, and loss of an attractive, rustic, outdoor-type atmosphere that brings out many general skaters. In fact the Bureau of Outdoor Recreation will provide matching funds for unenclosed ice rinks but not for enclosed ones, and this is very influential with municipalities who want to have ice rinks since this money, raised from the admission fees to the National Parks, makes significant economic difference.
The present invention makes possible holding ice at summer conditions (1) without increasing refrigeration tonnage, (2) without dripping from the ceiling and (3) generally without fogging. It also (4) eliminates wet ice and (5) reduces energy consumption during the winter season. Further, (6) the amount of energy required for adequate illumination is reduced.
I have found that the heat load on a slab of ice on a covered arena is only one to five percent by conduction of heat from the sides or underneath, is thirty to seventy percent by convection including primarily condensation, and is, surprisingly, 30 to 70 percent by radiation. The prior art and technical literature do not recognize the large effect of radiation and reradiation of heat from the roof or ceiling over an ice rink to the ice.
While some of this radiation is from lights, the large majority of it is from rereadiation of radiant energy which has fallen on the roof exterior or from the radiation to the ice of heat which the ceiling has gained through convection both inside and out.
It is well known that radiant energy is transferred proportional to the fourth power of the absolute temperature and thus as the temperature differential increases, radiant heat transfer becomes a rapidly increasing factor.
In an ice rink arena the large area of ice on the floor is at about 25° F, and the roof or air directly under the roof may be 75° to 100° F or even higher depending on the weather and climate. Thus the temperature differential may be far higher than in an air conditioned space, and the effect or radiant heat transfer will change from a minor one to a very major effect.
Radiation is further directly controlled by the coefficient of "emissivity", the measure of each material's relative ability to radiate compared to a perfect black body. In looking at published tables of emissivity one observes that paint, plaster, brick, cement, mortar, cinder block, stone, wood, asbestos, paper, glass, in short almost any material you would find on an interior surface, have a coefficient above 80 percent. Even white lacquer paint is 80 percent.
However, a tremendous exception to this is aluminum where an oxidized sheet would be about nine percent and polished aluminum foil wound be 4 to 5 percent. Certain expensive metals in polished state are equivalent such as bronze and copper, with polished gold being about two percent. Since aluminum foil is inexpensive, easy to handle and is already used as a facing for insulation materials and as a radiant insulation material itself, it is an advantageous choice.
The invention in one of its aspects provides a method of greatly reducing the flow of radiant energy into the ice slab of a covered ice arena by creating a downward facing surface of aluminum foil over the ice spaced at least 10 feet above the ice. This aluminum suspended ceiling may have air intake openings as will be explained further below.
The reason there is dripping from the ceiling or support members over many prior art ice rinks is because the surface of the ceiling or support members radiate strongly to the ice as caused by their high emissivity values and thus get much cooler because of the loss of heat by radiation. These prior art surfaces reach an equilibrium temperature where the heat flow lost by radiation will be balanced by the heat flow gained by conduction from the roof and convection from the surrounding air and also perhaps by some heat flow gained through radiation from light fixtures. If this temperature is below the dewpoint in the upper part of the arena, condensation will take place and eventually cause dripping.
When the surface has a low emissivity and does not radiate heat to the ice appreciably, the surface does not get cooler and will not go below the dewpoint and consequently will not drip. Also it follows that since the ceiling surface does not get wet, the deterioration of the surface and the materials behind it will not occur as it will when the ceiling is often wet.
In addition to reducing radiant heat flow toward the ice from the covering, this invention includes as part of its method painting the ice with a white reflective paint in order to reflect as much of the remaining radiant energy as possible. This paint is a water-base white paint and is painted over the entire ice surface by spray, brush, drag, mop, or ice resurfacing machine before the ice has reached its desired thickness. After the paint is dry and frozen, more ice is built on top of the paint to a total thickness of about one to two inches to provide paint-free ice for the final skating surface.
This white painted layer procedure in and of itself is not new and is done on many indoor hockey rinks for better appearance and so that visibility of the hockey puck and skaters will be better. However, I have found that used in conjunction with the other steps of this invention they enable economic maintenance of ice during warm months, for the white painted layer is also a step in eliminating radiant heat gain to the ice from extraneous sources such as lights and windows. White paint is very reflective of radiant heat emitted from high temperature sources such as electric lights and the sun, although it is not as good for radiant heat from low temperature sources such as the ceiling and walls.
Furthermore by having a highly reflective aluminum ceiling and a highly reflective white-painted ice floor, the amount of lighting required will be greatly reduced and thus the flow of radiant energy from lights will be less. Safety will be aided because glare is reduced and vision improved by having light come from a wide area of reflective materials rather than discreet sources of light as is commonly done. I have found in experimenting with a full size rink that the installation of an aluminum ceiling and painting the ice white reduced the lighting required by 50% and the refrigeration tonnage by 30%.
Fogging is caused by moisture laden warmer air coming in contact with the colder air stratified over the ice surface. Colder air being heavier tends to settle and remain over the ice. When the moist warmer air encounters the colder air, its ability to hold moisture is reduced, as is well known, and when the temperature falls below the dewpoint fog is formed. In an indoor enclosed rink it is possible to exclude most of the humid outdoor air while the air inside is dryed by condensation on the ice surface or in a dehumidifier. In a covered unenclosed rink humid air is free to enter the area.
To eliminate fogging without excessive condensation on the ice surface it is important to limit the amount of flow of outdoor air onto the ice and yet to provide enough air movement to prevent the stratification of the colder air. The former is done by erecting a perimeter solid fence around the ice surface, such as the usual hockey "dasher" boards and preferably increasing the height of this by transparent panels of plastic or shatter-proof glass, as is also common. The controlled air movement to prevent stratification is by fans which pull air from the area over the ice through openings in the aluminum suspended ceiling into the space above the suspended ceiling where it is warmed by the accumulated heat under the roof. This air will then either be discharged outside or be delivered back down around the outside of the suspended ceiling or through other openings in the said ceiling. This recirculation will reduce stratification and will prevent fogging.
An alternate method is to deliver air through openings in the perimeter boards which has been dryed by coming in contact with the cold brine piping in the header trench. The brine pipes are between 10° and 25° F and when air is blown across them condensation will occur which can be drained away. This dryer cooler air will escape into the area low over the ice through openings or joints in the perimeter boards, thus displacing moister air and dispelling fog.
Referring back to the control of radiation, I have also found that the method of creating low emissivity and high reflectivity above the ice and high reflectivity within the ice will greatly reduce the amount of energy required to freeze and maintain the ice slab regardless of whether the ice rink area is totally enclosed or not.
THE DRAWINGS
Referring to the drawings:
FIG. 1 is an overall cut-away perspective view of a full size skating roof under a typical peak roof open-sided building with a horizontal suspended ceiling covering the ice rink and perimeter dasher boards below;
FIGS. 2 and 3 show two types of suspended ceilings similar to present commercial manufacture, FIG. 2 showing painted metal panels hung from wires supporting fiberglass insulation bats and clipped together at their bent up edges by snap-on metal strips, FIG. 3 showing metal T-bars hung from wires supporting rigid panels of sheet rock, fiber board, fiberglass, cellulose fiber, or plastic foam, with aluminum foil facing on the lower side of the panels;
FIG. 4 is a cross-sectional view of the ice rink, the roof with open sides, the suspended ceiling, ventilating fans, lights, brine piping and headers, and refrigeration equipment and recirculating pump;
FIG. 5 shows a perspective detail of the header box attached to the dasher boards, the headers and brine piping, and the blower for supplying dehumidified air, and drain;
FIG. 6 shows application of an aluminum suspended ceiling in a totally enclosed arena building; and
FIG. 7 shows an aluminum foil liner attached to the inside of an air-supported structure or tent.
DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS
Referring now to the drawings in greater detail, FIG. 1 illustrates a conventional clear span peak roof structure 12 with internal steel truss supporting members 14 supported on columns 16 completely covering a conventional ice rink surrounded with perimeter hockey dashers boards 18. The roof is exposed to solar and sky radiation 20 and convectional heat transfer from wind currents 22 both inside and out. The ice 24 is exposed to radiation from the roof overhead made of normal materials of construction. In the present invention a suspended ceiling 26 of low emissivity and high reflectivity is interposed below the roof support member 14 suspended by wires 28 fastened to members 14.
In FIG. 2 one form of the detail of the suspended ceiling 26 of FIG. 1 is shown. Aluminum metal trays 30 are held together at their edge flanges 32 by metal locking clips 34 and suspended by wires 28 in common fashion. However, the lower surfaces of trays 30 which is the surface directly exposed over the ice is bare aluminum without paint or anodizing or other protective finish. Insulation bats 36 of a light material such as fiberglass rest in the trays to provide conductive insulation on the upper side of the suspended ceiling.
FIG. 3 shows an alternative form of ceiling 26 in which wires 28 suspend inverted "T" bars 38 also made of unpainted aluminum. Panels 40 of a lightweight rigid material, for example, sheet rock, fiber board, fiberglass, cellulose fiber or plastic foam, nest in the angles of the "T" bars to form a suspended ceiling in a common manner. However, the lower surface of panels 40 is covered with bare aluminum foil 42 so that the surface facing the ice below is aluminum. A layer of insulation 36, for example such as fiberglass bats, may be included above the panels.
The surface of reflective aluminum 42 facing downwardly has been described as bare aluminum foil. As an alternative this downward-facing reflective aluminum surface 42 may be formed by a layer of paper or of plastic, for example such as Mylar, coated with a film of aluminum so as to provide a low emissivity, high reflectivity surface. Thus, as used herein the term "surface of reflective aluminum" or "reflective aluminum surface" is intended to include these alternative surfaces 42 (FIG. 3).
FIG. 4 is a cross-sectional view of FIG. 1 also showing additional detail. Peak roofed building 12 is shown supported on open posts 16. The suspended ceiling 26 has vertical blowing fans 44 mounted in openings in ceiling 26 to circulate air from over the rink ice surface 24 to the space above ceiling 26 whence it will return through edge openings 46, fixture openings 47 or be blown outside by ventilation blower 48 in the upper end wall of building 12. Ice is maintained on the rink surface 24 by refrigerant circulated through conventional piping 52 connected in parallel loops to supply header 54 and return header 56. The refrigerant is supplied by a conventional refrigeration machine 58 and recirculating pump 60 mounted in machine room 62 in the usual manner.
Lighting is obtained from lighting fixtures 66 suspended by members 68 so as to be positioned below the level of the bare aluminum (FIGS. 2 and 3). These fixtures 66 are designed to project the light upwardly and to reflect light indirectly upward and along the reflective aluminum ceiling 26 as indicated by the arrows and, as indicated by arrow 69, to rereflect light from just below surface of ice floor 24 which is painted with a white water base paint 70 (FIG. 5) just below the upper ice slab 72 of FIG. 5. This rereflected light 69 bounces off ice and ceiling in all directions advantageously creating glareless illumination, much greater efficiency of lighting with less energy consumed, and less radiant energy striking and being absorbed by the ice, thereby reducing the use of energy in the refrigeration equipment.
The ice surface is bounded by a solid fence 18 which may serve as a "dasher" board for ice hockey. Additionally a transparent fence 19 may be added above the dasher boards to afford protection from being hit by flying hockey pucks and still permit vision of the game or of friends and neighbors who are skating.
FIG. 5 shows an enlarged detail view of the ice floor 24 made up of ice slab 72, ice white paint layer 70, refrigeration pipes or tubes 52, and supporting base sand, concrete or equivalent 74. Perimeter boards 18 enclose the ice surface and header box 76 encloses the header pipes along one side or end of the ice rink. One or more blowers 80 may be positioned to supply air into header box 76 for dehumidifying this air for the purpose of disspelling fog in humid weather. The air delivered into the box 76 will travel over and along cold header pipes 54 and 56 with its moisture condensing on these pipes and dripping off into drain pipe 82. While some of the condensation may freeze into frost on the header pipes, this will be prevented from building up too thick by the inherent insulation value of the frost and also by applying a specific insulation barrier 55 around the pipes, particularly colder supply pipe 54. The air having been cooled and having lost much of its moisture then passes out, as shown at 57, over the ice through opening cracks between parts of the fence 18. Other joints of the header box are sealed to insure the dry air going primarily as indicated at 57 to the ice. This dryer air over the ice will disspell fog and will reduce condensation on the ice surface, keeping the ice of better quality between times of resurfacing and refreezing.
FIG. 6 shows a similar ice arena but with the building totally enclosed with solid side walls 86. While the problem of holding ice in warm humid weather is far less severe in an enclosed building because temperature and humidity may be controlled by well known methods, I have found that a great energy saving may nontheless be made by use of the low emissivity-high reflectivity ceiling 26 combined with the highly reflective ice floor 24. The description of FIG. 4 will apply to the arena of FIG. 6, except that openings for air movement 44 to the space above the ceiling should be louvered to prevent air from passing through when ventilation is not required. Also ceiling 26 should be insulated on the upper side with insulation bats 36 as shown in FIG. 2 and FIG. 3.
FIG. 7 shows an air supported structure 90, commonly known as a "bubble", held up by pressure from a blower 92. In this case outdoor air is continually blown in through the blower so humid conditions prevail much of the time. An aluminum foil inner skin 94 acts to provide the low emissivity which stops the overpowering effect of reradiation from the bubble wall 90. This skin may be laminated to the wall or may be fastened as a drape at intermittent points to provide an air pocket between and to reduce stress on the inelastic aluminum surface. The radiant load on the ice in a bubble is higher than in permanent structures because of the lack of insulation value against solar heat. Even though the exterior surface may be colored white to obtain as high a reflectivity of solar radiation as possible, the outer surface soon becomes gray and dirty and becomes highly absorbent of solar radiation.
Except for radiant energy, as stated earlier, the primary heat load on the ice is by convection. However, I have found that this convection effect is actually a much different physical mechanism than usually conceived. It is not primarily the motion of warm dry air impinging against the ice causing heat flow into the ice, although this is present to a degree. This warm air impingement effect is countered by evaporative cooling of the ice by sublimation of the ice directly from ice to water vapor or evaporation from a wet surface to water vapor absorbed in the impinging air.
The primary heat load on the ice, other than radiation, is the condensation of water vapor from the adjacent layer of air immediately in contact with or close to the ice and the subsequent freezing of this condensation. This condensation and freezing effect may be considered to take place as a single transition, i.e. condensation and freezing both effectively occurring all at one time, a sort of reverse sublimation; and this effect is usually called "frosting", or "frosting up". Thus the data, tables and curves available in the literature on ice rinks, such as in Chapter 56, entitled Ice Skating Rinks, of the Volume on Applications of the Guide and Data Book of the American Society of Heating, Refrigerating and Air Conditioning Engineers, 1974, page 56.3; FIG. 3 gives the required tonnage, or refrigeration capacity, to freeze a given number of square feet of ice rink surface, in terms of wet bulb temperature rather than the normal dry bulb temperature. Inspection of these curves will show a very close and critical relation between wet bulb temperature and tonnage.
For example at 55° Fahrenheit wet bulb temperature one ton of refrigeration (12000 Btuh) will only hold 125 square feet of ice in a heavily used indoor ice rink, while at 45° one ton will hold 264 square feet, or over twice as much.
Thus it can be seen that if dryer air is kept closely adjacent to the ice surface the heat load on the ice will be far less and it will not matter how warm the air may be at a distance away from the ice. Dry air will tend to settle and stratify adjacent to the ice if it is cooler, that is heavier, and if protected and confined by a boundary solid fence and therefore, dry cold air can be used to great advantage to isolate the ice and exclude warm moist air from the ice.
Condensation of water vapor from the air, that is dehumidification, as distinct from "frosting" or "frosting up" is more efficiently done in a separate mode, that is, away from the ice floor itself, because, first, it is not frozen which would require release of the moisture's heat of fusion into the ice floor, but rather the water vapor condenses to liquid in a separate device and is drained away as water; second, this remote removal of water vapor, i.e. dehumidification, avoids the problem of formation of frost on the ice floor which has to be scraped off and new warm water refrozen to get smooth ice again, and, third, the efficiency of remote dehumidification is so much better where there is a fan and velocity rather than the unnatural convection produced by ice on a floor. That is, the air becomes cooled by the ice and tends to stay there instead of moving away, somewhat like a temperature inversion in the atmosphere.
To understand what I mean by unnatural convection consider what would happen if the ice were on the ceiling. Then, the air would lose its moisture to the ice above it, be cooled, and sink away to be replaced by warm moist air again. But on a floor this circulation does not happen except by the haphazard convection caused by skaters.
Ice on a floor will not generally lower the wet bulb temperature below about 55° F while a separate dehumidifying device with a blower can easily bring it down to 45° F.
Thus it can be seen from this analysis that remote dehumidifying does not add refrigeration lead, but actually decreases it and is employed to advantage as one of several steps for reducing energy requirements.
A typical installed tonnage for a usual year-round indoor ice rink is 105 tons to cover peak load conditions. Under such conditions we could assume the conductive load might be about 5% or 5 tons, the radiant load would be 50 tons (45 tons from the ceiling, 5 tons from the lights) and the convective (primarily "frosting" or "frost up") load 50 tons. If, by installing an aluminum ceiling, we reduce the emissivity from 90% to 5%, we eliminate 85% or 45 tons, or 38 tons, and perhaps by using indirect lighting we eliminate 4 of the 5 lighting tons, thus leaving a radiant load of 8 tons. By using dehumidification we reduce the 50 ton convective ice load to around 22 tons and add an average of 10 tons on a 24-hour basis to run the dehumidifier. Thus we would save 66 tons and add 10 tons, for a total saving of 56 tons out of 105, or 53% saving, and only 49 tons, less the lighting saving, is now needed to run the rink instead of 105 tons.
These figures are only assumed and depend on many factors which are hard to control such as usage, infiltration, ventilation requirements, frequency of resurfacing, weather, etc.
In an unenclosed rink the wet bulb temperature will more closely follow the outdoor conditions and such temperatures of 75° or 80° F are encountered. Convective loads will approximately double for each 10° rise, so 75° F wet bulb may require, using our prior example, 4 times 50, or 200 tons. To whatever degree dryer cooler air can be held over the ice surface, even though it is much hotter around the edge and above the fence, great savings can be made. The higher the fence the better and in this case the transparent acrylic plastic panels, sometimes sold under the tradename Plexiglass, will have a very helpful effect of keeping the cooler, dryer air over the ice since they go higher than the skaters heads and thus contain the air turbulence the skaters cause.
Although several different thermal functions are utilized to reduce the load on the ice and thus make possible ice in all climates in an unenclosed structure, or to reduce energy levels to a manageable and survivable consumption in an enclosed ice rink, they all depend upon eliminating the large and hitherto unrecognized radiant load. Other functions may or may not be added depending upon the situation.
From the foregoing, it will be understood that the illustrative embodiments of low emissivity-high reflectivity surfaces above an ice surface as shown above and the methods and structures of utilizing the same, above described, are well suited to provide the advantages set forth. And since many possible embodiments may be made of various features of the invention and as methods and systems here described may be varied in various parts, all without departing from the scope of the invention, it is to be understood that all matter here and before set forth shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense in that certain features of these embodiments may be used without a corresponding use of other features without departing from the scope of the invention.
As a reference and computation for the 45 tons of ceiling radiation load on the ice of a typical standard size (85 × 200 ft.) ice rink, as used above, I have referred to the Mechanical Engineers Handbook, edited by Lionel S. Marks, fifth edition, page 380, "Radiant Heat Transmission" by Prof. Hoyt C. Hottel. The formula is given as E (emissivity) × 0.173 × 10.sup. -8 (Stefan-Boltzmann constant) × A (area in sq.ft.) × T 4 (absolute temperature) Btu's per hour. In our case the temperature would be the temperature of the ceiling to the fourth power (T c ) 4 minus the temperature of the ice to the fourth power (T I 4 ). The area would be the area of the ice (17,000 sq.ft.) and we can assume that radiation gained by the ice from sources outside the ceiling directly above the ice are balanced by radiation losses to other areas from the ceiling above the ice.
Using T c of 65° F (525R) and T I of 25° F (485R) and average emissivity of 90%, we get 0.90 × 0.173 × 10.sup. -8 × 17,000 × (525 4 - 485 4 ) = 546,000 Btu per hour, or dividing by 12,000 Btuh per ton we get 45.5 tons.
|
Heretofore it has been completely impractical to try to create and hold ice for the purposes of ice skating, curling or sliding during summer weather unless the area were completely enclosed. This invention presents a method for doing this which is practical not only by keeping refrigeration requirements low but also by eliminating dripping, fogging and surface melting. This method also has the advantage of reducing energy requirements for holding an ice slab under indoor or outdoor conditions. The method includes creating a floor for ice under which tubes or pipes containing an antifreeze solution are laid, connecting a refrigeration plant to chill and recirculate the antifreeze solution, suspending a surface of aluminum foil facing downward covering the entire ice floor at least 10 feet above such floor, mounting fans to recirculate the air from below such aluminum surface to above it, freezing ice by applying water upon the floor, painting the ice white to reflect radiant energy, freezing more ice above the white paint, erecting a solid perimeter fence around the ice floor, blowing air through a header box alongside the rink to dehumidify the air and delivering that air through openings in the perimeter fence onto the ice floor area and certain combinations of the above steps. The low emissivity of the aluminum foil and the high reflectivity of the white paint prevent radiant energy from loading the ice while recirculation fans warm the cool moisture-laden and often foggy air over the ice by conveying it to the warm area above the suspended ceiling.
| 5
|
RELATED APPLICATION
This application is a continuation in part of application Ser. No. 10/182,889 filed Apr. 28, 2003 entitled “Apparatus, Methods, and Liners for Repairing Conduits”, now U.S. Pat. No. 7,073,536, which is a U.S. National filing under §371 of International Application No. PCT/US01/03498, filed Feb. 2, 2001.
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to an “insitu” method to repair underground pipes and conduits to reduce or eliminate ground water infiltration while stabilizing the proximate ground formation surrounding the pipes.
2. Background of the Invention
The Clean Water Act has mandated that ground water infiltration into our sewer systems be substantially reduced or eliminated. Many methods of repair have been devised over the last thirty years. Some of those repair methods include slip lining, pipe bursting, cured in place pipe lining (CIPP), fold and form thermoplastic lining, spot repairs, as well as the traditional dig and removal/replacement of pipelines.
It is a known fact that the federal interstate highway system has met and in certain cases exceeded its design life by controlling or reducing incidents of pavement collapse, settling and irregular surfaces. This has been achieved with the development of techniques for the injection of grouts or placement of epoxy patches. In addition, the concrete repair industry has developed and refined the utilization of expandable structural closed cell foams to raise, level and stabilize concrete slabs, foundations, pavements and buildings.
The “insitu lining” repair of pipes has been the most effective alternative to pipe “dig and replacement” for many year. Occasionally an existing annular space or void adjacent to the outside surface of the pipe or conduit has been injected with gelatinous grout materials to eliminate water infiltration into the pipe. This repair has been only temporary since the gelatinous material is not dimensionally stabile and often requires later replacement. The grout is not capable of stabilizing the ground around the pipe even if the entire annular space is filled with the gelatinous grout. The lack of stability and support can result in additional stress on the pipe structure, with eventual degradation of the pipe and resulting water infiltration.
Injection of expanding closed cell foams has seldom been used to repair pipes. Where the closed cell foams have been used to level or reinforce pipe sections, there has been migration of the foam into the pipe/conduit joint that, if left in place, can cause an occlusion or blockage. When this migration into the interior diameter of the pipe does occur, a cutting or grinding device must be inserted as a subsequent step to remove the excess foam.
Another issue is the typical foams being used today are polyurethane's which often contain isocyanate, a groundwater contaminant. Some research has been conducted to determine if the closed cell foam chemistry could be used with grout packers. The blowing agents in the foam, however, create a near immediate reaction that will not allow the annular space to be filled with the foam.
There are hybrid polyester/urethanes expandable closed cell foams that could be used and avoid isocyanate. However, these alternate foam formulations have not been well suited to curing in the ambient underground soil conditions.
The measure of physical properties of materials relevant to the present invention include ASTM D1621 Compressive Strength, ASTM D790 Flexural Strength, ASTM D1622 Density, ASTM C 273 Shear Strength, ASTM D 2126 Dimensional Stability, ASTM D696 Coefficient of expansion, ASTM D 543 Chemical Resistance, and ASTM D 2842 Water Absorption.
SUMMARY OF INVENTION
Insitu pipe repair methods have been developed utilizing techniques for heat assisted cured in place pipe lining (“CIPP”) utilizing epoxy repair materials. This technology has allowed the use of styrene free thermosetting or thermoplastic resins in an impregnated (“prepreg”) composite repair material that is cured with an expandable and heatable bladder. Thermoset resins are curable resins that can be introduced or impregnated into a fibrous repair material. The curing of the resin results in a change of phase of the resin from a liquid to a solid. As a solid, the repair material continues to have the fiber structure. This technology has been adapted for use in the repair or sealing of pipes or conduits, including sewer mains and lateral lines, (“pipes) and the junctions or interfaces of multiple pipelines.
This invention teaches the use of this technology in combination with the injection of chemical reactants creating expanding closed cell foam (“foaming liquids”) for stabilization of the surrounding ground proximate to the underground pipes. The heat assisted CIPP mechanisms and techniques for interior pipe repair thereby allow the use of more environmentally friendly foaming liquids than feasible in ambient conditions to stabilize the ground surrounding the pipe. The inflated bladder can provide a heat source for curing of the resin of the prepreg repair materials, closed cell foaming liquid resin and limiting resin redistribution, and a supporting mechanism for maintaining the pipe diameter and to prevent infiltration of the foam or foaming liquid into the pipe interior.
The invention also teaches use of the expandable bladder alone within the inside diameter of the pipe in combination with the injection of foaming liquids proximate to the exterior of the pipe surface. The invention also teaches use of an expandable and heatable bladder within the inside pipe diameter to assist in the cure of the injected foaming liquids.
The present invention provides for an improved method of stabilizing the adjacent underground soils or formation around the pipe, minimizing ground water infiltration into the pipe, while repairing the host pipe/conduit or connection. The invention also minimizes exfiltration of sewerage from the pipe. Such exfiltration is a problem particularly when the pipe system is fully charged during a rainfall event.
Other benefits of the invention will also become apparent to those skilled in the art and such advantages and benefits are included within the scope of this invention.
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. These drawings, together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 illustrates a typical sewer pipe and lateral connection.
FIG. 2 illustrates typical defects necessitating repair of a sewer pipe and sewer pipe connection.
FIG. 2A represents a cross sectional view of a defective pipe.
FIG. 3A illustrates the prior art use of foaming liquids.
FIGS. 4A and 4B illustrate the use of the inflatable bladder in combination with injection of foaming liquid.
FIG. 5 illustrates the pipe repair equipment utilized with simultaneous repair of the pipe interior and ground stabilization.
FIGS. 5A–5E further illustrate the pipe repair equipment.
FIG. 6C illustrates a detail of the woven repair material for a pipe interface repair.
FIG. 9 illustrates a woven repair material utilized in one embodiment of the invention.
FIGS. 10 and 10A are cross sectional views of a hybrid woven repair material.
FIGS. 11A and 11B are additional cross sectional views of other hybrid fiber woven repair material.
FIG. 12 is an illustration of the braided repair material.
FIG. 12A is an illustration of a rochelle knit.
FIG. 13 is an illustration of the helically wound repair material.
FIG. 14 is an illustration of multiply aligned pipe segments.
FIG. 14A is an illustration of mis-aligned pipe segments.
FIGS. 15 and 15A illustrate the realignment of pipe segments utilizing the invention.
FIGS. 16 and 16A further illustrate the realignment of pipe segments utilizing the invention.
FIGS. 17A through 17G provide a cross sectional view of the operation of one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The above general description and the following detailed description are merely illustrative of the subject invention and additional modes, advantages and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention. The teaching of this invention will be understood to be applicable for both the repair or support of sewer pipe connecting interface, as well as for linear and non linear pipelines.
FIG. 1 illustrates typical underground sewer pipe configuration that can be the object of repair by the method and apparatus of this invention. The pipes comprise a lateral line 500 typically emerging from a single building or home (not shown). The lateral line is installed for gravity drainage 640 into a collector sewer or sewer main pipe 200 through a connection or connecting interface 400 . Sewerage is gravity conveyed 650 through the diameter 300 of the sewer pipe 200 . The lateral pipe and the main sewer pipe each has a longitudinal axis 350 . However, over time, the orientation of the individual pipe segments may change from the original longitudinal axis, creating a “non linear” pipe. (Reference is made to FIGS. 14 and 14A .) Non linear pipe can also, of course, include curved pipe.
The lateral pipeline and the main sewer pipe are typically comprised of separate segments jointed by a male-female type connecting end flange. The female flange component 210 and corresponding male component 211 are illustrated in FIG. 2 . It will be appreciated that the sewer pipe system is buried within the ground 100 beneath the ground surface 105 . The system can be accessed through various ports such as manholes (not shown).
FIG. 2 is a cross sectional schematic of the sewer pipe 200 along the longitudinal axis 350 . The direction of the gravity flow of sewerage is shown by vector arrow 650 . The male 211 —female 210 coupling of the separate sewer pipe sections is also illustrated.
FIG. 2 illustrates a common problem experienced with sewer pipe systems. Due do a variety of causes, including the aging of the pipe material, ground shifts or settlement, etc., ground water 175 migrates into the sewer pipes 200 . This can cause the exfiltration of sewerage into the surrounding soil or ground water, particularly when the sewer lines are heavily charged, such as during a significant rain event. Alternatively, the infiltration of ground water can burden the sewerage treatment system thereby increasing treatment costs or causing inadequate treatment. (In addition to the obvious environmental damages that may result from inadequate sewer treatment, the inadequate treatment may result in fines and other damages being imposed by regulatory agencies.)
The infiltration of ground water often carries particles of the adjacent soil 100 into the sewer system, which can overtime result in voids 150 being created surrounding the pipe 200 . The creation of voids or increased interstitial spaces results in groundwater collecting proximate to the pipe. This groundwater can then pass, i.e., infiltrate, into the sewer pipe wall 250 through the cracks 240 or holes 255 . It can also pass through defects, such as gaps, in the junctions of each pipe segment 210 211 .
FIG. 2A is a schematic illustration across the longitudinal axis 350 of a section of the damaged sewer pipe 200 beneath the ground surface 105 and adjacent void 150 in surrounding soil 100 . Also illustrated are the pipe diameter 300 and cracks 240 and voids 255 through the thickness 251 of the pipe wall 250 . The several vector arrows 175 illustrate the flow of ground water from the soil 100 into the void 150 surrounding the pipe 200 and through the cracks 240 and holes 255 within the sewer pipe wall 250 . It will be appreciated that the voids intended to be remedied by the subject invention need not be of the large size depicted in these illustrations. Further, it will be appreciated that the subject invention is not limited to repair holes or cracks in pipes, but can be used to seal connections (or “couplings”) between pipe segments, or between pipe lines, e.g., a sewer collection pipe and one or more lateral pipes convey waste (“sewerage”) from individual residences, etc.
Use of close cell expandable foams have been used to fill subsurface voids in soils, including use to mechanically raise objects supported by the soil. This has been used in foundation leveling, etc., as taught by U.S. Pat. Nos. 4,567,708, 6,521,673 and 6,634,831. However, this technology has important limitations for use in filing voids surrounding sewer pipes or sealing/repairing pipe defects. One disadvantage is the infiltration of the closed cell foam into the interior pipe diameter (through which sewerage is intended to flow), thereby creating an occlusion that must be mechanically removed to prevent blockage of the sewage flow. In addition, the expansive pressure of the closed cell foam (useful in filling or compacting the soil particles or interstitial voids within the soil or between the underground soil and the structure, e.g., sewer pipe or lateral collector, to minimize water collection/infiltration), may also further damage the pipe wall.
FIG. 3A is a schematic illustration across the longitudinal axis 350 wherein closed cell foam 600 is injected from the ground surface 105 through the injection mechanism 650 into the void 150 within the ground 100 adjacent to damaged sewer pipe wall 250 . The foam equipment combines static head mixers 650 with a strong insertion device attached to pumps (not shown) located at the ground surface 105 . The cross section view illustrates the closed cell foam filling the void 150 and infiltrating into the diameter 300 of the sewer pipe 200 through the holes 255 and cracks 240 within the pipe wall 250 . The infiltrating foam is shown to create obstructions 337 338 339 within the pipe diameter 300 . It will be appreciated that the foam may not fill the entire void 150 , perhaps due to the presence of entrapped ground water (not shown), thereby allowing for the continued collection of ground water proximate to the repaired pipe. The migration of foam into the pipe can ultimately block the pipe diameter 300 unless a cutter/grinder unit (not shown) is inserted into the pipe and the occlusion is removed. It will be appreciated that it is desirable to avoid this time consuming and expensive step.
One embodiment of the apparatus and methods taught in this specification is the advantageous use of techniques for installing a pipe repair material (thermoset or thermoplastic impregnated liner) within the interior diameter of a sewer pipe in combination with injection of expanding closed cell foam proximate to the outer diameter of the sewer pipe. The repair material for the interior pipe diameter may be of a variety of structures, including a structure being defined as an arrangement of fibers such that the repair material has similar dimensions as the pipe diameter or pipe interface to be repaired or sealed. The arrangement of fibers further allows the repair material to be flexible and seamless. FIG. 9 illustrates an example of a woven structure 410 having a longitudinal axis 350 . In the illustration, fibers 118 119 intersecting at a variable angle 125 . It will be appreciated that the composition of fibers and fiber architecture can be varied, as shown in the cross sectional illustrations along the axis AA in FIGS. 10 , 10 A, 11 A and 11 B discussed later. In a preferred embodiment utilizing the repair material, the material includes a resin having a viscosity. An additive may be provided to alter the resin viscosity. It will be appreciated that it may be advantageous to increase resin viscosity to retard resin redistribution within the fiber repair material or fiber liner prior to and during the installation process.
A flexible and inflatable bladder is inserted within the pipe diameter. The bladder serves as a mold to press and hold the repair material to the interior surface of the pipe during the repair process. The inflated bladder, which, in an alternate embodiment of the invention, can be used without the resin impregnated repair material or liner, also minimize the migration of the chemical reactant or resulting foam injected into the underground soils proximate to the pipe. The migration of chemical reactants or foam can result in occlusion or obstruction of the pipe diameter. This would obviously hinder the flow of sewerage through the pipe.
The fibrous construction of the repair material, or the components of the inflatable bladder, can include conductive fibers, e.g., carbon fibers, that can be connected to an electrical power source. These conductive fibers, when powered with electric current, may provide electrically resistive heating directly through or immediately proximate to the thermosetting resin contained in the repair material. The combined and concurrent pressing of the resin impregnated fibers to the inner pipe wall surface with the heating of the thermosetting resin allows an improved repair and support. The addition of heat, in contrast to ambient conditions, allows more rapid curing. Further, this allows the bladder to remain in place as a mold pressing the repair material for a greater portion of the cure and minimizes the degradation of the repair by resin redistribution. It will be appreciated that the use of the expanding and heatable bladder also minimizes the formation of “annulae” between the interior pipe wall surface and the liner.
Further, heat from the bladder or repair material is also available to radiate through the thickness of the pipe wall to facilitate to the cure of the foaming liquid exterior to the pipe wall. Curing of the foam creates a phase change in the foam to a closed cell solid. The closed cell foamed solid can compact the underground proximate to the pipe, decrease voids or interstitial space containing infiltrating ground water, as well as support and seal the pipe and pipe junctions.
The availability of the proximate heat source also allows use of alternate foaming agents, particularly agents not containing isocyanates. It will be appreciated that isocyanates are considered to be a source of environmental contamination. These alternate reactants include hybrid polyurethane or polyester/polyurethane blend resin, and epoxy resins combined with diluents, catalysts, blowing agents and surfactants, an acrylimide, and cementitous slurry.
FIG. 4A is a schematic cross sectional illustration along the longitudinal axis 350 illustrating an embodiment of the method and apparatus of the invention by placing a flexible and inflatable heating bladder 450 inside the pipe diameter 300 . The bladder is placed in the area of the pipe having holes 255 or cracks 240 in the pipe wall 250 . In this manner, the inflated bladder can provide support to the damaged pipe and facilitate maintaining the pipe diameter 300 during the repair process. The bladder may have resistively heatable sub-components to facilitate the curing of the chemical reactant injected proximate to the exterior pipe wall surface 254 .
FIG. 4B is a schematic illustration across the longitudinal axis 350 of the pipe after inflation of the bladder 450 . The bladder, if used as a heat source, may assist in the curing of the closed cell foam. It will restrain the injectible chemical reactant and resulting foam 600 from permeating the pipe through coupling connectors ( 211 210 of FIG. 2 ) or cracks 240 or holes 255 in the pipe wall 250 . The migration of foam is illustrated in FIG. 3A by the multiple vector arrows. The liner 410 (not shown) may be placed over the bladder for reinforcement or to minimize binding of the bladder to the cured foam.
An embodiment of the invention includes the use of resistive energy as a source of heat for curing the injected chemical reactant, as well as to block the migration into the pipe diameter. This heat curing can be accomplished in combination with the placement of a resin impregnated (“prepreg”) repair material within the pipe diameter. As mentioned above, the repair material or the flexible bladder may contain electrically conductive fibers. Alternatively, the fiber can be a combination of electrically conductive fibers and non-conductive fibers, which include polyester, glass, aramid, and quartz fibers, and thermoplastic fibers such as, but not limited to polypropylene, nylon and polyethylene.
The repair process is illustrated in FIGS. 4A , 4 B and FIGS. 17A–G where one skilled in the respective arts observes that there are similarities in both systems, which require 50 K.W. generators and 150 CFM compressors and various cables and hoses. The present invention demonstrates the synergies between the two systems, which eliminates boiler trucks, and on site mixing and impregnation of repair material.
This invention addresses the cause and repair of connection offsets or misalignment of pipes and conduits. The misalignment of an originally installed linear pipe may result from faulty bedding surrounding the pipe, which is not tested as it is in pressure pipe/conduit situations, and ultimately can crack or offset the joints after the pipeline is back-filled. Another cause of misalignment is the result of the movement of ground water as already discussed. While some may contend this method is redundant and more costly, one skilled in the art will easily recognize the efficiencies and safety elements of the present invention
This embodiment of the invention provides methods of repairing the misalignment of pipe sections 250 A such as that shown in FIG. 14A . In this case, the non-linear conduit is buried below the ground surface 105 predominantly in a horizontal orientation as part of a pipe network, e.g., sewer system. The non-linear pipe consists of separate pipe or conduit segments 25 A, 25 B, 25 C, 25 D, 25 E, 25 F, 25 G that have moved from the original longitudinal axis 350 illustrated in FIG. 14 to a non congruous longitudinal orientation 351 and thus does not follow a strictly linear path.
The embodiment of the method taught by this invention comprises providing the inflatable bladder dimensioned to fit within the interior diameter 300 of the pipe 250 A, and particularly each non-congruous pipe segment 25 A, 25 B, 25 C, 25 D, 25 E, 25 F, 25 G. The bladder is dimensioned so as, when inflated, presses against the interior surface of each damaged, e.g. mis-aligned, cracked or broken, section of conduit. The bladder can be made of any strong flexible material. It will be appreciated that it may be advantageous to fit the bladder with one or more layers of protective outer sleeves or liners (“liners”). The liners can provide a repair material (sometime referred to as “material structure”) as discussed elsewhere herein, but may also provide protection to the bladder from sharp or jagged surfaces within the conduit sections. The bladder may be filled/inflated with fluid, such as water or air, and the effectiveness of the bladder would be compromised if the bladder was punctured.
FIGS. 15 and 15A illustrate an embodiment of the invention wherein the bladder 450 is placed within the diameter 300 of several mis-aligned pipe segments 25 A, 25 B, 25 C, 25 D, 25 E, 25 F, 25 G beneath the ground surface 105 . FIG. 15 illustrates the bladder with several pipe segments 25 B 25 E removed for clarity of illustration. The original or intended longitudinal axis of orientation 350 is also shown. It will be appreciated that the mis-alignment may be in any of the three axes of orientation (X, Y, Z).
FIG. 16 illustrates the next step of the repair method. Multiple chemical reactant insertion ports 650 are installed from the ground surface 105 to a desired location proximate to the pipe. In the illustrated situation, the ports are installed to be beneath the mis-aligned pipe segments 25 B, 25 C, 25 D, 25 E, 25 F. The goal of the repair is to push the pipe segments into closer alignment with the longitudinal axis 350 . A chemical reactant is injected through the ports into the ground 100 creating the expanding foam 600 . FIG. 16A illustrates the result of the injection of expanding thermosetting foam 600 , causing pipe segments 25 B, 25 C, 25 D, 25 E, 25 F to be pushed upward as shown by vector arrow 675 . The inflatable bladder 450 acts as a flexible mold having a control or guiding function in the realignment of the pipe sections, particularly with regard to the continuity of the pipe diameter 300 and common longitudinal axis of orientation 350 .
As suggested by the FIGS. 14 through 16A , substantial length of pipe can be simultaneously repaired by the invention. The length of inflatable and heatable bladder is not limited. Lengths of pipe extending from one access manhole to a second manhole may easily be simultaneously repaired by a single use of the method and apparatus of the invention.
Based upon the foregoing disclosure, it will be readily appreciated that the above method can be combined with the embodiment utilizing a repair material liner impregnated or containing a curing thermosetting or thermoplastic material to seal the pipe from the interior diameter. The repair material structure may be defined by a plurality of fibers such that the repair material is flexible and seamless. This structure is sometimes referred to as a woven “preform”.
Thee resin may be in the form of prepreg fibers or as a resin matrix surrounding the woven structure. The resin can be a polyester resin, a vinylester resin, a urethane polyester resin, a urethane-vinylester resin, an epoxy resin of a polyurethane resin. The resin is introduced into the repair material by either injection of infusion depending on the type of resin utilized.
A flexible and seamless repair material is able to adapt and conform to of the interior repair material will neither bind nor wrinkle to cause obstructions to material flow in the conduit. The construction and selection of the repair material also allows it to be used in conjunction with the inflatable bladder. The repair material may be placed as an outer liner on the deflated bladder.
Next, the repair material and bladder is placed in the conduit in close proximity to a damaged portion of the conduit. As the bladder is inflated, the repair material is pressed against the inner surface of the conduit wall. Finally, the resin is cured. Curing can be achieved in a number of ways, including but not limited in using hot water, steam, resistive heating, or infrared and ultraviolet radiation.
Preferably the material structure 410 is substantially cylindrical (as shown in FIGS. 9 and 13 ) to facilitate conformity with the non-linear conduit. The cylindrical structure has an interior diameter 301 oriented about a longitudinal axis 350 . However, the material structure is flexible and can be formed by braiding the fibers. A repair material 410 having a braided configuration of fibers 411 is shown in FIG. 12 . In braiding most, if not all, of the fibers 118 119 are arranged in a helical pattern (as shown in FIG. 13 ). However, triaxial braiding can be used to combine fibers at two different axial or helical angles with a non-helical, longitudinal fiber. Repair materials fabricated by braiding processes offer exceptional ability to conform to irregular conduit geometries. Because a braided repair material is formed with its reinforcing fibers positioned helically rather than perpendicularly to the longitudinal axis of the material structure, these fibers have the ability to change their braid angle 125 , and conform simultaneously in both the inside radius and outside radius of a section of a non-linear conduit.
Depending on the desired mechanical properties the density of the fiber braid can be varied to pack more fibers into the tubular arrangement to provide an increase in strength. Conversely, if the structural requirements are minimal, the braid density can be adjusted to where the material present in a volumetric area can be reduced. The angle 125 at which the fibers intersect each other, otherwise known as the braid angle, can also be varied. When the braid angle is increased, the fibers are positioned closer to perpendicular or vertical and the hoop strength of the finished repair material increases. This is desirable for conduits that are required to support a great amount of weight or withstand high internal pressures. The varying mechanical fiber compaction can be used, e.g., knitting, weaving and braiding.
Use of braid or similar types of mechanical fiber compaction construction also will facilitate the unlimited lengths of pipe that may be simultaneously repaired.
FIGS. 10 , 10 A, 11 A and 11 B are cross sectional representations of the fiber layers of a repair material illustrated in FIGS. 9 and 13 . Various reinforcing materials can be included in the braided construction to accommodate both performance and cost issues. FIG. 10 illustrates a combined placement of reinforcing fibers 122 , e.g. glass or nylon, with fibers 124 constructed of thermoplastic material. These fibers can be one of a combination of various engineered thermoplastics. In addition, thermoplastic films 130 may be used. These fibers, films and reinforcing fibers can be consolidated using any of the aforementioned methods. FIG. 10A illustrates repair material 410 comprised of a combination of reinforcing fibers 122 impregnated within a matrix of resin 131 . Various non-electrically fibers can be employed as reinforcement. The fiber construction can be varied as shown in FIG. 11A . The combination of fibers forms the material structure 410 . Additionally FIG. 11A also shows a film 130 of thermoplastic material that forms part of the material structure 410 .
Additionally, FIG. 11B illustrates that the material can include electrically conductive fibers 120 , for example carbon fibers, in order to cure the resin and electric current can be caused to flow through the conductive fibers to resistively heat the repair material. The fibers can be a combination of electrically conductive fibers 120 , thermoplastic fibers 124 and non-conductive fibers 122 e.g., polyester, glass, aramid, and quartz fibers. Other combinations and architectures will be apparent to persons skilled in the art.
When electrically conductive fibers are used in conjunction with the thermoplastic fibers and films, as illustrated in FIG. 11B , resistive heating can be generated. The heat causes the thermoplastic materials to melt and flow, permeating the electrically conductive fibers and other non-electrically conductive fibers. A reinforced thermoplastic composite results when the materials cool and harden. In this embodiment, the need for liquid thermosetting resin (which phase change solidification may be enhanced by the addition of heat) is eliminated offering unlimited shelf life and case of handling. Finished composite properties can be customized with the selection of an appropriate thermoplastic matrix and reinforcing fibers.
As shown in cross section in FIGS. 10 and 11A the repair material can contain fibers having both structural properties 122 and thermoplastic fibers 124 . Alternatively separate bundles of electrically conductive fibers 120 can be co-mingled with bundles of thermoplastic fibers 124 and structural or reinforcing fibers 120 as shown in FIG. 11B . In both cases, the bundles may be braided together to form the repair material.
In another preferred embodiment, the electrically conductive fibers have an exterior layer or coating of electrically conductive fibers than are then braided. In another preferred embodiment, the seamless material structure is formed by knitting the fibers. In knitting, the repair material is produced by inter looping continuous chains of fibers in a circular fashion. An enlarged view of knitted fibers 118 119 120 is shown in FIG. 12A . In a rochelle knit, it is possible to introduce the fibers in a basically longitudinal direction. Because the fibers 118 119 are looped in a circular fashion at every stitch, the finished tubular structure is inherently flexible. For example, in one linear inch of fiber stitch, the actual fiber length may be as long as two inches. This allows continuity in the fibers throughout the length as well as allowing the fiber loops to stretch or open up to variances in the conduit geometry. Various reinforcing materials can also be included in the knit construction to accommodate both performance and cost issues. In addition, electrically conductive fibers 120 can be used such that resistive heating is feasible to cure the resin.
In another preferred embodiment, the seamless material structure is formed from a combination of two or more material layers. A first material layer is a seamless, cylindrical tube configured to fit within a second material layer that has a seamless, cylindrical tube configuration. The material layers are formed from an arrangement of fibers, preferably either braided or knitted fibers. The first material layer is nested within the second material layer and then stitch-bonded together with a stitching thread to form the materials structure. Preferably, the stitch-in thread is elastic to further ensure flexibility of the repair material. In addition, electrically conductive fibers can be used such that resisitive heating is feasible to cure the resin.
Stitch bonding is a method by which different materials can be consolidated into various forms including seamless, tubular products. The consolidating results from either continuous or intermittent stitching or sewing through the various layers materials. Reinforcing fibers can be used and aligned in a helical arrangement to a accommodate geometry changes much like a braided composite. Stitch bonding also allows the use of a wider variety of electrically conductive material formats such as non-woven graphite formed into tapes. These tapes would be introduced into the composite at a helical angle.
In another preferred embodiment, the seamless material structure is formed from a combination of two ore more material layers. A first material layer is a seamless, cylindrical tube configured to fit within a second material layer that also has a seamless, cylindrical tube configuration. The material layers are formed from an arrangement of fibers, preferably either braided or knitted fibers. The first material layer is nested within the second material layer and then needle punched with a needle board to form the material structure. The needle board has a plurality of needles such that the needles penetrate the first material layer. When needles are driven through the first material layer, varying amounts of fibers from the first material layer are pulled through the cross section of the adjacent second material layer. These fibers effectively bind the material layers together. In addition to consolidation, the fibers also provide reinforcement in the Z axis, defined as the axis corresponding to the material layer thickness. The characteristics of the repair material, including flexibility, can be altered by varying the force applied to the needle board, the type and number of needles used, and the number of needle penetrations per square inch. In addition electrically conductive fibers can be used such that resistive heating is feasible to cure the resin.
In another preferred embodiment, an additive adapted to increase the resin viscosity is provided. The additive is mixed with the resin to form a resin-additive mixture whereby the resin viscosity is increased after a period of time has elapsed. The additive should be formulated such that the resin viscosity does not immediately increase because this could preclude either resin introduction or resin permeation of the repair material. The resin additive adheres to the fibers in the first and second material layers. As a result, the resin additive mixture stabilizes the fibers and the material layers. In addition electrically conductive fibers can be used such that resistive heating is feasible to cure the resin.
FIGS. 17A through 17G illustrate the sequential steps of the combined application of curing a foaming chemical reactant proximate to the exterior of underground 100 pipes, with placement of a curable liner on the interior pipe surface. FIG. 17A is a cross sectional view of a pipe 250 beneath the ground surface 105 and having an interior diameter 300 . The pipe has a longitudinal axis of orientation 350 . The pipe has an inner wall surface 256 , an exterior wall surface 254 and a wall thickness 251 . Also illustrated is an insertion port 650 for injecting expanding foam reactant at a selected location in relation to the buried pipe. Also shown is the deflated bladder 450 and separate material structure 410 positioned as an outer liner to the bladder.
FIG. 17B illustrates the same components within the ground 100 , but with the bladder 450 now inflated and placing the material structure/repair material 410 into near contact with the inner pipe surface 256 . The diameter 301 of the material structure is shown. In this cross sectional view, only a small portion of the original pipe diameter 300 is not occupied by the inflated bladder and material structure.
It will be appreciated that the bladder 450 is to be inflated to press the structural material 410 into contact with the inner pipe wall 254 and the space shown in the following Figures is for clarity of illustration only.
FIG. 17C illustrates the foaming chemical reactant 600 being injected into the ground 100 . The foam variously expands in all directions, as illustrated by the several vector arrows, creating a force compacting the underground soil, driving away interstitial groundwater and pressing against the outer pipe wall 254 now reinforced by the inflated bladder 450 . FIG. 17D illustrates this process with multiple injecting foams, causing the pipe to be substantially encased in the expanding foam 600 , thereby compacting the ground, driving interstitial groundwater, minimizing or filling voids adjacent to the pipe and thereby stabilizing the pipe.
FIG. 17E illustrates the curing of the foam assisted by electrically resistive heat created from current within the electrically conductive fibers within the repair material 410 . A portion of the radiating heat travels outward into the thickness of the pipe wall 251 and into the surrounding ground or foam. The distance or range of significant heat transfer 605 may be less than the area occupied by the foam 600 . However, within this area 605 , effective curing of the foam can be achieved, thereby effectively encapsulating the pipe wall, while simultaneously installing an interior reinforcing material (In another embodiment discussed previously herein, the conductive fibers can be contained within the bladder or a protective liner of the bladder separate from any repair material.)
FIGS. 17F and 17G illustrate a cross sectional area of the invention, illustrating the interior diameter 301 of the repair material 410 containing the inflated bladder 450 , the pipe thickness 251 , the area 605 of foam cured by the radiant heat, the outer area of foam 600 and the surrounding ground 100 .
The present invention also provides methods and apparatus for repairing a section of non-linear pipe such as the junction or interface 400 between two pipes 200 500 as illustrated in FIG. 1 . A preferred embodiment of the apparatus of the present invention is depicted in FIG. 5 . In accordance with the invention, the apparatus includes a main body 460 that is positioned in a first conduit 200 . The first conduit 200 may be pipe forming a main line of a sewer system. The main line 200 intersects a second conduit or lateral line 500 . Lateral line 500 is shown here in a perpendicular position essentially at a 90 angle to the main line pipe and intersects the main line pipe at the top portion. This condition is typical but may also be arranged in other configurations. For example, the lateral pipe may intersect the main line pipe at ±45 and can be located radially anywhere from the nine o'clock position to the 3 o'clock position.
Radial and vertical positioning of the apparatus is achieved remotely using appropriate controls, and communicated to the apparatus through an umbilical 350 . The entire assembly 460 is delivered to the point of repair using a winch or similar device (not shown) attached to the unit via cable assemblies 345 . Also illustrated are the heatable caul plates 465 and the flange portion of the repair material 411 . (It will be appreciated after reading the following paragraphs that FIG. 5 illustrates the repair material in a loaded position within the main body 460 of the apparatus.
FIG. 5A provides a cross sectional view of the apparatus depicted in FIG. 5 , showing the heatable caul plates 465 in a retracted position on an upper portion of the body 460 of the apparatus, thereby affording a minimal cross section and allowing passage into a main line that may contain offsets, protrusions, etc. The caul plates 465 (hereinafter referred to as “wings”) are articulated to allow this reduced cross section by the use of hinges 466 .
FIG. 5A illustrates the loading of the repair material 410 into the apparatus 460 in preparation for insertion at the intersection of the main line and lateral line. Repair material 410 is preferably constructed of a fibrous woven material capable of holding a heat hardenable or formable resin matrix. Material 410 is also constructed of a material that would be expected to include a portion 412 that conforms to the interior geometry of the lateral pipe wall, and be flexible enough to provide a flange face 411 in the main line pipe. (Reference is also made to FIG. 6C .) It is shown that the repair materials is wrapped around the retractable/inflatable bladder segment 440 . In 5 C, the method for loading the repair material 410 is also illustrated. Applying a fluid pressure to the body 460 through umbilical 350 pressurizes an inflation device in the form of a bladder 440 . This fluid pressure is regulated through the use of electro-pneumatic regulators located in rear housing 461 in the body 460 , and controlled remotely through signal wires in umbilical 350 . Pressure sensing is accomplished by sending units located within main body and transmitted through umbilical. All of the signal wires in the umbilical terminate at an operator interface control station (not shown). The force required during this step in minimal and sufficient to cause the bladder 440 to rigidize.
The repair material is constructed in such a fashion as to incorporate both the tubular lateral lining portion 412 as well as the flanged area 411 without the undesirable effect of a potentially weak seam at the transition from tubular to planar. With the bladder 440 pressurized, the material 410 , which may be pre-impregnated with a resin as described elsewhere in this specification, is wrapped 412 around the extended bladder 440 as shown by the vector arrow 676 and caused to lay flat 411 on the surface of the wings 465 . Depending on the structural requirements, layers of material can continue to be plied to achieve the desired strengths. With the lay-up complete, the pressure of the bladder 440 is lowered the material 410 can be inverted into the main body of the apparatus as shown in FIG. 5C . The main body contains a spindle 453 capable of rotation that is fixably attached within the body 460 at a posterior location. The spindle is sealed from the atmosphere to the use of o-rings and protrudes slightly from the body to allow attachment of a tool to cause rotation.
As shown in FIG. 5D , the bladder construction contains an internal tether 451 that is permanently attached to the interior of the bladder at fitting and removably attached to spindle 453 within the main body 460 . To invert the bladder 440 and repair material 410 into the main body for safe transport to the repair location, the tether is wound about the spindle causing the bladder to retract. With the repair material loaded into the device, a winch, or similar device is employed to pull the apparatus to the desired location within the pipeline. A closed circuit television camera (not shown) can be used to assist in determining the correct location and positioning. Once the entire assembly has been satisfactorily located in proximity to the repair area, final positioning commences vial remote control.
FIG. 5D shows the internal working of the apparatus. In order to facilitate rotary position, the apparatus contains a powered rotation mechanism located in the rear housing 461 . The rotational mechanism is attached to the main body by use of a coupling. The front section 462 of the body 460 contains a rotary bearing to compliment this action. Skids 472 are attached to both the front 462 and rear 461 sections to afford minimal surface contact with the main line pipe and ease pulling forces required.
FIG. 5D illustrates the apparatus used for placement of the flexible bladder 440 at the pipe interface section 400 . The apparatus is positioned in radially and longitudinally within one pipe 200 . The lift cylinders can be elevated by hydraulics or compressed air using a suitable medium. The lift cylinders are firmly attached to the front section 462 and rear section 461 with cylinder rams attached to the main body. When activated, cylinders 473 effectively lift the main body to force the top portion of the caul plate 465 to be in contact with the interior wall of the main line pipe at the area surrounding the lateral pipe opening. As the main body lifts, actuator arms 474 encounter the main line pipe wall, as depicted in FIGS. 5D and 5E . In FIG. 5E , the actuator arm bearings 474 convert the vertical motion to a lifting motion through a fulcrum attached to the main body. The opposite ends of the actuator arms are position under the wings 465 and cause the wings to unfold and compress the flanged area 411 of the repair material firmly against the main line pipe walls.
By introducing pressure to the interior of the main body through umbilical, the bladder and repair material is caused to invert into the lateral pipe. Increasing the pressure inside the bladder causes the tubular section of the repair material to conform to the inside geometry of the lateral pipe section.
The bladder and the caul plates may be constructed of a temperature resistant material and contain within the outer skin surface, electrically conductive fibers that are employed to produce heat when an electrical current passes through the fibers. The material surrounding the conductive fibers is a flexible, resilient substance such as silicone, fluorosilicone or fluoropolymer. Electrical wires conduct the electrical energy from remotely stationed, controllable power supplies to the electrically conductive fibers. Heating temperatures may be produced range between 200 F. to 400 F. depending on the cure requirements of the resin matrix selected for use in the repair material. These temperatures can be achieved in as little as 10 minutes enabling an extremely fast cure cycle.
In conjunction with the inflation of the bladder into the interior diameter of the pipe interface and the heating of the bladder and caul plate, reactants can be injected into the ground proximate to the interface to compact the soil and stabilize the soils adjacent to the pipe similar to the manner discussed earlier in regard to FIGS. 2 through 4B above. The inverted bladder thereby also serves to minimize the infiltration of injected reactant or reaction product into the interior diameter. Further, it will be readily appreciated that the heat of the bladder, caul plates or liner may be available to radiate through the thickness of the pipe wall to facilitate the cure of the injected reactant. Again, this heat source may also allow the use of reactants that are not effective in the ambient subsurface environment.
While specific embodiments have been illustrated and described, numerous modification are possible without departing from the spirit of the invention, as the scope of protection is only limited by the scope of the accompany claims.
This specification is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the manner of carrying out the invention. It is to be understood that the forms of the invention herein shown and describe are to be taken as the presently preferred embodiments. As already stated, various changes may be made in the shape, size and arrangement of components or adjustments made in the steps of the method without departing from the scope of this invention. For example, equivalent elements may be substituted for those illustrated and described herein and certain features of the invention may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the invention.
Further modifications and alternative embodiments of this invention will be apparent to those skilled in the art in view of this specification.
|
The apparatus and method for eliminating ground water infiltration while stabilizing the ground and repairing underground pipe/conduit and connections is taught in this art. The steps are to first inject, under pressure, expandable structural foam in the space adjacent and outside the pipe while blocking any infiltration of the foam into the interior of the pipe, conduit or connection. Concurrently or separately the inside diameter of the pipe is receiving a structural repair. The result is stabilized ground, elimination of ground water infiltration and repair of the host pipe conduit or connection.
| 4
|
This is a division of application Ser. No. 07/541,836, filed Jun. 21, 1990 now U.S. Pat. No. 5,074,366.
BACKGROUND OF THE INVENTION
Drilling highly deviated and horizontal wells has been known for decades, various methods and apparatus have been employed more or less successfully. Emphasis on horizontal drilling has been cyclical and dependent upon the price level of oil, gas and other natural resources which may be recovered via the use of such techniques.
Horizontal drilling apparatus, and particularly apparatus which can be precisely controlled as to depth and azimuth or direction are very useful in recovering natural resources from subterranean formations which are of nominal thickness, as conventional vertical drilling techniques can only intersect such formations for a short interval (i.e., the formation thickness) so that the total surface area of the wellbore exposed to the formation and from which the natural resources may be recovered is extremely limited. On the other hand, a horizontal drilling apparatus, and particularly a steerable apparatus, can not only intersect the target formation but follow its path under the earth for hundreds or even thousands of feet, exposing the wellbore to a formation surface area many orders of magnitude greater than that achievable by conventional vertical drilling techniques. The falling and stabilization of oil prices in recent years at levels less than half of those encountered in the early 1980's has generated renewed interest in horizontal drilling as a means to maximize production from each well drilled, and therefore the operator's profit margin.
In addition to natural resource recovery applications of horizontal drilling, enactment of environmental legislation during the past two decades and enhanced monitoring and enforcement activities by federal and state governments has opened vast new fields of opportunity for a compact, easily transportable, economical horizontal drilling method and apparatus which can be employed to drill monitoring, injection, recovery and barrier wells in the vicinity of land fills, industrial sites, toxic waste repositories and other locations in which the natural environment has or may become contaminated through man's intentional actions or neglect. Subsurface monitoring and remediation techniques for contaminated sites are in their infancy, but in most instances require the ability to not only surround but also to reach under the suspected or confirmed contaminated plume or volume of earth from a remote position outside of the zone of contamination. Moreover, the vast size of many sites requires the drilling and completion of hundreds if not thousand of wells at a single location.
Existing methods and apparatus for horizontal drilling have been developed for oil recovery, mineral recovery and for the installation of cables and pipes under rivers, swamps, highways, building and other natural and man-made obstacles. While potentially applicable to environmental remediation activities, they are generally expensive to build and to use, and in many instances lack the ability to follow a relatively precise path. This latter point is extremely important when drilling at very shallow depths, as inadvertently drilling from below into a plume of contaminated earth may result in catastrophic groundwater contamination where none previously existed. Drilling systems which can complete a well as it is being drilled are extremely desirable, from a rig time cost saving standpoint and, more important, because subsurface formations at shallow depths are generally unconsolidated and therefore lack inherent physical strength against collapse of the wellbore once the drill string is withdrawn. Such collapse requires redrilling of the well and also may enhance flow of contaminants from a contaminated but previously isolated zone above the wellbore, thus aggravating the existing problem.
In short, there has been a long felt and ever increasing need for a compact, economical, easily transportable horizontal drilling system which can be effectively used at environmental monitoring and remediation sites.
SUMMARY OF THE INVENTION
The method and apparatus of the present invention addresses the drilling needs of the environmental industry in a manner vastly superior to the prior art, and is also adaptable to other applications.
More specifically, the apparatus of the present invention comprises a steerable downhole drilling apparatus, also known as a bottom hole assembly, including an inner string of drill pipe terminating at its lower end in a fluid driven, preferably Moineau type motor driving an expandable drill bit. The inner string is removably disposed within an outer, larger diameter string which is preferably centralized and which, including centralizers, is of lesser diameter than the expanded diameter of the drill bit. The end of the outer string, which is preferably stabilized, includes a casing shoe having an inner shoulder or ledge thereon, which is of such diameter so as to engage an inner string stabilizer disposed at the end of the motor adjacent the drill bit, thus arresting the motor's passage through the open end of the outer string. The drill bit, when expanded, drills a wellbore of sufficient diameter to accommodate both the inner and outer strings and, when the desired reach of the wellbore has been achieved, the inner string is retracted through the outer string and the well is completed as desired.
The apparatus of the present invention also provides a steering capability, including a curve drilling capability, via the use of first and second stabilizers of selective and preferably adjustable eccentricity mounted on the downhole motor. When a curved drilling path is desired, such as when the wellbore commenced from the surface is to be turned to the horizontal, the motor stabilizers are adjusted to an extreme eccentric position, resulting in a tilting of the downhole motor with respect to the outer string, and resultant offset of the drill bit, causing it to drill a curved path. When the wellbore reaches the horizontal, which is predictable from the system characteristics but also verifiable by survey devices know in the art, the inner string is withdrawn and the motor stabilizers adjusted so as to cause the motor to be substantially concentrically oriented within the outer string, causing the drill bit to drill a straight well bore. In the event that, due to unforeseen formation characteristics or subsurface obstacles, it is desirable to redirect the wellbore, the inner string can be pulled again and a suitable degree of stabilizer eccentricity selected, whereupon the inner string is rerun to the end of the outer string, the bit expanded and a curved path drilled to the desired heading. Alternatively, a slight amount of eccentricity is maintained in the stabilizers, which results in a very slight bit tilt relative to the outer casing or liner. By partial rotation of the inner string through an arc with respect to the outer string, the bit offset may be directed up or down, left or right with respect to the existing instantaneous path of the wellbore, and continual course corrections made. This latter methodology is most suitably used when a steering tool is placed downhole immediately behind the motor, and real time wellbore path data obtained via a wireline or other means known in the art, including mud, acoustic or magnetic pulses, or radiotelemetry.
The method of the present invention comprises simultaneously drilling a wellbore and running a casing or liner while drilling. The method of the present invention also comprises simultaneously drilling a wellbore using a single drill bit and running a casing or liner while drilling, and additionally withdrawing the drill bit from the wellbore, leaving the casing or liner in place.
More specifically, the method of the present invention comprises providing an inner drill string including an expandable bit driven by a fluid motor having, providing an outer casing or liner string having a shoe at the bottom thereof to permit passage of the bit in an unexpanded mode therethrough while preventing passage of the motor, running the inner drill string into the outer string, expanding the bit to a diameter larger than that of the casing or liner string, and simultaneously drilling and casing a wellbore. The method further comprises the step of applying a longitudinal force to the drill bit through the drill string to cause it to engage the formation being drilled, and to cause the inner drill string to pull the outer string into the wellbore as it is being drilled. The method still further comprises the step of steering the bit to cause it to vary its path by providing means to offset the bit at an angle to the outer casing or liner string and selectively rotating the drill string through an arc of less then 360 degrees so as to reorient the bit tilt, and drilling at the new orientation. Moreover, the method comprises adjusting the bit offset to a plurality of angles to alter the radius of curvature of the wellbore being drilled. Finally, and by way of example and not limitation, the method comprises sensing the path of the wellbore as it is being drilled and reorienting the bit offset to correct for deviations of the wellbore from its intended path. Such sensing may be substantially continuous, and said reorientations of the bit tilt may be effected without pulling the inner drill string from the wellbore.
The method of the present invention, in one specific embodiment, also contemplates using one bottom hole assembly to drill the curved sector of the wellbore to the desired total vertical depth (TVD), cementing the outer string of casing in place, and drilling the horizontal sector of the wellbore with a smaller bottom hole assembly utilizing a slotted liner outer string, and withdrawing the inner drill string, leaving the liner string in place for well completion.
BRIEF DESCRIPTION OF THE DRAWINGS
The method and apparatus of the present invention will be more readily understood and fully appreciated by those of ordinary skill in the art through a review of the detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 comprises a schematic of a slant drill rig drilling a horizontal wellbore according to the present invention;
FIGS. 2A and 2B comprise, respectively, schematics of an inner drill string and an outer casing string which together comprise a bottom hole assembly according to the present invention suitable for drilling a curved wellbore;
FIGS. 3A and 3B comprise, respectively, schematics of an inner drill string and an outer liner string which together comprise a bottom hole assembly according to the present invention suitable for drilling a horizontal wellbore;
FIGS. 4A, 4B and 4C comprise enlarged schematics of the lower end of the inner drill string of the present invention disposed within the outer string in tripping, curved drilling and horizontal drilling modes;
FIGS. 5A, 5B, 5C, 5D and 5E comprise sequential schematics of the apparatus of the present invention drilling the curved and horizontal portions of a wellbore according to the method of the present invention;
FIG. 6 comprises a schematic of a motor coring apparatus which may be employed as part of the present invention;
FIG. 7 comprises a schematic of a survey tool which may be used to survey the wellbore drilled by the present invention or to steer the wellbore as it is being drilled; and
FIGS. 8A, 8B and 8C comprise, respectively, a side elevation, a side sectional elevation and a bottom elevation of an expandable drill bit particularly suited for use with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 of the drawings, a slant type drill rig 10 as is known in the art is depicted in the operation of drilling into the horizontally-oriented target zone or subterranean formation 12. As indicated by arrow 14, slant rig 10 is preferably capable of varying the tilt of the drilling mast from vertical to a predetermined angle, preferably seventy degrees, from vertical in order to permit reaching a horizontal wellbore orientation at various TVD's depending upon the job requirements. Slant rig 10 also includes a drive to rotate and to apply longitudinal force to bottom hole assemblies 40 and 140, the reason for which will hereinafter become apparent.
Before drilling of a well or a series of wells begins, each is carefully engineered to meet the objectives of the operation, be they monitoring, remediation or otherwise. The depth and direction of the horizontal portion of the wellbore, liner screen length and number of centralizers as well as completion, development and pumping methods are predetermined due to the contaminated or purportedly contaminated nature of the monitoring or remediation site.
After the above planning operation is completed, rig 10 is moved into place and aligned to drill the lateral or horizontal portion of the wellbore in the desired direction, the angle of the mast being adjusted to provide the desired TVD of the wellbore after a curved wellbore section of a given radius is drilled. Thereafter, a hole is augured into the earth from the surface using the power top drive of the drill rig, and a conductor pipe or casing 16 is set and cemented in place as shown at 18. The foregoing steps are well known in the art, and do not form a part of the present invention.
Referring now to FIGS. 2A and 2B of the drawings, the bottom hole assembly 40 for drilling the curved sector 20 (see FIG. 1) of the wellbore is shown to comprise inner drill string 50 and outer casing string 70.
Inner string 50 includes, from the top down, at least one stand of drill pipe 52, preferably in twenty foot lengths and of 27/8" diameter, formed of grade "G" low alloy steel. Each stand of drill pipe 52 includes pin and box threads at the ends thereof for connection to other stands above and below as drilling proceeds. Below the lowermost stand of drill pipe 52 is a 27/8" non-magnetic survey collar 54 with an orienting muleshoe (not shown) at the bottom interior thereof as is known in the art for receiving and orienting a survey or steering tool. Collar 54 also is provided with pin and box type threads for connection to the drill pipe 52 above and ball joint 56 of motor 58 below. Motor 58 is preferably a 63/4" diameter low speed high torque Moineau type hydraulic motor operable using fresh water as a drilling fluid, as no additives which may cause formation contamination are permitted in drilling at a monitoring or remediation site. Ball joint 56 is of a design, known in the art, wherein mutual rotation of collar 54 and motor 58 about the longitudinal axis of the bottom hole assembly 40 is prevented, while the included angle between the longitudinal axes of collar 54 and motor 58 is permitted to vary in order to isolate motor 58 from bending stresses, and particularly those attributable to the passage of the bottom hole assembly 40 through a short radius curve sector of the wellbore. Mounted on the exterior of the motor near the upper and lower ends thereof are stabilizers 60 and 62, which may each comprise mutually rotatable interior and exterior components which in a first mutual rotational orientation result in the exterior component substantially concentrically surrounding motor 58, and in a second rotational orientation result in the exterior component eccentrically surrounding motor 58, differing degrees of mutual rotational component orientation between the two extremes resulting in differing degrees of stabilizer eccentricity. Alternatively, stabilizers 60 and 62 may comprise slip-on or screw-on collar type stabilizers which may be interchanged depending upon the degree of eccentricity or concentricity desired. At the lower end of inner drill string 50, expandable bit 64 (shown in its expanded mode at 121/4" diameter) is secured to the driveshaft of motor 58. Expandable bit 64 may be of one of several designs known in the prior art, but an especially suitable design for both bit 64 and bit 164 is depicted in FIG. 8 of the drawings, and will be described in some detail hereafter. However, several suitable bit designs, including that of FIG. 8, are disclosed and claimed in copending U.S. patent application Ser. No. 541,841, filed on even date herewith and incorporated herein for all purposes by this reference.
Outer string 70 is comprised, beginning at the top, of one or more stands of nominal ten inch casing 72, preferably of high density polyethylene (HDPE), as this material is light, inexpensive, flexible and inert with respect to other substances, such as contaminants. Spring type centralizers 74, such as are known in the art, are placed at suitable intervals to centralize casing 72 within the wellbore prior to cementing. The number of centralizers 72 is dependent upon the length of the curve to be drilled and spring strength, the centralizer springs normally being of greater diameter than the hole diameter (in this instance 121/4") so as to be compressed to centralize the casing when run into the hole and permit cement to fully encompass it thereafter. Casing stands 72 have threaded connectors at each end thereof for securing stands to each other and to casing joint 76 at the lowermost or leading end of outer string 70. Casing joint 76 is preferably formed of HDPE, approximately nine inches in I.D. and 103/4" in O.D., and of a length approximating that of motor 58, not including ball joint 56. Upper and lower concentric stabilizers 78 and 80, respectively, are mounted on casing joint 76, and provide it with a 121/8" gage. Stabilizers 78 and 80 may be of steel or any other suitable material. At the bottom of casing joint 76, casing shoe 82, which preferably is integral with lower stabilizer 80, includes an inwardly extending shoulder 84 at its lower end to provide a seat for lower motor stabilizer 62, the purpose of which will be explained shortly.
Referring to FIGS. 3A and 3B of the drawings, a bottom hole assembly 140 for drilling the horizontal sector 30 of the wellbore according to the present invention is shown to comprise inner drill string 150 and outer liner string 170.
Inner string 150 includes, from the top down, drill pipe 52 and non-magnetic collar 54 as previously described with respect to inner string 50. Motor 158, secured to collar 54 by ball joint 156 of the same type as ball joint 56, is preferably of the same type but smaller diameter and lower power than motor 58, and preferably 43/4". Stabilizers 160 and 162 are of the same design as stabilizers 60 and 62, that is to say adjustable or replaceable as between concentric and eccentric orientations with respect to the motor axis. Expandable bit 164 is secured to the drive shaft of motor 158 and is shown in its 85/8" diameter expanded mode in the drawing.
Outer liner string 170 includes, from the top down, one or more stands 172 of six inch nominal HDPE slotted liner, surrounded at appropriate intervals by centralizers 174 to provide centralization during a subsequent completion (gravel packing) operation. At the bottom of lowermost liner stand 172 at the leading end of liner string 170 is casing joint 176 having upper and lower concentric stabilizers 178 and 180 thereon, providing an 81/2" gage. The I.D. of the joint is approximately 5.65" and the O.D., 6.6". Casing shoe 182, which is preferably integral with lower stabilizer 180, includes inwardly extending shoulder 184 at the bottom thereof to provide a seat for lower motor stabilizer 162.
Referring now to FIGS. 4A through 4C, the interrelationship between the inner drill string and outer casing or liner string of the present invention in forming bottom hole assembly 40 and 140 is depicted. FIG. 4A shows the lowermost end of inner drill string 50 as it is being either inserted within outer casing string 70 or withdrawn therefrom. As can be seen, the retracted blades 66 of bit 64 permit passage of the inner string 50 within outer string 70, as stabilizers 60 and 62 are of slightly lesser diameter than the I.D. of casing 72 and casing joint 76. Downward passage of inner string 50 is halted or arrested, however, when lower motor stabilizer 62 contacts shoulder 84 of casing shoe 82, as shown in FIGS. 4B and 4C. Thus, when inner string 50 reaches the end of its travel at the end of outer string 70, and motor 58 is supplied with hydraulic fluid through drill pipe 52 and non-magnetic collar 54, bit 64 begins to turn, bit rotation and fluid flow therethrough causing blades 66 to expand and drill to a diameter greater than that of outer string 70. As a forwardly longitudinally directed force is applied to bit 64 from the surface via drill pipe 52, outer string 70 is pulled forward by inner string 50 because of the interaction of shoulder 84 and lower motor stabilizer 62. The foregoing description of the bottom hole assembly 40 is equally applicable to the components 150 and 170 of bottom hole assembly 140, so the latter will not be described as a unit in detail.
FIG. 4B depicts bottom hole assembly 40 in a curved drilling mode, as can be seen from the bit offset 90 from the path of the wellbore as determined by upper and lower casing joint stabilizers 78 and 80. This offset is caused by the tilting of the motor 58 with respect to casing joint 76 due to the eccentricity of motor stabilizers 60 and 62. Thus, bottom hole assembly will drill a curved wellbore in the direction of bit offset, which is known and controlled at the surface, being changeable by rotation of the drill string 50 via drill pipe 52 through a partial arc to a new orientation, ball joint 56 ensuring exact rotation orientation of motor 58. While the foregoing comments have been directed to bottom hole assembly 40, they are equally applicable to bottom hole assembly 140.
FIG. 4C depicts bottom hole assembly 140 in a horizontal drilling mode, wherein stabilizers 160 and 162 are concentric with motor 158 or, at most, very slightly eccentric, so as to cause an almost indistinguishable amount of bit offset. If stabilizers 160 and 162 are truly concentric, the wellbore will be perfectly straight unless diverted by a change in subsurface formation characteristics or an obstacle. If stabilizers 160 and 162 are slightly eccentric, the bottom hole assembly 140 will drill a curve of extremely long radius, and the assembly can be steered, as assembly 40, by rotation of drill string 150 via drill pipe 52 through a partial arc to a new orientation. While the foregoing comments have been directed to bottom hole assembly 140, they are equally applicable to bottom hole assembly 40.
Referring now to FIGS. 5A through 5E of the drawings, a drilling operation utilizing the apparatus of the present invention and according to the method of the present invention will be described.
FIG. 5A depicts bottom hole assembly 40 as it drills a curved wellbore sector 20 from the end of surface casing or conductor pipe 16. It will be understood by those skilled in the art that, as the wellbore increases in length, additional sections of casing 72 and stands of drill pipe 52 are added to bottom hole assembly 40 at rig 10 on the surface. Bottom hole assembly 40 is advanced in the wellbore as drilling proceeds by pushing, or applying a forwardly longitudinally directed force to inner drill string 50, which then pulls casing string 70 with it. In this view, the eccentricity of motor stabilizers 60 and 62 has been exaggerated for clarity. When the wellbore reaches a horizontal orientation, inner drill string 50 is withdrawn from the wellbore and motor stabilizers 60 and 62 are either adjusted to a concentric orientation or, if replaceable types are used, concentric stabilizers slipped onto the motor, and drill string 50 reinserted into casing string 70. Next, as shown in FIG. 5B, bottom hole assembly 40 drills ahead horizontally a short distance, for example ten feet, to reduce the bending loads on casing shoe 82 and stabilizers 78 and 80 imposed by casing 72 being pulled into a curved orientation. Drill string 40 is again withdrawn, and casing string 70 is cemented into the wellbore by means known in the art, and preferably by an innerstring type cementing system whereby a cementing plug or shoe is run to casing shoe 82 and cement pumped down an inner string of small diameter tubing or drill pipe within casing string 70 to the end thereof through the plug and out into the annulus between the wellbore wall and the casing string, centralizers 74 providing a standoff for the cement 100 (see FIGS. 5C, D & E) to surround the string and encase it.
At this point, the innerstring cementing string is pulled from the well, and bottom hole assembly 140 is run within casing string 70 to casing shoe 82. As shown in FIG. 5C, motor 158 is started, and bit 164 expands and drills through the cement at the end of casing string 70 and casing shoe 82, stabilizers 178 and 180 on the exterior of liner string 170 preventing sidetracking of bit 164 as it drills through the shoe and into the formation.
As bottom hole assembly 140 advances into the formation, inner drill string 150 pulls liner string 170 with it, as shown in FIG. 5D, centralizers 174 maintaining liner 172 in the center of the well bore. In the same manner as with bottom hole assembly 40, additional sections of liner 172 and drill pipe 52 are added at rig 10 as the length of the wellbore increases. As can be seen in FIG. 5E, drilling fluid (water) is pumped to motor 158 through drill pipe 52 and then leaves the inner drill string through bit nozzles as is common in the art, after which it returns to the surface primarily through the annulus 180 between the liner string 170 and the wellbore wall until it reaches the cemented in place casing string 70 where it travels between the I.D. of the casing string and the O.D. of the liner string. Part of the fluid returning to the surface does so through the interior 190 of the liner string 170, due to the fact that the liner is slotted for purposes of subsequent gravel packing. However, all of the drilling fluid returns are taken to the surface, regardless of the path taken, to a tank or other receptacle where cuttings are removed, the fluid filtered, and reintroduced into the drill pipe as is known in the art. The drilling fluid circulation system, unlike many systems used in oil and gas drilling, is completely closed loop, so that no fluid is permitted to contaminate the surface of the job site.
After the desired length of the horizontal sector 30 of the wellbore is reached, inner drill string 150 is withdrawn from the well, while liner string 170 remains in place, centralized in annulus 180 by centralizers 174. It is then normally desirable to gravel pack the wellbore around the liner string 170 in order to prevent formation collapse, and clogging of the liner slots. A preferred procedure for gravel packing a horizontal wellbore is described and claimed in copending U.S. patent application Ser. No. 541,839, now U.S. Pat. No. 5,040,601, filed on even date herewith and incorporated for all purposes herein by this reference.
It will be understood and appreciated by those of ordinary skill in the art that the terms "casing string" and "liner string" as used herein both describe a tubular conduit within which a drill string may be run according to the present invention, and the terms "liner string" has been used for convenience to address a conduit, slotted or unslotted, of lesser diameter than another conduit, termed a "casing string". In fact, only a single conduit may be run in practicing the invention, and the use of two such conduits, the smaller thereof being apertured or slotted, is disclosed as exemplary of the preferred embodiment of the invention, and not as a limitation thereof.
FIG. 6 of the drawings depicts a coring assembly 200 which can be run into the wellbore o inner drill string 150 and driven by motor 158 in lieu of a drill bit. Coring assembly 200 includes a core bit 202 at the lower end of core barrel 204, which surrounds an inner tube (not shown) for receiving the core as is known in the art, the inner tube being supported on bearing means within the core barrel to maintain alignment with and rotational relationship with respect to core barrel 204 and core bit 202. Of course, if core orientation is unimportant, the inner tube could rotate with the core barrel. Unique to the coring assembly 200 is stabilizer 206, to ensure a straight coring path, and a flexible coupling 208 in the drive train between motor 158 and core barrel 204 to permit coring assembly 200 to pass through the short radius curved sector 20 of the well between the conductor pipe or casing 16 at the surface and the horizontal sector 30 of the wellbore. After a core is taken, coring assembly 200 is withdrawn from the well, and inner drill string 150 with a bit replaced on the drive shaft of motor 158 is again run into the wellbore for drilling ahead. Multiple core samples may be taken sequentially by rerunning coring assembly into the wellbore, and it is contemplated that at some sites it may be desirable to core completely through the plume of contaminants to measure relative concentrations and direction of travel of the contaminants.
FIG. 7 of the drawings schematically depicts an articulated survey tool 210 which can be employed inside drill strings 50 and 150 to measure dogleg of the wellbore and its orientation. From these measurements and a known reference section of the well, the azimuth and inclination of the wellbore (as well as the location of the bottom hole assembly at any given time) may be calculated using methods well known in the surveying art. The tool can be a single shot or multi-shot tool, of conventional or electromagnetic design. A tri-axial accelerometer is included arrows 212 for the ability to ascertain the high side of the drill string for steering purposes. The survey information can be stored in the tool on magnetic media for survey purposes, or transmitted to the surface real-time via wireline 214 for steering. Concentric stabilizers 216 surround the instrument housing of the tool to centralize it in the drill string, while orienting nose 218 at the lower end of the tool engages an orienting mule shoe at the bottom of nonmagnetic survey collar 54 at the end of the drill string. Strain gauges may be placed in section 220 of the tool to measure the relative bend between upper and lower tool housings 222 and 224. One suitable articulated downhole tool capable of use with the present invention is disclosed and claimed in U.S. Pat. No. 4,901,804, issued Feb. 20, 1990 and assigned to the assignee of the present invention.
FIGS. 8A-C disclose a drill bit 64 having two blades 66 pivotally mounted on bit body 300 having a threaded pin portion 302 at the top thereof, by which bit 64 may be secured to the driveshaft of downhole motor 58. It should be understood that bit 164, as previously referred to herein, may be identical to bit 64, except of smaller diameter for use with motor 158.
The lower portion of bit 64 comprises a blade housing 304 defining blade cavities 306 in which blades 66 are pivotally disposed on pivot pins 308, set in bores 310 which are perpendicularly oriented to the axis of bit 64, and laterally offset therefrom. Pins 308 are secured in blade housing 304 by any conventional means such as threaded pin head 310, the top of which is shown in FIG. 8A.
The bottom of bit 64 comprises pilot bit 312, including pilot blades 314 having hardfacing, such as a tungsten alloy, on at least the edges 316 thereof, edges 316 having a slight backrake with respect to the plane of the blades 66.
Referring to FIG. 8B, axial fluid entry counterbore 318 extends from the top of bit 64 to toroidal fluid plenum 320 surrounding the upper end of plunger bore 322 in which blade expansion plunger 324 is disposed, O-ring 326 providing a sliding fluid seal between the exterior of plunger 324 and the wall of plunger bore 322. The lower end of plunger 324 terminates at hemispherical blade contact 328. Upper end 330 of plunger 324 extends into counterbore 318 when bit blades 66 are in their retracted position, thus defining a restricted hydraulic flow area between plunger 324 and the wall of counterbore 318 for enhanced responsiveness to increases in fluid flow.
Bit blades 66 are generally planar in configuration, and may be described as winglike. Blades 64 have pivot pin apertures 332 therethrough, through which pivot pins 308 extend. The uppermost ends of blades 66 comprise small radiused plunger contacts 334 which are acted upon by blade contact 328. Preferably, the entire leading face 336 of each blade 66 is hardfaced, but at least the edge 338 is hardfaced. As with the pilot blades, edges 338 of blades 64 are preferably backraked. A spring-loaded ball detent (not shown) may be placed in the wall of the blade housing 304 in each blade cavity 306 adjacent each blade 64 to interact with a dimple on the side of each blade to maintain blades 64 in the retracted position against gravity as the bit is run or withdrawn horizontally. Alternatively, a torsional spring may be placed on the pivot pins to act on the blades, magnets may be used, or other means known in the art may be employed.
FIGS. 8A and 8C illustrate the drilling fluid paths utilized in bit 64. Toroidal plenum 320 feeds two pilot bit nozzles 340 via passages 342, and two bit nozzles 344 via passages 346. Nozzles 340 may be oriented parallel to the bit axis, or slightly inclined toward their respective pilot blades. Nozzles 344 are angled outwardly from the bit axis in order to provide a cleaning flow for blades 66 in their expanded position. Nozzles recesses 348 in the exterior of the bit permit nozzles 344 to be placed within the radial dimensions of the bit body while allowing a clear flow path toward the leading faces of the blades 66.
In operation, bit 64 would normally be run into the wellbore in its retracted position on drill string 50 within outer string 70. When it is desired to expand the bit to drill ahead, as shown in FIG. 5A, it is necessary to expand bit 64 to drill a bore larger than that of outer string 70, so fluid flow is commenced or increased to a sufficient volume to actuate plunger 324 to pivot blades 66 about pins 308 to extend from blade cavities 306 to increase the effective cutting diameter of the bit. As blades 66 contact the formation, the contact will further serve to expand the blades outwardly. As the bit rotates after full expansion of blades 66, the pilot blades 314 will cut the center of the bore being drilled, while blades 66 will cut the outer extent thereof surrounding pilot blades 314. The pilot bit nozzles and bit nozzles direct hydraulic flow to cool and clean the blades and to remove formation cuttings from the vicinity of the blades and up the wellbore annulus. If it is desired to withdraw bit 64 from the wellbore, fluid flow is reduced and the blades retract into cavities 304 when the tops thereof contact casing shoe 82 as drill string 50 is withdrawn into outer string 70, bit 64 then being pulled from the wellbore on drill string 50. The bit may then be replaced with a new bit, or reinserted in the well, and expanded as previously described.
While the foregoing description of the structure and operation of an expandable bit has been directed to bit 64, it should be understood that it is equally applicable to bit 164. Other, equally suitable bits for use with the present invention are described and claimed in the aforementioned and previously incorporated U.S. patent application Ser. No. 581,841.
While the apparatus and method of the present invention have been described with reference to certain preferred embodiments, it will be understood and appreciated by one of ordinary skill in the art that many additions, deletions and modifications to the preferred embodiments may be made without departing from the scope of the invention as hereinafter claimed.
|
The present invention comprises a method and apparatus for simultaneously drilling and casing a wellbore. More specifically, the apparatus comprises an outer conduit string containing an inner drill string carrying a bit capable of drilling a wellbore of greater diameter than the outer string. The drill string may be adapted to drill a nonlinear wellbore by offsetting the drill bit from the longitudinal axis of the outer string, and the drill bit is preferably retractable to permit withdrawal of the drill string after the wellbore is completed, leaving the outer string of casing or liner in place. The wellbore is drilled by rotating the drill bit and advancing the drill string by pushing from the surface, and the outer string is advanced by being pulled along by the drill string.
| 4
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a flush toilet equipped with a deodorizing apparatus, and more particularly, it relates to a flush toilet and a deodorizing method of the flush toilet capable of cleaning and sterilizing a toilet bowl.
[0003] 2. Description of the Related Art
[0004] To remove an odor during use of a flush toilet, it may be insufficient to merely flush it away after use, and various deodorizing apparatuses have heretofore been proposed to deodorize the flush toilet.
[0005] Japanese Patent Publication Laid-open No. 3-286052 discloses a deodorizing apparatus wherein after an odor in a toilet bowl is sucked in by an operation of a ventilator, the odor is blown to a water containing member supplied with water in order to dissolve an offensive odor components in the water in the water containing member, and then it is discharged to sewage through drain pipes. However, this deodorizing apparatus has problems that it is necessary to provide the drain pipe in an intermediate part between a discharge part of the bowl and the sewage and it is not easy to install the drain pipe in an existing bowl, and that because the water containing member contains water, a pressure loss is caused by the water containing member when the offensive odor components are sucked in.
[0006] Furthermore, Japanese Patent Publication Laid-open No. 2000-129747 discloses that sterile water is supplied to a filter having moisture retention properties, and the odor in the bowl is sucked in via this filter to adsorb and decompose the offensive odor components by the sterile water, and then new sterile water is supplied to the filter to clean the filter, and the bowl is also sterilized by this sterile water. However, such a method of supplying the sterile water to the filter has a problem that the sterile water might deteriorate the filter, and that the wet filter causes a great pressure loss to increase load in the suction of the offensive odor components.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a flush toilet equipped with a deodorizing apparatus and a deodorizing method of the flush toilet which effectively remove a source of an offensive odor in the flush toilet and which can decompose the odor and also clean and sterilize a toilet bowl.
[0008] A flush toilet of the present invention is equipped with a bowl and flushing means for flushing an inside of the bowl, and the flush toilet comprises: an electrolytic cell fitted with a pair of electrodes and storing water; a power source to electrify the pair of electrodes; odor suction means for sucking in an odor of excrement; and odor supply means for supplying the odor sucked in by the odor suction means into the electrolytic cell, wherein the electrodes are electrified by the power source to generate electrolytic water in the electrolytic cell, and the odor is removed by the electrolytic water.
[0009] The flush toilet defined in claim 2 according to the invention of claim 1 further comprises: an adsorption member which adsorbs the odor sucked in by the odor suction means; and heating means for heating the adsorption member to release the odor adsorbed by the adsorption member, wherein the odor released from the adsorption member is supplied into the electrolytic cell by the odor supply means to remove the odor.
[0010] In the flush toilet defined in claim 3 according to the invention of claim 1 or 2 , the odor supply means supplies the odor into the electrolytic cell from a position lower than a half of a height of the electrolytic cell.
[0011] In the flush toilet defined in claim 4 according to the invention of claims 1 to 3 , the odor is supplied into the electrolytic cell by the odor supply means in a state where the electrolytic water is stored in the electrolytic cell.
[0012] The flush toilet defined in claim 5 according to the invention of claims 1 to 4 comprises: a flow path to flow the water or the electrolytic water in the electrolytic cell into the bowl; and a valve which is provided in the flow path and which controls whether or not to allow the water or the electrolytic water to be flown into the bowl.
[0013] In the flush toilet defined in claim 6 according to the invention of claim 5 , the flushing means comprises a flush lever or switch to flow water into the bowl, and the valve is opened in conjunction with the lever or switch.
[0014] The flush toilet defined in claim 7 according to the invention of claim 5 or 6 further comprises: detection means for detecting that the bowl is in use, and when the detection means detects that the bowl is in use, the valve is opened for a predetermined period every predetermined time.
[0015] The flush toilet defined in claim 8 according to the invention of claims 5 to 7 comprises a manual switch to open the valve for the predetermined period.
[0016] In a deodorizing method of a flush toilet of the present invention to implement deodorization in such a manner that an odor of excrement is supplied into an electrolytic cell which stores water and which includes a pair of electrodes provided so that at least part of the pair of electrodes is immersed in the water, and the method comprises electrifying the pair of electrodes before and/or during and/or after the supply of the odor into the electrolytic cell to generate electrolytic water in the electrolytic cell, and decomposing odor components contained in the odor by the electrolytic water.
[0017] In the deodorizing method of the flush toilet defined in claim 10 according to the invention of claim 9 , the electrolytic water is flown into a bowl to clean, sterilize and deodorize the bowl.
[0018] According to the present invention, a source of an offensive odor in a flush toilet can be removed, and the odor can be decomposed. Moreover, according to the present invention, the bowl of the flush toilet can be cleaned and sterilized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic configuration diagram of a flush toilet equipped with a deodorizing apparatus in Embodiment 1 of the present invention;
[0020] FIG. 2 is a schematic configuration diagram of the flush toilet equipped with the deodorizing apparatus in Embodiment 2 of the present invention;
[0021] FIG. 3 is a schematic configuration diagram of the flush toilet equipped with the deodorizing apparatus in Embodiment 3 of the present invention;
[0022] FIG. 4 is a schematic configuration diagram of the flush toilet equipped with the deodorizing apparatus in Embodiment 3 of the present invention;
[0023] FIG. 5 is a schematic configuration diagram of the flush toilet equipped with the deodorizing apparatus in Embodiment 4 of the present invention;
[0024] FIG. 6 is a schematic configuration diagram of the flush toilet equipped with the deodorizing apparatus in Embodiment 4 of the present invention;
[0025] FIG. 7 is a schematic configuration diagram of the flush toilet equipped with the deodorizing apparatus in Embodiment 5 of the present invention;
[0026] FIG. 8 is a schematic configuration diagram of the flush toilet equipped with the deodorizing apparatus in Embodiment 6 of the present invention;
[0027] FIG. 9 is a schematic configuration diagram of an experimental apparatus to explain a decomposition treatment mechanism of odor components by electrolysis of the present invention; and
[0028] FIG. 10 is a schematic configuration diagram of a hot water cleaning device using ozone water as one example of a hot water cleaning device of the flush toilet equipped with the deodorizing apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Preferred embodiments of a flush toilet of the present invention will hereinafter be described in detail with reference to the drawings.
Embodiment 1
[0030] One embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 shows a schematic configuration diagram of a flush toilet 8 equipped with a deodorizing apparatus 1 as the one embodiment of the present invention.
[0031] In the present embodiment, the flush toilet 8 includes the deodorizing apparatus 1 comprising an odor adsorption device 100 and an electrolysis device 20 ; a bowl 2 ; a seat 3 ; a water storage tank 4 to flush the bowl 2 ; a water supply pipe 5 coupled to an unshown water pipe to supply water to the water storage tank 4 ; and a hot water cleaning device 30 comprising an unshown hot water tank and the like.
[0032] The odor adsorption device 100 comprises a disk-shaped adsorption member 11 rotated at a predetermined speed; an air intake fan 12 which takes in an odor in the bowl 2 and an odor in a toilet room from an odor suction port 29 and an odor suction port 29 A via an odor flow path 15 to pass air containing the odors to the adsorption member 11 and which passes and circulate the air; an electric heater 13 which heats the adsorption member 11 to +60° C. to +120° C.; a circulation path 14 which circulates the odors heated by the electric heater 13 while passing the air through the adsorption member 11 in a reproduction portion 14 A in the vicinity of the adsorption member 11 ; a circulation fan 16 provided in the circulation path 14 ; a throttle portion 17 provided in the circulation path 14 ; etc.
[0033] The adsorption member 11 comprises an odor absorbent such as zeolite, and the odor of the flush toilet passed through the odor flow path 15 is adsorbed and collected in the adsorption member 11 . Here, the odor to be removed by the present invention includes hydrogen sulfide (H 2 S), methyl mercaptan (CH 3 SH), ammonia (NH 3 ) and the like emitted from excrement or vomit and wafting in the bowl and the toilet room.
[0034] The adsorption member 11 is rotated at a predetermined speed in a direction of an arrow in FIG. 1 , and a part which has adsorbed the odor through the odor flow path 15 will soon be turned to be located in the vicinity of the reproduction portion 14 A. In the reproduction portion 14 A, air heated to a high temperature by the electric heater 13 is circulated in the circulation path 14 , and the part turned to the reproduction portion 14 A is heated to the above-mentioned temperature by the high-temperature air. The adsorption member 11 releases the adsorbed odor when it is heated. Then, the released odor is carried to the throttle portion 17 in the circulation path 14 on the high-temperature air. It is to be noted that an odor adsorption function of the adsorption member 11 is restored by releasing the odor in the reproduction portion 14 A. Then, this is continuously performed along with the rotation of the adsorption member 11 .
[0035] On the other hand, one end of an intake pipe line 18 is connected to the circulation path 14 on an upstream side of the throttle portion 17 , while the other of the intake pipe line 18 is connected to an air diffusing pipe 26 of the electrolysis device 20 described later. Furthermore, an air pump 19 and a check valve 21 (directed forward to the air diffusing pipe 26 ) located on the air diffusing pipe 26 side of the air pump 19 are interposed in the intake pipe line 18 , and the air containing the odor stopped before the throttle portion 17 in the circulation path 14 by an operation of the air pump 19 is taken into the intake pipe line 18 , and then fed to the air diffusing pipe 26 via the check valve 21 .
[0036] The electrolysis device 20 comprises an electrolytic cell 23 ; a pump 6 which supplies water from the water storage tank 4 or the unshown water pipe into the electrolytic cell 23 via a supply pipe 7 ; the air diffusing pipe 26 which discharges (bubbles) the odor sent from the odor adsorption device 100 into the water in the electrolytic cell 23 ; at least one pair of electrolytic electrodes 24 , 25 provided in the electrolytic cell 23 ; an electrolytic water flow path 27 which is a flow path to flow the water in the electrolytic cell 23 into the bowl 2 through an outlet port 28 A; a valve 31 which controls water flowing from the electrolytic cell 23 to the electrolytic water flow path 27 ; a controller 22 which includes a microcomputer or the like, has a predetermined direct-current power source, electrifies the electrolytic electrodes 24 , 25 and controls an operation of an unshown motor to rotate the fans 12 , 16 , the electric heater 13 and the adsorption member 11 and operations of the air pump 19 , the valve 31 and the like; etc.
[0037] Both of the electrolytic electrodes 24 , 25 comprise insoluble metal electrodes based on, for example, platinum-iridium (Pt—Ir), and a distance between them is 3 mm, for example. It is to be noted that in the present invention, the electrolytic electrode means an electrode which is immersed in a water solution as water to be electrolyzed and which contributes directly to the electrolysis, and the electrolytic electrode also includes part of an electrode which is immersed to contribute directly to the electrolysis. Moreover, the electrolytic electrodes 24 , 25 comprise the pair of electrodes, but a plurality of electrolytic electrodes may be provided instead.
[0038] Furthermore, FIG. 10 shows a schematic configuration diagram of the hot water cleaning device 30 using ozone water as one example of the hot water cleaning device 30 of the flush toilet 8 in the present invention. This hot water cleaning device 30 comprises a shower nozzle 52 and a jet 51 which jets water to and wash a pubic region; a water passage 56 which supplies jet water to the jet 51 ; a heater 50 which heats water to produce warm water between the water passage 56 and the shower nozzle 52 ; an electrolysis device 55 which generates ozone water; electrolytic electrodes 53 , 54 which are immersed in the water flowing through the water passage 56 placed in the electrolysis device 55 ; and a controller 57 which includes a microcomputer or the like, has a predetermined direct-current power source, electrifies the electrolytic electrodes 53 , 54 and controls electrification of the heater 50 and the like; etc.
[0039] Of the electrolytic electrodes 53 , 54 , the electrolytic electrode 54 which serves as an anode comprises, for example, an electrode based on platinum-tantalum (Pt—Ta) as an ozone generating electrode, while the electrolytic electrode 53 which serves as a cathode comprises an insoluble metal electrode based on, for example, platinum-iridium as described above, and a distance between the electrodes is 6 mm, for example. It is to be noted that the platinum-tantalum-based electrode is an electrode in which an intermediate layer containing platinum is formed on a surface of a conductive base substance such as titanium, and a surface layer comprising a dielectric such as tantalum oxide and niobium oxide is formed on a surface of the intermediate layer. By using such a platinum-tantalum-based electrolytic electrode 54 as the anode, generation of hypochlorous acid can be restrained and ozone water of high concentration can be produced even when tap water containing chloride ions is electrolyzed.
[0040] In the above configuration, an operation of the flush toilet 8 equipped with the deodorizing apparatus 1 in the present embodiment will be described. It is to be noted that the tap water has been previously stored in the water storage tank 4 and the electrolytic cell 23 before use of the flush toilet in the present embodiment. In addition, about 5 to 200 mg/l in general, about 17 mg/l on average of chloride ions is contained in the tap water for sterilization depending on regions and seasons.
[0041] Deodorization Mode
[0042] First, a deodorization mode to deodorize the flush toilet will be described. When the flush toilet 8 is used and excrement such as human waste is discharged into the bowl 2 , an odor caused by hydrogen sulfide, methyl mercaptan, ammonia and the like is produced in the bowl 2 and the toilet room as described above. Here, by sensing the use of the toilet, for example, by an unshown odor sensor or by an unshown seating sensor for the seat 3 , or by a manual switch, the controller 22 operates the fan 12 and also operates a rotating motor of the adsorption member 11 to rotate the adsorption member 11 at the predetermined speed. By the operation of the fan 12 , the air containing the odor in the bowl 2 and the toilet room is passed from the odor suction port 29 and the odor suction port 29 A to the adsorption member 11 via the odor flow path 15 , whereby hydrogen sulfide, methyl mercaptan, ammonia and the like which are odor components are sucked and collected in the adsorption member 11 .
[0043] Such an operation of collecting the odor into in the adsorption member 11 is generally performed for a predetermined period, for example, five minutes every time the flush toilet is used.
[0044] Odor Component Decomposition Mode
[0045] Furthermore, the flush toilet is used a predetermined number of times, for example, three times, and the odor collection is performed the predetermined number of times, and a certain amount of the odor components is thus collected in the adsorption member 11 . Then, an odor component decomposition mode is executed.
[0046] When the odor component decomposition mode is executed, the controller 22 operates the fan 16 and the air pump 19 , and also operates the rotating motor of the adsorption member 11 to rotate the adsorption member 11 at the predetermined speed, thereby electrifying the electric heater 13 for heat generation.
[0047] The adsorption member 11 which has adsorbed and collected the odor components in the above-mentioned deodorization mode will soon reach the reproduction portion 14 A by the rotation, where the adsorption member 11 is heated by the high-temperature air circulated by the fan 16 and heated by the electric heater 13 . By heating the adsorption member 11 in this manner, the odor components adsorbed by the adsorption member 11 are released, and moved to the throttle portion 17 of the circulation path 14 together with the high-temperature air. The air containing a large amount of the released odor components is taken into the intake pipe line 18 by the air pump 19 , and arrives at the air diffusing pipe 26 provided at the bottom of the electrolytic cell 23 of the electrolysis device 20 via the check valve 21 . The air containing the large amount of the odor components fed to the air diffusing pipe 26 is bubbled in an amount of 0.1 to 50.01/min, preferably an amount of 0.5 to 1.01/min in the water within the electrolytic cell 23 , and passes between the electrolytic electrodes 24 , 25 and around them in a form of bubbles.
[0048] On the other hand, the controller 22 supplies electric power to the electrolytic electrodes 24 , 25 . At this time, the electrolytic electrode 24 to which a positive potential is applied serves as the anode, while the electrolytic electrode 25 to which a negative potential is applied serves as the cathode. Further, the controller 22 may change polarities of the electrolytic electrodes 24 , 25 every predetermined time, for example, three minutes. If the polarities of the electrolytic electrodes 24 , 25 are changed in this manner, the electrolytic electrode 24 serves as the cathode and the electrolytic electrode 25 serves as the anode, and moreover, scale such as calcium sticking to surfaces of the electrodes can be removed.
[0049] Furthermore, since the tap water generally containing about 17 mg/l of chloride ions as described above is stored in the electrolytic cell 23 in which the odor components have dissolved, the chloride ions emit electricity to produce chlorine in the electrolytic electrode 24 which serves as the anode (Reaction Formulas (1), (2)). Subsequently, chlorine dissolves in the water, and hypochlorous acid is produced (Reaction Formula (3)). Reaction Formulas (1), (2), (3) are shown below.
NaCl→Na + +Cl − (1)
2Cl − →Cl 2 +2e − (2)
Cl 2 +H 2 O→HClO+HCl (3)
[0050] Furthermore, the air fed into the electrolytic cell 23 as described above easily contacts the water, and the odor components contained in the air therefore dissolve in the water. Thus, hydrogen sulfide, methyl mercaptan, ammonia and the like which are the odor components dissolve in the water and are decomposed by the electrolytic water containing hypochlorous acid, thereby releasing air in a cleaned state into the toilet room.
[0051] It is to be noted that regarding the electrolysis by the electrification of the electrolytic electrodes 24 , 25 in accordance with the controller 22 described above, the tap water in the electrolytic cell 23 may be electrolyzed in advance for a predetermined period before the bubbling of the odor components so that the electrolytic water containing hypochlorous acid may be produced in the electrolytic cell 23 , or the tap water may be electrolyzed during the bubbling, or the tap water may be electrolyzed after the odor components are dissolved in the tap water.
[0052] Here, a decomposition treatment mechanism of the odor components using the electrolysis of the water solution will be described with reference to FIG. 9 . In addition, FIG. 9 is a schematic configuration diagram of an experimental apparatus to explain the decomposition treatment mechanism of the odor components.
[0053] This experimental apparatus comprises a sealed glass vessel 43 which stores 300 ml of test water; the air diffusing pipe 26 which bubbles the odor components in the test water; an odor sealing pack 41 and an air pump 42 which feed test odor components to the air diffusing pipe 26 ; a recovery pack 45 to collect a gas over a surface of the water in the glass vessel 43 ; a liquid gathering syringe 44 which gathers the test water; the electrolytic electrodes 24 , 25 which are immersed in the test water; and the controller 22 .
[0054] The test water used includes the following two kinds: a water solution in which sodium chloride (NaCl) is dissolved in purified water to have a chloride ion concentration of 5 mg/l (hereinafter referred to as Cl − 5 mg/l water), and a water solution in which sodium chloride (NaCl) is dissolved in purified water to have a chloride ion concentration of 17 mg/l (hereinafter referred to as Cl − 17 mg/l water).
[0055] Furthermore, the odor components to be evaluated in the present experiment include three kinds of odor components: hydrogen sulfide, methyl mercaptan and ammonia. These odor components are diluted with argon gas so that a gas concentration of hydrogen sulfide may be 3 ppm, that a gas concentration of methyl mercaptan may be 3.2 ppm, and that a gas concentration of ammonia may be 4.8 ppm, and these are then sealed into separate odor sealing packs 41 . These components are bubbled in the test water at a flow volume of 0.5 ml/min by the air pump 42 via the air diffusing pipe 26 . Then, the odor components which have passed through the test water are collected by the recovery pack 45 , and gas concentration measurement of the odor components is made by a gas chromatograph and a detector tube, while the test water is gathered by the liquid gathering syringe 44 , and solution components of the test water are analyzed by an ion chromatograph. It is to be noted that the gas concentrations of the odor components are about ten times as high as the gas concentrations of the odor contained in the odor in general flush toilets.
[0056] Then, the platinum-iridium-based electrolytic electrodes 24 , 25 similar to the ones described above are immersed in the test water. It is to be noted that the electrolytic electrodes 24 , 25 used in the experiment have dimensions including a length of 60 mm, a width of 35 mm and a thickness of 2 mm, and the distance between the electrodes is 3 mm as above. Then, a constant current having a current density of 20 mA/cm 2 is applied to the electrolytic electrodes 24 , 25 by the controller 22 .
[0057] Since the chloride ions are contained in the test water as described above, the chloride ions emit electricity to produce chlorine (Cl) in the electrolytic electrode 24 which serves as the anode. Subsequently, chlorine dissolves in the water, and hypochlorous acid (HClO) is produced (Reaction Formulas (1), (2), (3)).
[0058] Table 1 shows the concentration (mg/l) of hypochlorous acid in the test waters before and after bubbling and the concentration (ppm) of hydrogen sulfide as the gas concentration of the odor component in a recovery gas pack. In this case, the following test waters were used: the above-mentioned Cl − 5 mg/l water electrolyzed for three minutes before five-minute bubbling of the odor components described later (hereinafter referred to as Cl − 5 mg/l electrolytic water), and the above-mentioned C − 17 mg/l water electrolyzed for three minutes before five-minute bubbling of the odor components described later (hereinafter referred to as Cl − 17 mg/l electrolytic water). Then, 3 ppm of hydrogen sulfide was sealed as the odor component into the odor sealing pack 41 , and the hydrogen sulfide gas was bubbled for five minutes in the respective test waters. Table 2 shows the concentration of hypochlorous acid and the concentration of hydrogen sulfide in a case where the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water are also electrolyzed during the five-minute bubbling.
[0059] As apparent from Table 1 and Table 2, 1 ppm of hydrogen sulfide was also detected in the Cl − 5 mg/l water after the bubbling, and when the odor in the recovery gas pack was smelled, an unpleasant odor of hydrogen sulfide was perceived. On the contrary, hydrogen sulfide was not detected from the recovery pack after the bubbling in the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water. Further, in accordance with the solution analysis by the ion chromatograph, sulfate ions (SO 4 2− ) were detected from the test waters after the bubbling in the case of the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water. It was presumed from the above that hydrogen sulfide was decomposed by hypochlorous acid into odorless sulphuric acid. A degradation reaction of hydrogen sulfide by hypochlorous acid is shown below in Reaction Formula (4).
H 2 S+4HClO→6H + +SO 4 2− +4Cl − (4)
[0060] In addition, no difference was recognized in the concentration of hydrogen sulfide after the bubbling between the case where the electrolysis was also implemented during the bubbling (Table 2) and the case where the electrolysis was not implemented (Table 1). However, the concentration of hypochlorous acid after the bubbling was higher in the case where the electrolysis was also implemented during the bubbling. It is thus considered that more hydrogen sulfide can be decomposed in the case where the electrolysis is implemented, and that sterilizing and odor eliminating effects are improved when the electrolytic water in the electrolytic cell 23 of the present invention is flown into the bowl 2 as described later.
TABLE 1 Hypochlorous acid Hydrogen sulfide concentration (mg/l) concentration (ppm) Before After Before After bubbling bubbling bubbling bubbling Cl − 5 mg/l 0 0 3.0 1.0 water Cl − 5 mg/l 3.0 1.5 3.0 Undetected electrolytic water Cl − 17 mg/l 7.0 4.0 3.0 Undetected electrolytic water
[0061]
TABLE 2
Hypochlorous acid
Hydrogen sulfide
concentration (mg/l)
concentration (ppm)
Before
After
Before
After
bubbling
bubbling
bubbling
bubbling
Cl − 5 mg/l
0
0
3.0
1.0
water
Cl − 5 mg/l
3.0
5.7
3.0
Undetected
electrolytic
water
Cl − 17 mg/l
7.0
15.5
3.0
Undetected
electrolytic
water
[0062] Table 3 shows the concentration (mg/l) of hypochlorous acid in the test waters before and after bubbling and the concentration (ppm) of methyl mercaptan as the gas concentration of the odor component in the recovery gas pack. In this case, the test waters used were: the Cl − 5 mg/l water, the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water. Then, 3.2 ppm of methyl mercaptan was sealed as the odor component into the odor sealing pack 41 , and the methyl mercaptan gas was bubbled for five minutes in the respective test waters. Table 4 shows the concentration of hypochlorous acid and the concentration of methyl mercaptan in a case where the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water are also electrolyzed during the five-minute bubbling.
[0063] As apparent from Table 3 and Table 4, 0.9 ppm of methyl mercaptan was also detected in the Cl − 5 mg/l water after the bubbling, and when the odor in the recovery gas pack was smelled, an unpleasant odor of methyl mercaptan was perceived. On the contrary, methyl mercaptan was not detected from the recovery pack after the bubbling in the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water. Further, in accordance with the solution analysis by the ion chromatograph, metal sulfonic acid (SO 4 2− ) was detected from the test waters after the bubbling in the case of the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water. It was presumed from the above that methyl mercaptan was decomposed by hypochlorous acid into metal sulfonic acid which was an odorless component. A degradation reaction of methyl mercaptan by hypochlorous acid is shown below in Reaction Formula (5).
CH 3 SH+3HClO→CH 3 SO 3 H+3HCl (5)
[0064] In addition, no difference was recognized in the concentration of methyl mercaptan after the bubbling between the case where the electrolysis was also implemented during the five-minute bubbling (Table 2) and the case where the electrolysis was not implemented (Table 1), as in the case of hydrogen sulfide described above. However, the concentration of hypochlorous acid after the bubbling was higher in the case where the electrolysis was also implemented during the bubbling. It is thus considered that more methyl mercaptan can be decomposed in the case where the electrolysis is implemented, and that the sterilizing and odor eliminating effects are improved when the electrolytic water in the electrolytic cell 23 of the present invention is flown into the bowl 2 as described later.
TABLE 3 Hypochlorous acid Methyl mercaptan concentration (mg/l) concentration (ppm) Before After Before After bubbling bubbling bubbling bubbling Cl − 5 mg/l 0 0 3.2 0.9 water Cl − 5 mg/l 2.6 1.2 3.2 Undetected electrolytic water Cl − 17 mg/l 7.0 4.5 3.2 Undetected electrolytic water
[0065]
TABLE 4
Hypochlorous acid
Methyl mercaptan
concentration (mg/l)
concentration (ppm)
Before
After
Before
After
bubbling
bubbling
bubbling
bubbling
Cl − 5 mg/l
0
0
3.2
0.9
water
Cl − 5 mg/l
2.6
4.8
3.2
Undetected
electrolytic
water
Cl − 17 mg/l
7.0
15.2
3.2
Undetected
electrolytic
water
[0066] Table 5 shows the concentration (mg/l) of hypochlorous acid in the test waters before and after bubbling and the concentration (ppm) of ammonia as the gas concentration of the odor component in the recovery gas pack. In this case, the test waters used were: the Cl − 5 mg/l water, the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water. Then, 4.8 ppm of ammonia was sealed as the odor component into the odor sealing pack 41 , and the ammonia gas was bubbled for five minutes in the respective test waters. Table 6 shows the concentration of hypochlorous acid and the concentration of ammonia in a case where the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water are also electrolyzed during the five-minute bubbling.
[0067] As apparent from Table 5 and Table 6, 0.5 ppm of ammonia was also detected in the Cl − 5 mg/l water after the bubbling, and when the odor in the recovery gas pack was smelled, an unpleasant odor of ammonia was perceived. On the contrary, ammonia was not detected from the recovery pack after the bubbling in the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water. Further, in accordance with the solution analysis by the ion chromatograph, ammonium ions (NH 4 + ) were not detected from the test waters after the bubbling in the case of the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water. It was presumed from the above that ammonia dissolved in the test waters was decomposed by hypochlorous acid due to a so-called break point. Degradation reactions of ammonia by hypochlorous acid are shown below in Reaction Formulas (6) to (8).
NH 4 + +ClO − →NH 2 Cl+H 2 O (6)
NH 2 Cl+ClO − →NHCl 2 +H 2 O (7)
NH 2 Cl+NHCl 2 →N 2 ↑+ 2 3H 2 Cl (8)
[0068] In addition, no difference was recognized in the concentration of ammonia after the bubbling between the case where the electrolysis was implemented during the five-minute bubbling (Table 2) and the case where the electrolysis was not implemented (Table 1), as in the cases of hydrogen sulfide and methyl mercaptan described above. However, the concentration of hypochlorous acid after the bubbling was higher in the case where the electrolysis was also implemented during the bubbling. It is thus considered that more ammonia can be decomposed in the case where the electrolysis is implemented, and that the sterilizing and odor eliminating effects are improved when the electrolytic water in the electrolytic cell 23 of the present invention is flown into the bowl 2 as described later.
TABLE 5 Hypochlorous acid Ammonia concentration concentration (mg/l) (ppm) Before After Before After bubbling bubbling bubbling bubbling Cl − 5 mg/l 0 0 4.8 0.5 water Cl − 5 mg/l 3.0 1.5 4.8 Undetected electrolytic water Cl − 17 mg/l 7.0 5.0 4.8 Undetected electrolytic water
[0069]
TABLE 6
Hypochlorous acid
Ammonia concentration
concentration (mg/l)
(ppm)
Before
After
Before
After
bubbling
bubbling
bubbling
bubbling
Cl − 5 mg/l
0
0
4.8
0.5
water
Cl − 5 mg/l
2.4
4.3
4.8
Undetected
electrolytic
water
Cl − 17 mg/l
7.0
15.0
4.8
Undetected
electrolytic
water
[0070] Thus, the Cl − 5 mg/l electrolytic water and the Cl − 17 mg/l electrolytic water were used as the test waters so that hydrogen sulfide, methyl mercaptan, and ammonia could be decomposed in a significantly short time by simply bubbling them in the test waters.
[0071] In the flush toilet 8 of the present embodiment, the odor components bubbled in the electrolytic cell 23 as described above are decomposed with the electrolytic waters containing hypochlorous acid by the electrolysis. Further, in accordance with the electrolytic electrodes 24 , 25 of the embodiment, there are also produced, in the water solution by the electrolysis, ozone, oxygen, hydrogen peroxide, or hydrogen peroxide radical, superoxide radical (O 2 − ), hydroxy radical (•OH) and singlet oxygen radical (′O 2 ). These can be used to decompose the odor components contained in the air discharged into the water in the electrolytic cell 23 . It is to be noted that in order to electrify the electrolytic electrodes 24 , 25 , there are provided an unshown hypochlorous acid concentration sensor, an ozone concentration sensor and the like, and control may thus be performed so that the electrolysis is stopped when detection values of these concentration sensors reach predetermined values.
[0072] Furthermore, in the electrolysis device 20 of the present invention, deodorized air in which the odor components are decomposed rises in the form of bubbles in the electrolytic cell 23 , and bursts in an upper part of the electrolytic cell 23 including hypochlorous acid, ozone and the like. Thus, an unshown air outlet is provided in the upper part of the electrolytic cell 23 so that hypochlorous acid and the like contained in the burst bubbles are discharged into the toilet room. Thus, the odor components are also decomposed which are contained in the ambient air and which could not be collected by the odor adsorption device 100 , and the air is also sterilized.
[0073] Moreover, in the odor component decomposition mode described above, a total amount or a predetermined amount of the electrolytic water in the electrolytic cell 23 after the odor component decomposition is drained from the outlet port 28 A via the electrolytic water flow path 27 in conjunction with the unshown flush lever, flush switch or the like to flow flushing water for the bowl 2 stored in the water storage tank 4 or in accordance with opening of the valve 31 every predetermined time by the controller 22 , thereby flushing the bowl 2 using the flushing water together. Thus, the bowl 2 is, for example, bleached, cleaned, deodorized, sterilized, by hypochlorous acid and the like contained in the electrolytic water, and capacity of cleaning the bowl can be improved as compared with a case where the inside of the bowl is cleaned with the flushing water alone as in ordinary flush toilets.
[0074] It is to be noted that the valve 31 may be opened for a predetermined period every predetermined time when it is detected that the bowl 2 is in use by detection means detecting the use of the bowl 2 , for example, by the unshown seating sensor for the seat, thereby flowing the electrolytic water in the electrolytic cell 23 into the bowl 2 .
[0075] Furthermore, in accordance with the hot water cleaning device 30 of the present embodiment, the electrolysis device 55 can electrolyze the water before jet to the pubic region from the jet 51 provided at the tip of the shower nozzle 52 as described above in order to form the water into ozone water. Thus, regions around the pubic region are sterilized by ozone, and effects in, for example, hemorrhoid treatments are also expected.
[0076] It is to be noted that in a case of a configuration wherein changes can be made by an unshown switch or the like in an amount or time of the electrification of the electrolytic electrodes 53 , 54 by the controller 57 , a concentration of the ozone water to wash the pubic region can be changed to, for example, a low concentration as required. Further, the ozone water of high concentration can be produced and used for, for example, sterilization and cleaning of, for example, the jet 51 or the bowl 2 .
Embodiment 2
[0077] FIG. 2 shows a schematic configuration diagram of a flush toilet 8 equipped with a deodorizing apparatus 1 in a second embodiment of the present invention. It is to be noted that those assigned with the same numbers in FIG. 2 as those in Embodiment 1 have the same or similar functions and effects. In this case, a configuration similar to that in Embodiment 1 is provided except that an adsorption member 11 is provided in a circulation path 14 without a rotation mechanism such as the motor described above, that an odor flow path 15 communicates with a circulation path 14 , and that lids 32 A, 32 B are provided at a portion where the odor flow path 15 is connected to the circulation path 14 . It is to be noted that the adsorption member 11 in the present embodiment does not have the rotation mechanism, but when capacity of the adsorption member 11 to adsorb and release odor components is to be increased, the rotary adsorption member 11 similar to that in Embodiment 1 can be provided in the circulation path 14 .
[0078] In the present embodiment, an odor in the flush toilet sucked in by a fan 12 from the odor suction port 29 passes through the adsorption member 11 provided in the circulation path 14 as described above, thereby gathering the odor in the adsorption member 11 .
[0079] Furthermore, in a deodorization mode, the lids 32 A, 32 B are opened by a controller 22 so that the odor is adsorbed by the adsorption member 11 , but the controller 22 closes the lids 32 A, 32 B as soon as the deodorization mode is terminated. Subsequently, an odor component decomposition mode is performed, and in this case, an operation similar to that in Embodiment 1 is performed, that is, air in the circulation path 14 is circulated by a fan 16 , and the air heated by a heater 13 heats and restores the adsorption member 11 , so that the adsorption member 11 releases the adsorbed the odor components. Then, the released odor substances are carried on high-temperature air to be sucked in by an air pump 19 at an upstream portion of a throttle portion 17 , and then taken into an intake pipe line 18 to be fed to an air diffusing pipe 26 via a check valve 21 . According to such a configuration, it is also possible to collect the odor components in the flush toilet and decompose them by electrolysis. Subsequently, cleaning and the like of a bowl 2 are also performed by electrolytic water in an electrolytic cell 23 as in Embodiment 1.
[0080] It is to be noted that in the flush toilet 8 equipped with the deodorizing apparatus 1 in the present embodiment, for example, even when the odor components are released from the adsorption member 11 in the odor component decomposition mode, it is possible to avoid a disadvantage that the released odor components are again diffused in a toilet room and the like because the adsorption member 11 is housed in the circulation path 14 . Moreover, it is possible to reduce a size of the deodorizing apparatus 1 of the present invention since the rotation mechanism or the like of the adsorption member 11 is not needed.
Embodiment 3
[0081] Next, FIGS. 3 and 4 show schematic configuration diagrams of a flush toilet 8 equipped with a deodorizing apparatus 1 in a third embodiment of the present invention. It is to be noted that those assigned with the same numbers in FIGS. 3 and 4 as those in the above embodiments have the same or similar functions and effects. In this case, a configuration similar to those in the above embodiments is provided except that an electrolytic water flow path 27 branches into outlet ports 28 B and 28 C in addition to an outlet port 28 A at a downstream portion of a valve 31 .
[0082] Thus, in the flush toilet 8 equipped with the deodorizing apparatus 1 in the present embodiment, electrolytic water from an electrolytic cell 23 is flown into a bowl 2 in three directions by the outlet ports 28 A, 28 B and 28 C, so that cleaning and the like inside the bowl 2 can be implemented more uniformly and in a wider range than in a case where the cleaning and the like inside the bowl 2 are implemented with the electrolytic water using the outlet port 28 A alone as in the embodiments described above. It is to be noted that the three outlet ports 28 A, 28 B and 28 C are provided in the present embodiment, but the number of outlet ports can naturally be increased or decreased as required.
Embodiment 4
[0083] FIGS. 5 and 6 show schematic configuration diagrams of a flush toilet 8 equipped with a deodorizing apparatus 1 in a fourth embodiment of the present invention. It is to be noted that those assigned with the same numbers in FIGS. 5 and 6 as those in the above embodiments have the same or similar functions and effects. In this case, a configuration similar to those in the above embodiments is provided except that an electrolysis device indicated by 40 in FIGS. 5 and 6 is partially different from the electrolysis device 20 in the above embodiments. That is, the electrolysis device 40 in the present embodiment uses a water storage tank 4 as an electrolytic cell thereof instead of an electrolytic cell 23 in the above embodiments.
[0084] Thus, in the flush toilet 8 equipped with the deodorizing apparatus 1 in the present embodiment, the water storage tank 4 installed in an ordinary flush toil is used similarly to the electrolytic cell 23 without separately providing the electrolytic cell 23 in the electrolysis device 40 , thereby allowing a further reduction in size of the deodorizing apparatus 1 . Further, since electrolysis is performed in the water storage tank 4 in the present embodiment, electrolytic water containing hypochlorous acid is generated in water contained in the water storage tank 4 , so that, for example, propagation of mold and miscellaneous germs in the water storage tank 4 can be prevented to keep the inside of the water storage tank 4 clean, and a toilet room can be better deodorized.
[0085] It is to be noted that in the present embodiment, cleaning of a bowl 2 with the electrolytic water can be performed by opening/closing a valve 31 every flush or every predetermined time as in the embodiments described above.
Embodiment 5
[0086] FIG. 7 shows a schematic configuration diagram of a flush toilet 8 equipped with a deodorizing apparatus 1 in a fifth embodiment of the present invention. It is to be noted that those assigned with the same numbers in FIG. 7 as those in the above embodiments have the same or similar functions and effects.
[0087] In the deodorizing apparatus 1 in the present embodiment, an odor generated in the flush toilet is sucked into an intake pipe line 18 provided with a check valve 21 from an odor suction port 29 via an odor flow path 15 by an operation of an air pump 19 , and also fed to an air diffusing pipe 26 . Then, air containing odor components fed to the air diffusing pipe 26 is subjected to a decomposition treatment of the odor components using electrolytic water in an electrolytic cell 23 as in the embodiments described above.
[0088] In such a configuration, the odor in the flush toilet can be removed in the present embodiment without using an adsorption member 11 or the like described above. Thus, further reductions in size and cost of the deodorizing apparatus 1 can be achieved.
[0089] However, in this case, it is required that as soon as the odor caused by hydrogen sulfide, methyl mercaptan, ammonia and the like is generated in a bowl 2 and a toilet room as described above, use of the flush toilet be sensed, for example, by an unshown odor sensor or by an unshown seating sensor for a seat 3 , or a controller 22 drive the air pump 19 and electrify electrolytic electrodes 24 , 25 of an electrolysis device 20 by use of a manual switch so that the odor is introduced to the electrolytic cell 23 of the electrolysis device 20 . The electrolysis device 20 is usually operated every time the flush toilet is used, which may decrease operation efficiency of the electrolysis device. However, significant reductions in size and cost of the deodorizing apparatus 1 can be achieved as described above, and it is therefore needless to say that this configuration may be effective depending on a form in which it is used.
[0090] It is to be noted that the odor in the flush toilet is sucked in by the air pump 19 in the present embodiment, but the odor in the flush toilet may be sucked using, for example, a fan.
Embodiment 6
[0091] FIG. 8 shows a schematic configuration diagram of a flush toilet 8 equipped with a deodorizing apparatus 1 in a sixth embodiment of the present invention. It is to be noted that those assigned with the same numbers in FIG. 8 as those in the above embodiments have the same or similar functions and effects. The deodorizing apparatus 1 in this case comprises a buffer tank 33 and an air valve 34 in an intake pipe line 18 between a check valve 21 and an air diffusing pipe 26 , in addition to the configuration of the deodorizing apparatus 1 in Embodiment 5.
[0092] Thus, in the deodorizing apparatus 1 of the present embodiment, an odor generated in the flush toilet can be stored for a predetermined time or in a predetermined amount even though the deodorizing apparatus 1 does not comprise an odor adsorption portion such as an adsorption member 11 , and the stored odor can be decomposed by an electrolysis device 20 as necessary. That is, according to the deodorizing apparatus 1 of the present embodiment, when the odor caused by hydrogen sulfide, methyl mercaptan, ammonia and the like during use of the flush toilet as described above is generated in a bowl 2 and a toilet room, the use of the flush toilet is sensed, for example, by an unshown odor sensor or by an unshown seating sensor for a seat 3 , or a controller 22 drives an air pump 19 and keeps the air valve 34 closed by use of a manual switch so that the odor can be stored in the buffer tank 33 . The stored odor can be fed to an electrolytic cell 23 and decomposed thereby if necessary as described above. Thus, the odor can be stored without providing the adsorption member 11 or the like, and an operation of the electrolysis device 20 can be controlled as required, thereby allowing further energy saving and a size reduction of the deodorizing apparatus 1 .
[0093] It is to be noted that in the embodiments described above, cleaning by draining the electrolytic water from the electrolytic cell 23 into the bowl 2 is performed when the bowl 2 of the flush toilet is washed after termination of the odor component decomposition mode. However, this is not a limitation. The tap water in the electrolytic cell 23 can be always electrolyzed by the controller 22 every predetermined time to store the electrolytic water, and a predetermined amount of the electrolytic water can be drained every time the bowl 2 is washed to accomplish the cleaning of the bowl 2 . Further, the use of the flush toilet is sensed, for example, by the odor sensor or by the unshown seating sensor for the seat 3 , or the manual switch is operated, so that the odor of excrement discharged in the bowl 2 can be directly removed during the use of the flush toilet owing to hypochlorous acid and the like contained in the electrolytic water by draining the electrolytic water every predetermined time or in accordance with the operation of the valve 31 using the unshown switch during the use of the flush toilet. Thus, the unpleasant odor during the use of the flush toilet can be reduced.
[0094] Furthermore, a so-called Western-style toilet equipped with the seat 3 has been described in the above embodiments, but the present invention is not limited thereto. The deodorizing apparatus 1 of the present invention may be provided in a so-called Japanese-style toilet without the seat or in a urinal for men.
[0095] Still further, the platinum-iridium-based material is used for the electrolytic electrodes 24 , 25 in the embodiments described above, but the material is not limited thereto, and carbon, for example, can also be used. Moreover, hydrogen sulfide, methyl mercaptan and ammonia have been described as the odor components by way of example in the above embodiments, but it is needless to say that these are not the only odor components which can be removed by the deodorizing apparatus 1 of the present invention.
|
An object of the present invention is to provide a flush toilet and a deodorizing method of the flush toilet which effectively remove a source of an offensive odor in the toilet and which can decompose the odor and also clean and sterilize a toilet bowl.
A flush toilet 8 is equipped with a deodorizing apparatus 1 , and the deodorizing apparatus 1 comprises: an electrolytic cell fitted with at least a pair of electrodes and storing tap water; odor suction means for sucking in an odor in the toilet; odor supply means for supplying the odor sucked in by the odor suction means into the electrolytic cell, odor adsorption means capable of adsorbing and releasing the odor; and odor supply means for supplying the odor released from the odor adsorption means to the electrolytic cell.
| 4
|
BACKGROUND OF THE INVENTION
[0001] In general, the invention relates to rapidly dissolving collagen films, methods of preparation, and the use of these films for rapid compound delivery.
[0002] The ability to specifically deliver a compound to a particular site in the human body is a desirable goal in many areas of medicine. For example, in cancer therapy, administration of chemotherapeutic agents to a tumor site with minimal exposure to surrounding tissues would dramatically reduce undesirable side effects to the surrounding tissues, or the body as a whole, while facilitating delivery of potent doses to malignant cells.
[0003] In addition, the inhibition of wound healing is beneficial in certain circumstances, for example, following glaucoma filtration surgery (otherwise known as trabeculectomy). The initial stage in the process of wound healing is characterized by the movement of intravascular components, such as plasma and blood proteins, to the extravascular area (Peacock, In: Wound Repair, 491-492, 1984, ed. EE Peacock, WB Saunders Co, Philadelphia, Pa.). Neutrophils and macrophages then migrate to the injury site, functioning to prevent infection and promote fibroblast migration. Subsequent phases of wound healing include fibroblast secretion of collagen, collagen stabilization, angiogenesis, and wound closure (Costa et al., Opth. Surgery 24: 152-170, 1993).
[0004] During surgery for the treatment of glaucoma, a fistula is frequently created to allow for post-operative drainage of intraopthalmic fluid from the eye. Accordingly, the inhibition of fistula healing is beneficial in order to extend the drainage time and reduce intraopthalmic pressure. Several therapies have been adopted to inhibit fistula healing, including beta irradiation, 5-fluorouracil treatment, and mitomycin (also known as mitomycin-C or mitomicin) treatment (Costa et al., Opth. Surgery 24: 152-170, 1993).
SUMMARY OF THE INVENTION
[0005] The present invention provides a method of preparing a rapidly dissolving collagen film which includes a therapeutic compound. The method involves (i) preparing a purified solution of monoreactive-amine modified collagen, e.g., a glutaric anhydride derivatized collagen, (ii) heating the collagen solution to about 35-45° C. for a time sufficient to reduce collagen viscosity, (iii) adding the compound to the heated collagen solution, and iv) casting the solution into thin layers, wherein the solution dries and forms the film.
[0006] The invention also includes a collagen film prepared by the above described method and a collagen film which rapidly dissolves upon exposure to about 35° C. Preferably, the collagen film dissolves within five to ten minutes upon exposure to about 35° C. More preferably, the collagen film dissolves within two minutes upon exposure to about 35° C. . Most preferably, the collagen film dissolves within one minute or 30 seconds upon exposure to about 35° C.
[0007] The therapeutic compound contained within the rapidly dissolving collagen film may be an inhibitor of cell proliferation, e.g., an anti-metabolic antibiotic, anti-metabolite, anti-fibrotic, anti-viral compound, or angiostatic compound. Preferably, the compound is an anti-metabolic antibiotic, e.g., mitomycin, daunorubicin, mithramycin, bleomycin, or doxorubicin.
[0008] Alternatively, the therapeutic compound may be an anti-metabolite. Examples of useful anti-metabolites include 5-fluorouracil, 5-fluorouridine-5′-monophosphate, 5-fluorodeoxyuridine, 5-fluorodeoxyuridine-5′-monophosphate, and 5-fluroorotate.
[0009] In yet other applications, the therapeutic compound contained within the rapidly dissolving collagen film is an anti-fibrotic. Examples of useful anti-fibrotics include inhibitors of prolyl nydroxylase and lysyl hydroxylase, e.g., iron chelators, α,α-dipyridyl, o-phenanthroline, proline analogs, lysine analogs, and free radical inhibitors and scavengers; inhibitors of collagen secretion, e.g., colchicine, vinblastin, cytochalasin B, copper, zinc, and EGTA; inhibitors of collagen secretion and maturation, e.g., BAPN, vincristine, and D-penicillamine; and stimulators of collagen degradation, e.g., EDTA and colchicine.
[0010] As noted above, the therapeutic compound may also be an anti-viral drug. Examples of anti-viral drugs that can be used in the invention include vidarabine, acyclovir, AZT, and amantadine.
[0011] Finally, angiostatic drugs, e.g., angiostatin, as well as other miscellaneous anti-cell proliferative drugs, e.g., tissue plasminogen activator (TPA), heparin, cytosine arabinoside, and gamma-interferon, may also be used in the rapidly dissolving collagen films described herein.
[0012] In addition to methods of collagen film preparation, the invention also provides a method of rapidly delivering a compound dose to a specific tissue site in a mammal. The method involves administering a collagen film containing the compound dose to the tissue site, wherein the collagen film rapidly dissolves upon exposure to the mammalian tissue site. Using this method to deliver toxic compounds, the toxic side effects are essentially restricted to the specific tissue site of compound delivery.
[0013] In a related aspect, the invention also includes a method of treating a mammal to inhibit cellular proliferation, e.g., wound healing or tumor growth, at a specific tissue site. The method involves administering a collagen film comprising an inhibitor of cell proliferation, e.g., an anti-metabolic antibiotic, anti-metabolite, anti-fibrotic, anti-viral compound, or angiostatic compound, to the tissue site, wherein the collagen film rapidly dissolves upon exposure to the tissue and delivers a dose of the compound sufficient to inhibit cell proliferation at the tissue site.
[0014] In preferred embodiments, the cell proliferation inhibitor is mitomycin, 5-fluorouracil, or an anti-fibrotic. In addition, in other preferred embodiments, the collagen film dissolves within five to ten minutes upon exposure to the mammalian tissue site, more preferably, within two minutes, and, most preferably, within one minute or 30 seconds. In addition, the mammal is preferably a human.
[0015] This method can be used, for example, in treating a mammal undergoing surgery for glaucoma. In this application, the collagen film is administered to the trabeculectomy-created fistula in the mammal, wherein the dose of cell proliferation inhibitor is sufficient to inhibit closure of the fistula. Preferably, the cell proliferation inhibitor used is mitomycin at a dose of 200-400 μg and may be administered in a 4×4 mm collagen film patch. Most preferably, the mitomycin dose is 400 μg.
[0016] Use of this treatment results in reduced post-operative intraocular pressure. Preferably, post-operative intraocular pressure as a result of this method is less than 16 mmHg, more preferably, less than 12 mmHg, and, most preferably, less than 6 mmHg.
[0017] As used herein, by “mono-reactive amine-modified” is meant reacted with a monoreactive amine-modifying agent, also known as a monoacylating or sulfonating agent. Useful agents include, without limitation, anhydrides, acid halides, sulfonyl halides, and active esters. The modifying agent is preferably a compound or combination of compounds which contains an acidic, carboxylic, or sulfonide group, or generates an acidic, carboxylic, or sulfonic group during reaction.
[0018] By “inhibitor of cell proliferation” is meant an inhibitor of an increase in the number of cells located at a particular site. Such inhibition may occur by inhibition of cell migration or attachment, cell replication, cell survival, or angiogenesis.
[0019] By “specific tissue site” is meant the area of tissue directly in contact with the collagen film administered to the tissue.
[0020] By “rapidly dissolves” is meant dissolves, or melts, in approximately 30 minutes or less.
[0021] The present invention provides a number of advantages. For example, the present techniques and collagen film compositions facilitate an improved approach for delivering a compound in situations where both a precise dose and accurate placement are required. The dose can be adjusted to any desired amount, i.e., by modifying the concentration of compound in the film or the size of the film, and the solid nature of the film allows its placement at any site in the body which can be reached by surgical techniques. In addition, the invention provides for the rapid dissolution of the collagen film upon exposure to normal body temperature. Taken together, these features ensure that a delivered compound achieves a certain concentration at a specific site, reducing possible inaccuracy due to mistaken dose or improper placement.
[0022] For delivery of mitomycin or 5-fluorouracil to a post-trabeculectomy fistula, the present invention represents an improvement over current empirical techniques employed, which typically involve placing a sponge wetted with compound on the fistula site for 3-5 minutes.
[0023] The advantage of delivering essentially all compound to a specific site also provides for limited compound delivery to tissues surrounding the delivery site. This advantage is especially relevant when the compound to be delivered has toxic effects. By restricting delivery to the targeted tissues, any unintentional or unnecessary toxic damage to surrounding tissues is reduced.
[0024] Furthermore, compounds, such as mitomycin, exhibit increased stability in the collagen film as compared to stability in solution. Thus, one collagen film sample preparation can be subdivided and used for several applications over the course of several weeks. This feature provides the advantages of reducing experimental variation when administered over several days and eliminating the need for daily pre-surgical sample preparation.
[0025] Other features and advantages of the invention will be apparent from the following detailed description thereof, and from the claims.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Described herein are methods of preparing collagen films containing therapeutic compounds that readily dissolve upon exposure to normal human body temperature (35-37° C.). These collagen films can be used for the rapid and accurate delivery of compounds to specific tissue sites.
[0027] For the purposes of this invention, collagen can be collected, solubilized, subjected to modification by mono-reactive, amine-modifying agents, and re-precipitated by any standard technique, e.g., those provided in DeVore et al. (U.S. Pat. No. 4,713,446), herein incorporated by reference. The following example is provided as an illustration and is in no way intended to limit the scope of the invention.
[0028] Preparation of Collagen
[0029] As a first step toward producing rapidly dissolving films, soluble collagen was prepared by standard procedures. Young calf hide was washed thoroughly with reagent alcohol and with deionized, pyrogen-free water, cut into approximately 1 cm 2 sections, and stirred overnight in 40 volumes of 0.5 M acetic acid. The mixture was then supplemented with pepsin (3% hide wet weight) and stirred for 72 hours. The digested, solubilized collagen was filtered through cheesecloth and precipitated by increasing the NaCl concentration to 0.8 M. The collagen was then cycled twice through steps of redissolution, in 0.5 M acetic acid, and reprecipitated. The collagen precipitate was then redissolved in 0.1 N acetic acid, dialyzed against 0.1 M acetic acid, filtered (0.45 μm), and refiltered (0.22 μm).
[0030] The purified, telopeptide-poor collagen was derivatized with glutaric anhydride as previously described (U.S. Pat. Nos. 5,631,243 and 5,492,135). Briefly, the collagen solution (approximately 3 mg/ml) was adjusted to pH 9.0 with 10 N and 1 N NaOH. While stirring the solution, glutaric anhydride was added at 10% (weight of collagen). For twenty minutes, the stirring continued, and the pH was maintained.
[0031] The pH of the solution was adjusted to 4.3 with 6 N and 1 N HCl to precipitate the derivatized collagen. The precipitate was centrifuged at 3500 rpm for 30 minutes. The pellet was washed three times in pyrogen-free deionized water and then redissolved in phosphate buffered glycerol (2% glycerol in 0.004 M phosphate buffer, pH 7.4) to achieve a final concentration of approximately 10 mg/ml.
[0032] Preparation of Collagen Films Containing Mitomycin
[0033] To prepare collagen films containing mitomycin, the collagen solution, described above, was heated in a 35° C. water bath for 30 minutes to reduce viscosity. Mitomycin (e.g., Mutamycin®, Bristol Myers Squibb, Princeton, N.J.), also known as mitomicin C, was added to the heated collagen. The collagen solution was then poured into petri dishes in a thin layer and allowed to air dry under a laminar-flow hood.
[0034] Collagen film melting time at 35° C. was measured after placing the films in 0.8% saline in a 35° C. water bath. Pre-heated collagen films melted in approximately one minute. In contrast, collagen films poured into petri dishes without pre-heating melted at 35° C. in approximately 30 minutes.
[0035] Mitomycin-containing collagen films had a final mitomycin concentration of 400 μg per 16 mm 2 . 6 mm diameter discs were cut from the film and applied to human subconjunctival fibroblasts derived from Tenon's membrane layered in 96 well plates (CSM supplemented with 10% fetal bovine serum). After 72 hours, mitomycin-induced inhibition of cell division was assessed by measuring the reduction in fluorescence intensity (RFU) using a fluorogenic CalceinAM assay (see, for example, Decherchi et al., J. Neurosci. Meth. 71: 205 (1997); Sugita, Pflitgers Arch. 429: 555 (1995); Padanilam et al., Ann. NY Acad. Sci. 720: 111 (1994); Lichtenfels et al., J. Immunol. Meth. 172: 227 (1994); and Wang et al., Human Immunol. 37: 264 (1993)). The mitomycin-containing collagen films inhibited approximately 91% of the cell division demonstrated in control cells.
[0036] Mitomycin-containing films may be stored for later use. For example, mitomycin activity in the collagen films described above was maintained for at least 6 weeks after preparation of the films (stored at 4° C.). Administration of mitomycin-collagen films, 2, 4, and 6 weeks old, demonstrated 91%, 90%, and 92% inhibition of cell division, respectively, compared to mitomycin-free controls. These values were comparable to the % cell death inhibition elicited by administration of a freshly prepared mitomycin solution (0.4 mg/ml solution, dissolved in USP sterile water).
[0037] In contrast to the stability of mitomycin in the collagen film, HPLC analysis of the mitomycin solution determined that stability was maintained for only 4 days following storage at ambient temperature and 4° C. in the dark. Dissolution and storage in 0.9% saline or phosphate buffer (pH 7.4) is not recommended due to degradation and precipitation.
[0038] Use
[0039] Rapidly dissolving collagen films containing therapeutic compounds are useful for various treatments. For example, the collagen-mitomycin film may be administered to the external opening of the fistula created during glaucoma filtering surgery (trabeculectomy). Immediately following surgery, a collagen film, e.g., a 4×4 mm patch, containing 100-1000 μg mitomycin (preferably 400 μg), is directly applied to the external opening of the fistula prior to replacing the scleral flap. Administration of the mitomycin increases the duration of fistula patency, increasing filtration from the eye and reducing intraocular pressure.
[0040] Other compounds may also be administered to the trabeculectomy-created fistula to increase filtration during recovery. For example, 5-fluorouracil-containing films may be administered in the same fashion to deliver a 5-fluorouracil dose of 25-250 μg (preferably 100 μg). Other alternative compounds that are effective for this treatment are anti-fibrotic, angiostatic, and anti-viral compounds.
[0041] Administration of the rapidly dissolving collagen films containing inhibitors of cell proliferation are also useful for treatment during recovery from other surgical procedures where prevention of wound healing is beneficial.
[0042] In addition, the collagen films of the invention may be administered to reduce cellular proliferation in specific tissue sites, such as for the localized inhibition of neoplastic or non-neoplastic cell growth. For this application, any chemotherapeutic compound may be dissolved in the collagen matrix in concentrations appropriate for inhibiting cell growth.
OTHER EMBODIMENTS
[0043] While the treatment regimens described herein are preferably applied to human patients, they also find use in the treatment of other animals, such as domestic pets or livestock.
[0044] Moreover, while the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure come within known or customary practice within the art to which the invention pertains and may be applied to the essential features hereinbefore set forth, and follows in the scope of the appended claims.
|
Disclosed herein are collagen films which rapidly dissolve at 35° C. Also disclosed are methods for the preparation of the collagen films and their use as a vehicle for delivering a dose of therapeutic compound to a specific tissue site.
| 0
|
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to an apparatus and method for surgical devices. More particularly, the present disclosure relates to a surgical instrument capable of eliminating or substantially limiting counter torque in a surgical fastening apparatus.
[0003] 2. Background of Related Art
[0004] Surgical fastening devices wherein tissue is first grasped or clamped between opposing jaw structure and then joined by surgical fasteners are well known in the art. Several types of known surgical fastening instruments are specifically adapted for use in various procedures such as end-to-end anastomosis, gastrointestinal anastomosis, endoscopic gastrointestinal anastomosis, and transverse anastomosis among others. U.S. Pat. Nos. 5,915,616; 6,202,914; 5,865,361; and 5,964,394 are examples of surgical fastening instruments. Although the fasteners are typically in the form of surgical staples, two-part polymeric fasteners may also be employed.
[0005] Surgical fastening instruments can include two elongated jaw members used to capture or clamp tissue. One jaw member typically contains a staple cartridge that houses a plurality of staples arranged in a single row or a plurality of rows while the other jaw member has an anvil that defines a surface for forming the staple legs as the staples are driven from the staple cartridge. The stapling operation is usually effected by one or more cam members that translate through the staple cartridge, with the cam members acting upon staple pushers to sequentially or simultaneously eject the staples from the staple cartridge. A knife may be provided to move axially between the staple rows to cut or open the stapled tissue between the rows of staples. U.S. Pat. Nos. 3,079,606 and 3,490,675 disclose examples of this kind of instrument.
[0006] Some surgical fastening instruments contain rotating components that facilitate actuation of the surgical instrument, deployment of the surgical fasteners, or articulation of the surgical instrument. For instance, U.S. Pat. No. 7,114,642 to Whitman (“Whitman”) discloses a stapling mechanism including two rotating flexible drive shafts. One drive shaft controls the movement of an upper jaw while the other drive shaft controls the stapling and cutting actions of the mechanism. Essentially, the flexible drive shafts transmit torque from a motor in a handle to the distal end of the shaft. Each drive shaft is driven by a different motor and they are not operatively connected with each other. The torque transmitted by each drive shaft produces a counter torque that can turn or steer the jaws of the surgical mechanism to one direction. This undesirable motion of the jaws can prevent the surgeon from having full control of the surgical instrument. The stapling mechanism of Whitman does not have any mechanism, device, or component to eliminate the detrimental effects of the torque, i.e., the counter torque. Other surgical instruments having torque transmitting components also fail to provide adequate measures to limit or eliminate counter torque. Therefore, it is desirable to develop a surgical instrument capable of eliminating or substantially limiting counter torque.
SUMMARY
[0007] The presently disclosed a surgical instrument includes a first elongated member and a second elongated member. The first elongated member and the second elongated member are operatively connected to each other and configured to rotate in opposite directions to substantially limit counter torque. These elongated members can consist of flexible shafts. Because the shafts are operatively connected to one another, they are redundant and can fully operate the instrument even if one of the shafts breaks.
[0008] An embodiment of the surgical instrument includes a cartridge housing a plurality of fasteners, an anvil, a sled disposed in the cartridge, and first and second elongated members disposed in the cartridge. The anvil and the cartridge are relatively movable between spaced and approximated positions. The cartridge has a sled positioned therein. The sled includes a cam member designed to drive the fasteners through tissue and toward the anvil, and at least one bore disposed therethrough for receiving at least one drive member. One or more drive members can be operatively attached to the first or second elongated members, or both. The drive member can optionally consist of a lead screw. The surgical instrument further includes a channel partially encompassing the cartridge and a neck. The neck, which is flexible, is secured to the channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Embodiments of the presently disclosed surgical instrument are described herein with reference to the accompanying drawings, wherein:
[0010] FIG. 1 is a perspective view of a surgical instrument in accordance with an embodiment of the present disclosure operatively connected to an actuation apparatus;
[0011] FIG. 2 is a perspective view of the surgical instrument of FIG. 1 ;
[0012] FIG. 3 is a perspective exploded view of the surgical instrument of FIGS. 1 and 2 ;
[0013] FIG. 4 is an perspective view of a clamp cam of the surgical instrument of FIGS. 1-3 ;
[0014] FIG. 5 is a perspective longitudinal cross-sectional view of the surgical instrument of FIGS. 1-3 ;
[0015] FIG. 6 is a perspective view of a portion of the surgical instrument of FIGS. 1-3 ;
[0016] FIG. 7 is a side cross-sectional view of the surgical instrument of FIGS. 1-3 ;
[0017] FIG. 8 is a perspective cross-sectional view of the surgical instrument of FIGS. 1-3 , as taken through section lines 8 - 8 of FIG. 7 ;
[0018] FIG. 9 is a top cross-sectional view of the surgical instrument of FIGS. 1-3 ;
[0019] FIG. 10 is a top sectional view of the surgical instrument of FIGS. 1-3 , taken around section 10 of FIG. 9 ;
[0020] FIG. 11 is a top cross-sectional view of the surgical instrument of FIGS. 1-3 , as taken through section lines 11 - 11 of FIG. 7 ;
[0021] FIG. 12 is a top sectional view of the surgical instrument of FIGS. 1-3 , as taken around section 12 of FIG. 11 ;
[0022] FIG. 13 is a perspective view of the gooseneck of a surgical instrument in accordance with an embodiment of the present disclosure;
[0023] FIG. 14 is a top cross-sectional view of the gooseneck of a surgical instrument in accordance with an embodiment of the present disclosure;
[0024] FIG. 15 is a top view of the actuation apparatus of FIG. 1 ;
[0025] FIG. 16 is a top view of the surgical instrument of FIGS. 1-3 ;
[0026] FIG. 17 is a top view of the actuation apparatus of FIGS. 1 and 15 ;
[0027] FIG. 18 is a top cross-sectional view of a portion of the surgical instrument of FIGS. 1-3 ;
[0028] FIG. 19 is a perspective cross-sectional view of a portion of the surgical instrument of FIGS. 1-3 , as taken through section lines 19 - 19 of FIG. 18 ;
[0029] FIG. 20 is a front elevational view of the portion of the surgical instrument of FIG. 19 ;
[0030] FIG. 21 is a side cross-sectional view of a portion of the surgical instrument of FIGS. 1-3 ;
[0031] FIG. 22 is a side sectional view of a portion of the surgical instrument of FIGS. 1-3 , as taken around section 22 of FIG. 21 ;
[0032] FIG. 23 is a top cross-sectional view of a portion of the surgical instrument of FIGS. 1-3 ;
[0033] FIG. 24 is a top view of the actuation apparatus of FIGS. 1 , 15 and 17 ;
[0034] FIG. 25 is a perspective view of a portion of the surgical instrument of FIGS. 1-3 ;
[0035] FIG. 26 is a perspective view of the gear couplers and pinions of a surgical instrument in accordance with an embodiment of the present disclosure;
[0036] FIG. 27 is a top cross-sectional view of a portion of the surgical instrument of FIGS. 1-3 ; and
[0037] FIG. 28 is a side cross-sectional view of a portion of the surgical instrument of FIGS. 1-3 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0038] Embodiments of the presently disclosed surgical instrument will now be described in detail with reference to the drawings wherein like reference numerals identify similar or identical elements. In the drawings and in the description which follows, the term “proximal,” as is traditional, will refer to the end of the surgical instrument that is closest to the operator while the term “distal” will refer to the end of the surgical instrument that is farthest from the operator. In the present disclosure, the words “a,” “an,” or “the” are to be taken to include both the singular and the plural. Likewise, any reference to plural items shall, where appropriate, include the singular.
[0039] The present disclosure relates to a surgical instrument for use with a surgical fastening apparatus or any other suitable surgical device. In fact, the presently disclosed surgical instrument can be applied to a whole line of surgical devices where torque is transmitted from one point to another. In addition, this surgical instrument can be employed in many kinds of surgical procedures. Surgeons may utilize the instrument in endoluminal procedures. During such procedures, surgeons introduce a surgical instrument through a body lumen. Doctors can also use the presently disclosed surgical instrument in endoscopic procedures. In this kind of procedure, doctors use a surgical instrument through or in combination with an endoscope.
[0040] Referring now to FIG. 1 , a surgical instrument for use with a surgical fastening apparatus is generally designated as 100 . In the interest of brevity, this disclosure will focus primarily on systems, methods and structures of surgical instrument 100 . A detailed discussion of the remaining components and method of use of a surgical fastening apparatus is disclosed in U.S. Pat. No. 6,241,139, the entire content of which is incorporated herein by reference. Briefly, a surgical fastening apparatus comprising surgical instrument 100 includes an actuation apparatus 10 . Surgical instrument 100 is releasably secured to a distal end of actuation apparatus 10 .
[0041] Actuation apparatus 10 includes a motor 12 , a gearshift lever 16 , and gears 18 . Motor 12 supplies input rotation to apparatus 10 and is operatively connected to at least one gear 18 . Gears 18 are axially trapped between two columns 20 and are configured to mesh with each other. Each column has a pair of bores 21 extending therethrough. Bores 21 are configured to receive drive members 22 . Drive members 22 are operatively coupled to flexible shafts 139 . Gearshift lever 16 controls the axial movement of flexible shafts 139 . A user can actuate gearshift lever 16 to translate flexible shafts 139 distally or proximally.
[0042] Additionally, apparatus 10 includes an articulation mechanism 30 including an articulation knob 32 and at least one steering wire 34 . Articulation knob 32 is operatively coupled to at least one steering wire 34 . In embodiment illustrated in FIG. 1 , articulation knob 32 is operatively connected to two steering wires 34 . A user can axially move steering wires 34 back and forth by rotating articulation knob 32 . This axial motion causes the articulation of surgical instrument 100 .
[0043] During operation, a user articulates surgical instrument 100 by pulling one steering wire 139 . The movement of the steering wire bends gooseneck 130 and effectively articulates surgical instrument 100 to one side or the other. Gooseneck 130 bends towards the side of the wire that was pulled. In practice, the operator rotates articulation knob 32 apparatus 10 to move a steering wire 34 and thereby articulate surgical instrument 100 .
[0044] Referring to FIG. 2 , surgical instrument 100 includes a gooseneck 130 , channel 150 , a cartridge 110 , and an anvil 120 movably secured in relation to cartridge 110 . Channel 150 partially encompasses cartridge 110 . Cartridge 110 , which can be replaceable, houses a plurality of fasteners 190 (see FIG. 3 ) in retention slots 114 . Retention slots 114 can be arranged in a single row, as shown in FIG. 2 , or in a plurality of rows. Gooseneck 130 is secured to channel 150 . Specifically, a distal end of gooseneck 130 can be attached to a proximal end of channel 150 . In turn, a proximal end of gooseneck 130 is operatively secured to the distal end of actuation apparatus 10 . (See FIG. 1 ). Gooseneck 130 facilitates articulation of surgical instrument 100 and can be flexible.
[0045] Further, gooseneck 130 includes at least one hole 141 configured to receive a steering wire 34 . The depicted embodiment shows a gooseneck 130 having two holes 141 extend therethrough. In addition, gooseneck 130 includes at least one bore 132 adapted to receive a flexible shaft 139 . The illustrated embodiment shows a gooseneck 130 having two bores 132 extending through at least a portion of the length of gooseneck 130 . Although the drawings show bores 132 having a cylindrical shape, bores 132 can have any suitable shape.
[0046] Flexible shafts 139 are operatively connected to each other and are configured to rotate in opposite directions, i.e., clockwise and counterclockwise. Since the flexible shafts 139 rotate in opposite directions, the torque transmitted by each flexible shaft 139 is canceled, thereby eliminating or substantially limiting the counter torque. As shown in FIG. 1 , flexible shafts 139 are positioned on a neutral axis that extends along a portion of the length of surgical instrument 100 . The depicted embodiment shows one flexible shaft 139 on top of the other. Flexible shafts 139 , however, can be placed in numerous arrangements. For instance, flexible shafts 139 can consist of coaxial elongated members positioned on a neutral axis extending along at least a portion of the length of surgical instrument 100 .
[0047] With reference to FIG. 3 , gooseneck 130 surrounds at least a portion of flexible shafts 139 and steering wires 34 . The distal end of gooseneck 130 is secured to the proximal end of channel 150 by a plurality of screws 160 positioned around the circumference of channel 150 . Screws 160 are disposed in a plurality of threaded bores 144 disposed around the circumference of a transition member 140 . Transition member 140 is internally interposed between gooseneck 130 and channel 150 . Channel 150 has a plurality of holes 152 positioned around the circumference of its proximal end. Each hole 152 is designed to receive screws 160 . Similarly, gooseneck 130 has a plurality of holes 136 configured to receive screws 160 . Holes 136 of gooseneck 130 are located around the circumference of the distal end of gooseneck 130 . Screws 160 attach gooseneck 130 to channel 150 through holes 152 of channel 150 , holes 136 of gooseneck 130 and threaded bores 144 of transition member 140 . To properly fix channel 150 to gooseneck 130 , holes 152 of channel 150 , threaded bores 144 of transition member 140 , and holes 136 of gooseneck 130 are substantially aligned with each other.
[0048] Transition member 140 has at least one hole 143 disposed therethrough for receiving steering wires 34 . Although FIG. 3 shows holes 143 having a cylindrical shape, it is envisioned that holes 143 can have any suitable shape. Additionally, transition member 140 includes at least one longitudinal hole 142 extending therethrough for receiving flexible shafts 139 . In one embodiment, transition member 140 includes two holes 142 having a cylindrical shape. (See FIG. 3 ). Holes 142 , however, can have any shape so long as they are adapted to receive flexible shafts 139 .
[0049] A distal end of each flexible shaft 139 is operatively secured to a pinion shaft 138 . Pinion shafts 138 are configured to rotate and, consequently, cause the rotation of pinions 154 . Each pinion 154 is attached to a distal end of a pinion shaft 138 . As seen in FIG. 26 , pinions 154 include at least one tooth 154 a or a plurality of teeth 154 a. Tooth or teeth 154 a extends radially as well as longitudinally. The longitudinal portion of tooth or teeth 154 a is adapted to axially engage with gear couplers 156 .
[0050] Returning to FIG. 3 , each pinion 154 is configured to mesh with each other such that the rotation of a flexible shaft 139 rotates the other flexible shaft 139 . As discussed hereinabove, a gear 18 is operatively attached to the proximal end of each flexible shaft 139 . Gears 18 are configured to mesh with each other such that the rotation of one flexible shaft 139 rotates the other flexible shaft 139 . Thus, flexible shafts 139 are operatively connected to each other at their proximal and distal ends. Since flexible shafts 139 are operatively connected with each other, one flexible shaft 139 is redundant. Only one flexible shaft 139 is needed to operate surgical instrument 100 . If, for any reason, one flexible shaft 139 breaks, the other flexible shaft 139 can still actuate surgical instrument 100 .
[0051] As shown in FIG. 26 , the longitudinal portion of tooth or teeth 154 a of each pinion 154 is adapted to axially engage with gear couplers 156 . Gear couplers 156 have at least one longitudinal tooth or a plurality of teeth 156 a, and at least one radial tooth or a plurality of teeth 156 b. Longitudinal tooth or teeth 156 a of gear couplers 156 extend proximally and are configured to axially engage with tooth or teeth 154 a of pinions 154 .
[0052] Returning to FIG. 3 , clamp pinions 162 have at least one radial tooth or teeth 162 a for meshing with radial tooth or teeth 154 of pinions 154 and are permanently attached to the distal ends of short lead screws 158 . The longitudinal length of short lead screws 158 is less than the longitudinal length of lead screws 112 . Short lead screws 158 are axially trapped in transition member 140 and cartridge 110 . Surgical instrument 100 can optionally include bearings to axially trap short lead screws 158 .
[0053] In addition, surgical instrument 100 includes a link 122 positioned within a proximal end portion of channel 150 . Particularly, a first end 122 a of link 122 is pivotably connected to the proximal end of an anvil 120 by a link pin 126 . A second end 122 b of link 122 sits in a slot in cam clamp 164 . Optionally, at least one projection 122 c can extend from second end 122 b of link 122 . Projections 122 c can pivotably fix link 122 to clamp cam 164 .
[0054] Clamp cam 164 is positioned within an inner proximal portion of channel 150 and includes at least one bore 164 a for receiving pinion shafts 138 , at least one bore 164 b for receiving at least one short lead screw 158 , and a slot 164 c configured to receive at least a portion of anvil 120 , as seen in FIG. 4 . At least a portion of each pinion shaft 138 is disposed in bores 164 a. Short lead screws 158 are threadedly engaged to threaded bores 164 b of cam clamp 164 . The rotation of short lead screws 158 causes the translation of cam clamp 164 proximally or distally. During operation, as cam clamp 164 moves proximally, projections 122 c slides along the inner diameter of channel 150 , link 122 becomes more vertical, raising proximal end of anvil 120 and causing the distal end of anvil 120 to drop and clamp tissue. Conversely, the distal motion of cam clamp 164 causes projections 122 c to slide distally within channel 150 . As projections 122 c move distally, the proximal end of anvil 120 descends, causing the distal end of anvil 120 to ascend and unclamp tissue.
[0055] With reference to FIG. 5-7 , each gear coupler 156 is mounted to the proximal end of each lead screw 112 . Lead screws 112 are at least partially threaded and are at least partially disposed within cartridge 110 , as shown in FIG. 5 . Cartridge 110 includes a tissue contacting surface 113 having at least one row of longitudinally spaced-apart retention slots 114 , a plurality of pushers 192 , a plurality of fasteners 190 , and a sled 116 slidably positioned therein. Retention slots 114 are adapted to receive fasteners 190 . Those skilled in the art will contemplate a cartridge 110 with any number of rows of retention slots 114 . For example, cartridge 110 may include two rows of retention slots 114 . In this embodiment, a knife can be placed between these two rows of retention slots 114 . Nonetheless, irrespective of the number rows of retention slots 114 , cartridge 110 can include a knife to cut tissue. The knife can be operatively attached to sled 116 . Additionally, the cartridge may include an electrical or mechanical interlock mechanism to prevent distal motion of sled 116 unless anvil 120 is in its closed position.
[0056] Sled 116 includes a cam member 116 b and at least one threaded bore 116 a adapted to receive lead screw 112 . Pushers 192 have a surface 192 a that cooperates with and is complementary to cam member 116 of sled 116 . During operation of surgical instrument 100 , sled 116 translates through cartridge 110 to advance cam member 116 b into sequential or simultaneous contact with pushers 192 , to cause pushers 192 to translate vertically within retention slots 114 and urge fasteners 190 from retention slots 114 into the staple deforming concavities 125 a of an anvil 120 . The staple deforming cavities 120 a are configured to crimp staples.
[0057] Anvil 120 includes a tissue contacting surface 125 having a plurality of staple deforming concavities 125 a. A single staple deforming concavity 125 a can be adapted to cooperate with the legs of one fastener 190 . Alternatively, two or more staple deforming concavities 125 a can cooperate with the legs of a single fastener 190 .
[0058] A pivot pin 128 pivotably secures anvil 120 to channel 150 . Channel 150 has at least one hole 150 a designed to receive pivot pin 128 , as seen in FIG. 2 . Pivot pin 180 rests on a support surface 164 d of clamp cam 164 , as shown in FIG. 6 . A proximal end portion 124 of anvil 120 is positioned within channel 150 . Link pin 126 pivotably attaches proximal end portion 124 of anvil 120 and link 122 .
[0059] As discussed hereinabove, channel 150 encompasses at least a portion of cartridge 110 . Optionally, screws 153 can connect channel 150 and cartridge 110 with each other, as seen in FIG. 3 . In this embodiment, channel 150 includes at least one hole 151 configured to receive a screws 153 .
[0060] In operation, surgical instrument 100 applies fasteners 190 to tissue whilst, at the same time, eliminating or substantially limiting counter torque. During use, an operator must first make sure that the surgical instrument 100 is in its neutral position, as shown in FIGS. 7 and 8 . When surgical instrument 100 is in its neutral position, anvil 120 and cartridge 110 are spaced apart from each other and pinions 154 are not meshed with clamp pinions 162 , as seen in FIGS. 7-10 . Additionally, in the neutral position, sled 116 is disposed on a proximal portion of cartridge 110 (see FIG. 7 ) and pinions 154 are not axially engaged with gear couplers 156 (see FIGS. 11 and 12 ). It is also contemplated that the surgical instrument could be configured to eliminate the neutral position and simply operate in a sequential closure-fire-open mode.
[0061] After placing surgical instrument 100 in its neutral position, a user may approximate it to a tissue portion. To position surgical instrument 100 in the desired surgical site, an operator can endoluminally introduce surgical instrument 100 into the body through a body lumen. Alternatively, an operator can use surgical instrument 100 through or in combination with an endoscope to reach the desire location. The tissue portion should be located between anvil 120 and cartridge 110 .
[0062] A user can articulate surgical instrument 100 to position it on the desired location by moving steering wires 34 . As discussed hereinabove, an embodiment of the presently disclosed surgical instrument 100 includes a gooseneck 130 having two holes 141 each adapted to receive a steering wire 34 , as seen in FIG. 13 . As seen in FIG. 14 , gooseneck 130 is at least partially formed by a plurality of triangular shaped sections 130 a that are spaced apart from each other. In addition, gooseneck 130 is made of a flexible material. Each steering wire 34 includes a knot 34 a to secure gooseneck 130 and steering wires 34 at their respective distal ends.
[0063] In use, an operator can rotate articulation knob 32 counterclockwise, as indicated by arrow “CCW,” to translate proximally a steering wire 34 , as indicated by arrow “A.” In response to the proximal motion of steering wire 34 , surgical instrument 100 articulates in the direction indicated by arrow “B.” A user can also articulate surgical instrument 100 in the opposite direction by rotating articulation knob 32 clockwise.
[0064] Once the user places surgical instrument 100 in the desire surgical site, the user may move gearshift lever 16 proximally, as indicated by arrow “C,” to translate flexible shafts 139 proximally in the direction indicated by arrows “D,” as seen in FIGS. 17 and 18 . The proximal motion of flexible shafts 139 consequently moves pinion 154 in the direction indicated by arrows “E” into a proximal position, as shown in FIGS. 18 and 19 . When pinions 154 are located on the proximal position, radial teeth 154 a of pinions 154 mesh with teeth 162 a of clamp pinions 162 , as shown in FIG. 19 .
[0065] After pinions 154 are placed in their proximal positions, a user can activate actuation apparatus 10 to rotate at least one flexible shaft 139 . In one embodiment, actuation apparatus 10 rotates one flexible shaft 139 clockwise and the other flexible shaft 139 counterclockwise. The rotation of flexible shafts 139 in opposite directions eliminates or substantially reduces counter torque in surgical instrument 100 . While flexible shafts 139 rotate, pinions 154 rotate in the direction indicated by arrows “F”, as seen in FIG. 20 . Since at this point radial teeth 154 a of pinions 154 are meshed with teeth 162 a of clamp pinions 162 , as soon as pinions 154 rotate, clamp pinions 162 begin to rotate in the direction indicated by arrows “G,” as illustrated in FIG. 20 .
[0066] With reference to FIGS. 21-23 , when clamp pinions 162 rotate, cam clamp 164 translates proximally in the direction indicated by arrow “H.” As cam clamp 164 moves proximally, link 122 pivots in a counterclockwise direction “I” with respect to pivot pin 126 , raising proximal end of anvil 120 . While the proximal end of anvil 120 moves vertically, the distal end of anvil 120 descends in the direction indicated by arrow “J” and clamps tissue.
[0067] With reference to FIG. 24-28 , after clamping tissue, the operator can move gearshift lever 16 , in the direction indicated by arrow “K,” to translate flexible shafts 139 distally as indicated by arrow “L.” When flexible shafts 139 are distally translated, teeth 154 a of pinions 154 axially engage with longitudinal teeth 156 a of gear couplers 156 , as seen in FIG. 26 . Once pinions 154 and gear couplers 156 are axially engaged with each other, gear couplers 156 rotates in response to the rotation of at least one flexible shaft 139 . The rotation of gear couplers 156 causes the corresponding rotation of lead screws 112 in the direction indicated by arrows “M.” While lead screws 112 rotate, sled 116 translates distally through cartridge 110 in the direction indicated by arrows “N,” as depicted in FIG. 27 . Sled 116 advances cam member 116 b into sequential contact with pushers 192 , to cause pushers 192 to translate vertically within retention slots 114 and eject fasteners 190 . Pushers 192 displace fasteners 190 in the direction indicated by arrows “ 0 ” and towards the staple deforming concavities 125 a of anvil 120 , as shown in FIG. 28 . An electrical or mechanical interlocking mechanism may be provided to prevent firing unless anvil 120 is in the closed position.
[0068] After clamping and stapling a tissue portion, the user can reverse the input rotation using apparatus 10 . At this moment, at least one flexible shaft 139 rotates and causes the rotation of pinions 154 . When pinions 154 rotate, clamp pinions 162 begin to rotate. The reverse rotation of clamp pinions 162 causes the distal translation of clamp cam 164 . As clamp cam 164 moves distally, projections 122 c of link 122 translate distally within channel 150 . When projections 122 c move distally, the proximal end of anvil 120 descends, causing the distal end of anvil 120 to rise and unclamp the tissue portion, as shown in FIG. 7 . The reversed input rotation can optionally rotate lead screws 112 and translate proximally sled 116 to its original retracted position.
[0069] It will be understood that various modifications can be made to the embodiments disclosed herein. For example, the surgical instrument may include staples, two-part fasteners or any other suitable fastening element. Further, the cartridge can have a more than one row of longitudinally spaced apart retention slots. Further still, the cartridge can have any suitable elongated member capable of translating the sled instead of lead screws. Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure.
|
A surgical instrument comprises a first elongated member and a second elongated member, the first elongated member and the second elongated member being operatively connected and configured to rotate in opposite directions to substantially limit counter torque. The first and second elongated members are flexible shafts. The surgical instrument can be configured to apply fasteners to a tissue portion. This embodiment of the surgical instrument includes a cartridge having a plurality of fasteners, an anvil, said anvil and cartridge being relatively movable between spaced and approximated positions, and a sled disposed in the cartridge. The sled includes a cam member. The cam member is designed to drive the fasteners through tissue and toward the anvil.
| 0
|
FIELD OF THE INVENTION
The present invention relates to telecommunications in general, and, more particularly, to a method of managing an enterprise's non-telecommunications facilities, such as environmental control, via the telecommunications infrastructure that is present.
BACKGROUND OF THE INVENTION
An enterprise that desires its employees to be productive has to enable effective communications by providing some type of telecommunications infrastructure. For example, the enterprise can use call-handling equipment such as private branch exchanges to enable employees to communicate conveniently with one another, as well as with people external to the enterprise. A private branch exchange, in particular, is capable of routing incoming calls from a telecommunications network, such as the Public Switched Telephone Network, via one or more transmission lines to any of the on-premises telephones that exist within the enterprise. Similarly, the private branch exchange is also capable of handling outgoing calls from any of the on-premises telephones to the telecommunications network.
Additionally, the private branch exchange is capable of providing telecommunications features that enable the forwarding of calls, the transferring of calls, conferencing, and so forth. Typically, each user of an on-premises telephone can create a customized profile that is stored at the private branch exchange and indicates to the exchange how to present information to and respond to signals from a telephone. In short, a private branch exchange—or other types of call-handling equipment, for that matter—provides a powerful tool with which employees are able to communicate with one another and accomplish work in the process.
Meanwhile, the same enterprise that desires productive employees has to provide comfortable working conditions by regulating environmental conditions at acceptable levels, conditions such as temperature and lighting. Of course, from a facilities cost perspective, it can be expensive to maintain such a workplace. Particular costs include those related to providing environmental control, but also other costs such as ensuring employee safety and enforcing building security. Some costs are incurred during normal working hours and some are incurred after hours.
Often an enterprise has to consider tradeoffs between saving facilities costs and adequately providing for its employees. For example, an enterprise might want to manage its energy costs during the winter by lowering the indoor air temperature by as much as possible and as often as possible. Of course, lowering the temperature too much causes employees to experience discomfort.
Therefore, an effective technique is needed to manage facilities costs, without some of the disadvantages in the prior art.
SUMMARY OF THE INVENTION
The present invention enables the managing of environmental conditions within an enterprise workplace and, in doing so, provides an improvement in facilities cost management over some techniques in the prior art. In accordance with the illustrative embodiment of the present invention, a data-processing system such as a private-branch exchange monitors the workplace by using one or more telephones, or other “telecommunications endpoints” to which the exchange is connected, in the workplace area. The exchange determines whether people are present in the workplace area by monitoring which endpoints are in use. Additionally, the exchange monitors the sounds that are received by the microphones of the endpoints. Based on knowing which endpoints are in use, the exchange generates control signals for the purpose of controlling one or more environmental conditions such as temperature, lighting, and so forth. In some embodiments of the present invention, the exchange examines the audio content of the received signals and bases the control signals on the audio content analyzed.
The advantage that is gained in the illustrative embodiment over some techniques in the prior art is accomplished by leveraging much of the existing telecommunications infrastructure within an enterprise. With some techniques in the prior art, improving the management of environmental conditions and facilities costs can require a costly retrofit of an office building with an improved sensor network. In contrast, the management system in the illustrative embodiment is able to leverage the use of the existing infrastructure by using the telecommunications endpoints that are already present, typically in each and every room, in order to manage the non-telecommunications facilities and costs.
As an example of how the illustrative embodiment manages a building, suppose first that the building is kept at a slightly cooler temperature at night than during the workday. At the start of the workday, a first person arrives and goes to use his telephone to call a second person across the building. The private branch exchange of the illustrative embodiment senses the “off-hook” condition of the first person's phone and, when the second person answers, the off-hook condition at the second phone. The exchange infers from the off-hook signals that people must be present in the two offices; it know then to generate a control signal to raise the temperature at or near the first person's office and additionally near the second person's office.
Continuing with the example, in some embodiments the exchange performs a keyword analysis of the audio content of the conversation between the two people. The first person comments in passing, “Gee, it's too cold in this office.” In monitoring the audio content being uttered by the first person, the private branch exchange discerns the reference to the office being “too cold” and generates a control signal to raise the air temperature in her office. Additionally, if the second person comments that his room “too hot,” the exchange discerns the content and, as a result, generates a control signal to lower the air temperature in his office.
Finally, at the end of the normally-scheduled workday in the example, if a predetermined amount of time elapses without the exchange having detected any audio signals or endpoint usage, which might suggest that the employees have left for the day, the exchange can then generate a control signal to apply the nighttime settings to the rooms of one or both of the people.
As suggested by the example above, the illustrative embodiment of the present invention features the management of environmental conditions. However, it will be clear to those skilled in the art, after reading this specification, how to make and use alternative embodiments of the present invention in which the data-processing system is able to manage other types of facilities, such as building security and employee safety systems. It will also be clear to those skilled in the art, after reading this specification, that other techniques are possible that involve using signals from one or more telecommunications endpoints, in order to control a building.
The illustrative embodiment of the present invention comprises: receiving, at a data-processing system, a first in-use signal from a first telecommunications endpoint that is part of a plurality of endpoints that are situated within a first geographic area and that are served by the data-processing system, the first in-use signal indicating that a user is using the first telecommunications endpoint, the data-processing system being capable of setting up a telephone call between the first telecommunications endpoint and a second telecommunications endpoint; and generating a first control signal for changing a first environmental condition, the first control signal being based on the receiving of the first in-use signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts schematic diagram of the salient components of telecommunications system 100 in accordance with the illustrative embodiment of the present invention.
FIG. 2 depicts a diagram of the salient components of enterprise environment 101 within system 100 .
FIG. 3 depicts a block diagram of the salient components of private branch exchange 102 within system 100 .
FIG. 4 depicts a flowchart of the salient tasks that are related to managing the environmental facilities within enterprise environment 101 , in accordance with the illustrative embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 depicts schematic diagram of the salient components of telecommunications system 100 in accordance with the illustrative embodiment of the present invention. System 100 comprises enterprise environment 101 , private branch exchange 102 , and environmental control system 103 , interrelated as shown.
Enterprise environment 101 represents the telecommunications facilities at a particular location of an enterprise, such as an office complex of a corporation, a school building, a hospital, a church, and so forth. Environment 101 comprises a plurality of N telecommunications endpoints that are capable of originating, receiving, or otherwise handling telephone calls for their users. Each endpoint within environment 101 is connected to private branch exchange 102 for the purpose of enabling telephone calls and for carrying out the techniques of the illustrative embodiment. Environment 101 is described below and with respect to FIG. 2 .
The telecommunications infrastructure that is present within environment 101 provides the connectivity between the endpoints and private branch exchange 102 . The infrastructure comprises one or more telecommunications networks, including a local area network (LAN), along with switches, routers, and other networking equipment. In some embodiments, the infrastructure comprises the Internet or possibly other Internet Protocol-based networks. The endpoints within environment 101 , in some embodiments, might be connected to private branch exchange 102 via the Public Switched Telephone Network, which is a complex of telecommunications equipment that is owned and operated by different entities throughout the World. As those who are skilled in the art will appreciate, the endpoints within environment 101 might be interconnected with private branch exchange 102 via other combinations of network infrastructure.
With respect to the non-telecommunications facilities that affect enterprise environment 101 , environmental facilities are used to control the enterprise's environmental conditions. Such environmental conditions include, but are not limited to, temperature, humidity, lighting, air quality, and so forth. These environmental conditions are controlled by environmental control system 103 .
Private branch exchange 102 is a data-processing system, such as a server or switch, which enables the users of multiple endpoints to communicate with other endpoint users, in well-known fashion. Exchange 102 receives audio and control signals from endpoints that are involved in one or more telephone calls, generates output signals, and applies those generated signals to selected phone calls or endpoints, in accordance with the illustrative embodiment of the present invention. Exchange 102 is described in detail below and with respect to FIG. 3 .
In accordance with the illustrative embodiment, the techniques of the illustrative embodiment are implemented at a private branch exchange. However, it will be clear to those skilled in the art, after reading this specification, how to make and use alternative embodiments of the present invention, in which the techniques are implemented at a data-processing system that comprises functionality other than that of a private branch exchange, such as a teleconference bridge.
Environmental control system 103 comprises infrastructure such as heating, ventilation, and air-conditioning units, which are used to provide environmental conditions that make the enterprise environment suitable for occupancy and use by its employees. System 103 receives control signals from private branch exchange 102 and applies those signals for controlling one or more environmental conditions (e.g., temperature, lighting, etc.), in accordance with the illustrative embodiment of the present invention.
FIG. 2 depicts a diagram of the salient components of enterprise environment 101 , in accordance with the illustrative embodiment of the present invention. In particular, FIG. 2 depicts an overhead view of an office workplace, in which many people are situated within the office space and, as office workers, are also users of telecommunications endpoints. Depicted telecommunications endpoints 201 - 1 through 201 -N can be situated on a desk within an employee's office or cubicle, in a conference room, or in a common area such as a pantry, copy room, or hallway wall. Endpoints 201 - 1 through 201 -N are connected to private branch exchange 102 in well-known fashion.
For reasons of clarity, the office space depicted in FIG. 2 is shown as a single space, enclosed by wall 202 , with no additional wall or partitions separating the endpoints from one another. However, it will be clear to those skilled in the art, after reading this specification, how to make and use alternative embodiments of the present invention, in which there is a different partitioning between two or more of the endpoints than depicted. For example, the endpoints might be in rooms separated by walls, in cubicles with half-wall partitions, or arranged in some combination thereof. Additionally, two or more endpoints might be collocated within the same room or cubicle.
Furthermore, although FIG. 2 depicts a total of nine telecommunications endpoints, it will be clear to those skilled in the art, after reading this specification, how to make and use alternative embodiments with a different number of endpoints.
Telecommunications endpoint 201 -n, where n has a value between 1 and N, inclusive, is capable of originating, receiving, or otherwise handling a telephone call for its user, in well-known fashion. Endpoint 201 -n is able to call, or to be called by, another endpoint. In order for its user to participate in a telephone call, endpoint 201 -n is able to dial a telephone number that private branch exchange 102 understands; the exchange subsequently routes the corresponding call to the appropriate endpoint being called. Endpoint 201 -n can be an analog telephone, an ISDN terminal, a softphone, an Internet-Protocol phone, a cellular phone, a cordless phone, a PBX deskset, a conference phone or “speakerphone”, or some other type of telecommunications appliance.
Enterprise environment 101 as depicted is divided into four environmental control areas, zones 203 - 1 through 203 - 4 . The environmental conditions that apply within each zone are controllable on a zone-by-zone basis. For example, the conditions that apply to the office spaces situated within zone 203 - 1 can be different from those that apply to zone 203 - 2 , which can be different from those that apply to zones 203 - 3 and 203 - 4 . Although four zones are depicted in FIG. 2 , it will be clear to those skilled in the art, after reading this specification, how to make and use alternative embodiments of the present invention in which there is a different number of zones within the enterprise area being controlled.
FIG. 3 depicts a block diagram of the salient components of private branch exchange 102 , in accordance with the illustrative embodiment of the present invention. Exchange 102 comprises network interface 301 , processor 302 , and memory 303 , interconnected as shown. Exchange 102 is capable of performing the tasks described below and with respect to FIG. 4 .
Network interface 301 comprises the circuitry that enables exchange 102 to receive signals from and transmit signals to the endpoints within environment 101 , in well-known fashion. In accordance with the illustrative embodiment, interface 301 receives and transmits audio signals that are represented in Internet Protocol packets, in well-known fashion. Additionally, interface 301 comprises the circuitry that enables exchange 102 to exchange signals with environmental control system 103 , in accordance with the illustrative embodiment of the present invention. In accordance with the illustrative embodiment, interface 301 receives and transmits environmental control signals via the Building Automation and Control Networks (BACnet) protocol, as is known in the art. As those who are skilled in the art will appreciate, in some alternative embodiments interface 301 receives and transmits audio or control signals, or both, in a different format.
Processor 302 is a general-purpose processor that is capable of receiving information from network interface 301 , of executing instructions stored in memory 303 , of reading data from and writing data into memory 303 , and of transmitting information to network interface 301 . In some alternative embodiments of the present invention, processor 302 might be a special-purpose processor.
Memory 303 stores the instructions and data used by processor 302 , in well-known fashion. Memory 303 might be any combination of dynamic random-access memory (RAM), flash memory, disk drive memory, and so forth.
In accordance with the illustrative embodiment, memory 303 stores a database that comprises information on where each endpoint is situated relative to other endpoints, what the relationship is between endpoints and zones, and so forth. In some alternative embodiments, the database is stored at another data-processing system, and exchange 102 is able to access the database through the other system.
FIG. 4 depicts a flowchart of the salient tasks that are related to managing the environmental facilities within enterprise environment 101 , in accordance with the illustrative embodiment of the present invention. As those who are skilled in the art will appreciate, some of the tasks that appear in the flowchart can be performed in parallel or in a different order than that depicted. Moreover, those who are skilled in the art will further appreciate that in some alternative embodiments of the present invention, only a subset of the depicted tasks are performed.
At task 401 , private branch exchange 102 receives and processes one or more input signals from endpoints 201 - 1 through 201 -N in well-known fashion. Exchange 102 receives, from endpoints 201 - 1 through 201 -N, one or more signals that indicate whether each endpoint is in use. An endpoint is in use, for example, when its user is utilizing the endpoint to handle a telephone call, to retrieve voice mail, or to invoke some other feature that results in the signaling of exchange 102 . The in-use signaling can come from endpoint 201 -n in the form of an “off-hook” indication, dialed digits, or a packet message that indicates that the user is utilizing the endpoint. As those who are skilled in the art will appreciate, other signals from endpoint 201 -n can be used to indicate that the endpoint is being used.
In accordance with the illustrative embodiment, at least some of the inputs signals that exchange 102 receives are audio signals, which contain content uttered by the endpoint users. As an example, exchange 102 can receive audio content when an endpoint user calls a designated telephone extension and speaks commands to affect one or more environmental conditions. Alternatively, exchange 102 can receive audio content that is part of the user's conversations with each other that occur via the private branch exchange.
In some alternative embodiments, exchange 102 monitors for the presence and utterances of people even when the endpoints are not in use. For example, through the microphone of each endpoint, exchange 102 can monitor for sounds, classify those sounds by probable source (e.g., human-made, etc.), and determine whether a human user is adjacent to an endpoint. As those who are skilled in the art will appreciate, exchange 102 can check for audio signals continuously, sporadically, or periodically.
In some other alternative embodiments, exchange 102 supports a digit-based interactive voice response (IVR) system, in which a user who wants to adjust an environmental condition (e.g., temperature, etc.) calls a telephone extension that routes to the IVR system via exchange 102 . Exchange 102 then works through an “IVR tree,” as is well-known in the art. For example, an IVR transaction between the system and a user who is feeling cold in her office in room 3 D- 203 might progress as follows:
System: “You are calling from room 3D-203. Press or say ‘1’ if
you are calling about that room”
User selects ‘1’
System: “Press or say ‘1’ if your call is about your room
climate. Press or say ‘2’ to . . . ”
User selects ‘1’
System: “Press or say ‘1’ if it is too hot. Press or say ‘2’ if
it is too cold . . . ”
User selects ‘2’
System: “Thank you. Your request is being processed.”
As those who are skilled in the art will appreciate, other variations of an environment-controlling IVR system are possible. For example, in some embodiments, exchange 102 supports a voice-based IVR system, as is known in the art, in which the system is able to receive and process phrases such as “too hot”, “too cool”, “too humid”, and so forth.
Exchange 102 , in yet some other alternative embodiments, supports the reception and analysis of keywords, independently of an IVR system. For example, a user can call a telephone extension that routes through exchange 102 and, when the call is answered, can then speak commands such as “Building control. Too hot. Turn down heat.” Alternatively, the user can speak such commands near her endpoint and without having called the extension first; exchange 102 can receive those commands via the endpoint's microphone and process them.
Exchange 102 , in some additional alternative embodiments, is able to receive and process audio signals that represent the conversations that endpoint users have with each other when they use their endpoints during the course of a workday. A relatively simple form of processing involves the spotting of keywords, such as “too hot”, “too cold”, “stuffy”, “in here”, “in my room”, and so forth. For example, at one point in the conversation between the two endpoint users, the user of endpoint 201 - 1 utters, “Gee, it's too cold in my room”. Exchange 102 receives the audio signal from the user and recognizes “too cold” and “in my room”. As a result, the exchange generates a controlling signal, as described below and with respect to task 402 . In a more complex form of conversational analysis, in some embodiments exchange 102 analyzes ongoing conversations between users on their endpoints.
Private branch exchange 102 is able to discern the audio content of the received audio signals by using speech recognition techniques that are well-known in the art. For example, exchange 102 is able to correlate the received sounds—or lack thereof—with signal profiles stored in its database. In addition, although the examples above feature content without any command syntax, the users' utterances could be alternatively phrased as explicit commands (e.g., “raise the temperature,” etc.) and recognized.
At task 402 , exchange 102 generates, for a given environmental condition that is controllable by environmental control system 103 , a controlling signal that specifies the value of the environmental condition, such as the temperature to take effect for a particular zone. As those who are skilled in the art will appreciate, other environmental conditions can be controlled as well, such as humidity, lighting, air quality, and so forth. The controlling signal is based on the content of the one or more input signals received from the endpoints. In some embodiments, the controlling signal might be based on one or more in-use signals. Exchange 102 generates a controlling signal for each environmental condition to be controlled.
For example, suppose that exchange 102 has already set up a telephone call between endpoints 201 - 1 and 201 - 8 . At one point in the conversation between the two endpoint users, the user of endpoint 201 - 1 utters, “Gee, it's too cold in this room.” In accordance with the illustrative embodiment, private branch exchange 102 discerns in the audio content the user's reference to the cold temperature and, as a result, generates a control signal to raise the air temperature. In some embodiments, exchange 102 specifies the particular zone of the user, in this case zone 203 - 1 , as part of the generated message.
As a second example, the same scenario applies, except that the user of endpoint 201 - 8 utters, “Really? Well, it think it's too hot in my office, and the lighting is too bright in here,” in response to the first user's comment. In accordance with the illustrative embodiment, private branch exchange 102 discerns in the audio content the user's reference to the hot temperature and bright lighting and, as a result, generates one or more control signals to lower the air temperature and dim the lighting. In some embodiments, exchange 102 specifies the particular zone of the user, in this case zone 203 - 3 , as part of the generated message.
In some alternative embodiments, the controlling signal can also be based on one or more additional considerations such as the spatial closeness of the first telecommunications endpoint to the second telecommunications endpoint. For example, exchange 102 might generate a controlling signal to raise the temperature by three degrees on behalf of the user of endpoint 201 - 1 if the other endpoint involved is in another zone, but only by one degree if the other endpoint is within the same zone as endpoint 201 - 1 .
The controlling signal, in some other alternative embodiments, can be based on not having received any content within any audio signal from one or more endpoints within a predetermined amount of time. For example, if endpoint 201 - 1 has not been used for a couple of hours, exchange 102 might assume that the user is no longer in the office and might lower the temperature a bit, in order to save energy. And as those who are skilled in the art will appreciate, different rules can be applied at different times throughout the day (e.g., the start of the workday, the end of the workday, the middle of the night, etc.).
At task 403 , exchange 102 transmits the generated controlling signal to environmental control system 103 for the purpose of controlling the selected environmental condition or conditions.
Exchange 102 continually executes the already-described tasks during its operation, thereby controlling the environmental conditions within the geographic area in which the endpoints are situated.
The illustrative embodiment of the present invention features the management of environmental conditions. However, it will be clear to those skilled in the art, after reading this specification, how to make and use alternative embodiments of the present invention in which the data-processing system is able to manage other types of facilities, such as building security and employee safety systems. As one example of a non-environmental application, the system might detect, through one or more of endpoints 201 - 1 through 201 -N, a human-generated sound that normally should not be present during a particular time of the night; in this case, it notifies building security that a possible intruder might be present. The system can perform detection of specific sounds, such as a loud scream, by accounting for audio characteristics such as timbre, pitch, volume, and so forth, and can take appropriate action based on the values of one or more of the characteristics. So, if the system determines that a signal sounds more like a burglar than a mouse, it can notify building security.
As another example of a non-environmental application, if the system detects, through one or more endpoints, a human-generated sound of a particularly troubling nature, such as cries for help outside of normal working hours, it notifies building safety that an employee might be in need of medical assistance.
It is to be understood that the disclosure teaches just one example of the illustrative embodiment and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the following claims.
|
A technique is disclosed that enables the managing of environmental conditions within an enterprise workplace and, in doing so, provides an improvement in facilities cost management over some techniques in the prior art. A data-processing system such as a private-branch exchange monitors the workplace by using one or more telephones, or other “telecommunications endpoints” to which the exchange is connected, in the workplace area. The exchange determines whether people are present in the workplace area by monitoring which endpoints are in use. Additionally, the exchange monitors the sounds that are received by the microphones of the endpoints. Based on knowing which endpoints are in use, the exchange generates control signals for the purpose of controlling one or more environmental conditions such as temperature, lighting, and so forth. In some embodiments of the present invention, the exchange examines the audio content of the received signals and bases the control signals on the audio content analyzed.
| 7
|
TECHNICAL FIELD
The invention relates to a band joining system and to a method of preparing and making a join in a band, such as a transmission belt.
BACKGROUND ART
Bands and belts of the type envisaged by the present invention include belts having an internal reinforcing member typically made from textile fibers or wire strands, the reinforcing member being enclosed within the remainder of the belt which is an extrudate made up from TP polyester or polyurethane resins.
In order to provide a continuous band or belt from an extruded section, there are a number of prior art systems in existence.
A first prior art method involves butt welding. However, such butt welding methods tend to introduce a weakness at the join area and great care must be taken when aligning the two ends for welding.
A second prior art method involves utilizing connectors for joining one end of belt to another. While such a system may be quick and convenient, it tends to be compromised in terms of strength/performance.
In each of the abovementioned systems, there is introduced weakness into the system since the reinforcing member running through the belt is cut and strength of the join is compromised.
It is an aim of embodiments of the present invention to provide an improved method for preparing and making a join in bands/belts having a reinforcing member.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, there is provided a method of making a join between two ends of banding material, the method comprising the steps of:
preparing a first of the two ends by removing a first amount of material of the band to form a first stepped region;
removing from an end region of the second of the two ends an amount of material of the band to form a second stepped region;
heating the first and second stepped regions to cause partial melting thereof; and
bringing the heated first and second stepped end regions into contact so that the first and second stepped regions cooperate to form an overlapped welded join.
Preferably, the first amount of material is removed from above an internal reinforcing member of the first end of the band and the amount of material removed from the end region of the second of the two ends is removed from below a reinforcing member.
Preferably, the reinforcing members remain substantially intact following the removal of material.
Preferably, the reinforcing members of the first end region and second end region overlap in the welded join.
Preferably, the step of heating the first and second stepped regions is performed by applying hot air to those regions.
Preferably, following the steps of preparing the first and second ends, the first and second ends are supported in a special tool which allows the first and second ends to be held in opposed relation to one another and be heated.
Preferably, the tool in a first configuration allows the first and second stepped regions to be heated and, in a second configuration, brings the first and second stepped regions together and supports them during the formation of the join.
Preferably, during formation of the join, the first and second ends are squeezed together so as to hold them in compression. Efficient compression may be realized by ensuring that a first lateral side of the first stepped end is fully supported by the tool and a second lateral side of the second stepped end (which opposes the first lateral side of the first stepped end) is fully supported so that during compression pressure is brought to bear efficiently across the join.
Preferably, when forming the first and second stepped regions, the internal reinforcing member in the stepped regions of each band is left intact. Alternatively, in the case where multiple reinforcing strands are provided, one or more of the strands may be removed during the formation of the stepped areas, leaving the remainder to overlap during joining.
A finished join may be trimmed of flash in a finishing step.
According to a second aspect of the invention, there is provided a tool for holding, in use, first and second band end regions in close proximity during the formation of a welded join, the tool comprising:
first and second arms pivotally attached to one another in a scissor type configuration;
first and second guide means associated with the first and second respective arms, the first and second guide means being arranged to support respectively the first and second band ends during formation of the join.
Preferably, the first and second guide means each comprise a guide region having a channel formed therein, the channel having a cross-section approximating to the cross-section of the band and being arranged to receive respective first and second cut end regions of the band therein.
Preferably, the channels each comprise a base and two side walls. The side walls may be parallel. The side walls may be disposed such that in the first channel the side walls slope in a first direction with respect to the base and in the second channel the side walls slope in a second direction with respect to the base.
Preferably, when the band is approximately of a "V" section each channel is arranged to have one side wall which fully supports one side of the V-section and another side wall which leaves the other side of the "V" unsupported.
Preferably, in the first channel it is a first side of the "V" which is supported and in the second channel it is a second side which is supported.
Alternatively, the channels are of arcuate cross-section and are used to receive rounded band end regions.
Preferably, first and second removable covers are provided associated with the guide regions of the first and second respective guide means. The covers are preferably removable to allow extraction of a band after joining.
The first and second guide means are preferably pivotally attached to the respective first and second arms and, further, there is preferably provided a pair of sliding connections, such that, a slot formed in said first guide means is associated with a post of the second arm and a slot formed in the second guide means is associated with a post of the first arm, the arrangement being such that when handle regions of the first and second arms are squeezed together, the first and second guide means are arranged to move toward one another in a manner specified by the formation of the sliding connections and pivotal attachments.
According to a third aspect of the invention, there is provided an attachment for a hot air gun, the attachment comprising a nozzle comprising a first, inlet end for attachment to an air gun to receive hot air therefrom, and a second, outlet end, the second end having a plurality of apertures formed therein, the apertures being arranged to divert air which flows predominantly in a first direction at said first end, into a second direction, substantially perpendicular to the first direction.
Preferably, the first end is shaped so as to cooperate with an output of the hot air gun and the second end is comparatively flattened with respect to the first end, the second end having apertures formed on upper and lower surfaces thereof.
Preferably, the second end is adapted to cooperate with the tool of the second aspect, whereby the second end may be inserted, in use, between first and second band end regions so as to heat them while they are being held by the tool of the second aspect.
Preferably, an upper surface of the second end is shaped so as to conform with the formation of the first band end region and a lower surface thereof is shaped to conform to the formation of the second band end region.
The second end may be provided with a locator, at an approximate mid-point thereof, the locator being adapted to cooperate with locating means formed by cooperation of the respective guide means.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings, in which:
FIGS. 1A and 1B show a pair of transmission belt ends prepared for a joining operation;
FIG. 2 shows a cross-sectional view along line C-C' showing the formation of the belt of FIG. 1;
FIGS. 3A and 3B are front and reverse views respectively showing a tool which is arranged for aiding the joining operation;
FIG. 4 shows detail of part of the tool of FIG. 3;
FIGS. 5A to 5C show respectively a side view, a view in the direction of arrow "A" of FIG. 5A and a view in direction of arrow "B" of FIG. 5A of a nozzle for use with a hot air gun for preparation of a join;
FIGS. 6A to 6C show details of the channel regions of the tool of FIGS. 3A and 4;
FIG. 7 and FIG. 8 are, respectively, a cross-sectional view through the core of and a view from above of a cut end region of a circular cross-section transmission belt;
FIG. 9A and FIG. 9B are front and reverse views respectively showing a tool which is arranged for aiding the joining operation of a circular cross-section transmission belt;
FIG. 10 shows a clamp for use with the tool of FIGS. 9A and 9B;
FIG. 11 is a view showing detail of the tool of FIGS. 9A and 9B with two clamps of the type shown in FIG. 10 in position; and
FIG. 12 is an end-on view from the direction of arrow Z showing detail of the arrangement of FIG. 11, shown with a circular cross-section transmission belt in place.
Throughout the drawings hatched lines (---) represent hidden detail.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIG. 1, first 1, and second 2, band end regions are shown. The band end regions 1, 2 may in fact be the extreme ends of a single length of belting which is to be joined into a continuous loop or, alternatively, they may be ends of separate lengths of belting which, for one reason or another, simply need to be joined together.
The belt material comprises, in general, an extrusion of plastics material such as TP polyester or polyurethane resin with an internal reinforcement 3, 4. The reinforcement 3, 4 may comprise a single reinforcing member or a plurality of reinforcing members made up of textile fibres, wire strands etc.
In order to prepare the end regions 1, 2 for joining together, they are cut as shown in FIG. 1 such that a first amount of material "A" is removed from the belt end region 1 so as to form a stepped area comprising a ledge region 5 on one side of which the reinforcing member 3 is retained along with the extrudate material. The formation of this stepped region is made by performing a number of cuts, comprising a first angled cut 6, a second straight cut to form the ledge 5 and a third angled cut 7.
In similar fashion to that described for the band end region 1, band end region 2 is prepared for joining by removing material from a region "B" from one side of the band 2 at the band end region and forming a ledge 8, on one side of which there is the reinforcing member and the remainder of the extrudate material and on the other side of which the material is absent. The particular form which it is desired to bring about on the band region 2 is a stepped form which complements the stepped formation on the end region 1. To do this, a first angled cut 9 is made, a second straight cut along ledge 8 is made and a third, angled, cut 10 is made.
FIG. 2 is a cross-sectional view which shows that the band in question is a "V" type belt having a narrow top surface "a" and a wider bottom surface "b". Comparing FIGS. 1 and 2 it will be seen that the line D-D' represents the cut marked at point "E" in FIG. 1A.
In order to assist accurate cutting of the band at the end regions 1, 2, a cutting template or special cutting tool may be provided.
It should be noted that for both end regions 1, 2, the reinforcing member 3, 4 is left largely intact. Where the reinforcing member comprises multiple strands, one or more of those multiple strands may be removed, but a majority remainder is retained at each band end region 1, 2 so that when a join is made, there is provided an overlapping of reinforcing members to at least some degree. A view of a finished join is shown in FIG. 1B to illustrate the concepts discussed above in relation to FIG. 1A.
Referring to FIG. 1B, it can be seen that the stepped regions of the band end regions 1, 2 overlap and that, at the very center of the join, reinforcing members 3, 4 overlap each other.
In order to form a join such as that shown in FIG. 1B, the extrudate material of the band end regions 1, 2 adjacent to the join area (i.e. the regions closest to the stepped areas) are locally heated such that material at these boundary regions melts. Once material at the boundary regions is in a molten state, the two end regions are brought together in the configuration shown in FIG. 1B to form a welded join.
By forming an overlap join in this manner, the join strength relies on the shear strength of the mating surfaces which is enhanced by the adhesion of each of the reinforcing members to the extrudate. In particular, it will be appreciated that, in contrast to butt welding, since the join is constituted by a larger area then this will contribute to an enhanced strength and, by including both reinforcing members, each of those members will adhere to both sides of the join. In other/words, by cutting the band end regions such that regions of the reinforcing members are practically exposed, each reinforcing member will contact material on both sides of the join.
Referring now to FIGS. 3A and 3B, a tool for holding prepared ends of belting material is shown. The tool comprises a pair of pivotally mounted arms 11, 21, the arms having a scissor type action such that when they are squeezed together and rotated about common pivot point 12, their extreme ends 13, 23 move toward one another. Pivotally attached to the extreme ends 13, 23 of arms 11, 21 respectively are provided guide means comprising blocks of material 14, 24 fixedly attached to respective guide regions 16, 26. Each block of material 14, 24 has a pivotal connection, P1, P2, and is also provided with a sliding connection given by movement of sliders S1, S2 fixedly provided on arms 11, 21 and adapted for movement within slots 25, 15 respectively of blocks of material 24, 14.
The guide regions 16, 26 of the guide means may be attached to the blocks of material 14, 24 by screw fixings or similar or, of course, in other embodiments may be integrally casted or moulded etc. so as to cooperate directly with the arms 11, 21.
The guide region 16 has an internal channel 30 to receive a first end region of extruded belt material and the second guide region 26 also has an internal channel 31 to receive the other end region. These channels are shown by hatched and solid lines in FIG. 3A but may be seen more clearly by referring to FIG. 4 which is an end view from arrow C on FIG. 3A. The channels are covered by removable plates 32, (only one of which is shown in FIG. 4) so that the covered channels provide complete support for the two end regions of banding material. The top plates 32 are removably held in position by thumb wheels 34, 35 which allow the plates to be taken off (as in FIG. 3A) so that after a join has been made, the banding material may be removed from the tool. Further features of the tool are shown in FIGS. 3B and 4, such as fixing means 36 for attaching the guide regions to their respective blocks of material. There is also shown in FIGS. 3A and 3B a gap 40 which is formed by the cooperating guide means and which, as will be explained later, serves as a locating means.
FIGS. 6A, 6B and 6C show the formation of the channels 31, 30. As can be seen, the band of the example has a "V" type formation and the channels 30, 31 each have parallel sloping sides, but those sides slope in opposite directions such that a side wall "g" of band end 2 and a side wall "h" of band end 1 are enclosed by an overhanging side wall of channels 30, 31 whereas side walls "h" of band end 2 and "g" of band end 1 are not.
Referring now to FIGS. 5A to 5C, there is shown a nozzle for a hot air gun for use with the apparatus of the present invention. The nozzle 50 is adapted for use with a hot air gun having a circular output attachment, the nozzle 50 being adapted to mate with such circular output. The main feature of the nozzle 50 is a snout region 51 of the nozzle which has a plurality of holes 52 formed therein both on a top side 53 and a bottom side 54 thereof, for reasons which will be explained later, the snout 51 has a turned up region 55 at one end and a turned down region 56 at the other with a substantially horizontal region linking the two ends. At a mid-point between the two ends, there is provided a locator 57.
The method of joining and welding together end regions of a belt will now be described with reference to FIGS. 3 to 5.
Firstly, the prepared belt end region 1 is inserted into guide region 26 and, similarly, the prepared belt end region 2 is inserted into guide region 16 of the tool of FIG. 3. The end regions are inserted such that the cut areas 5, 6, 7 of the band end region 1 are flush with, or nearly flush with a mating surface 27, 28, 29 of the guide 26 and that the cut regions 8, 9, 10 are flush with or nearly flush with mating surfaces 17, 18, 19 of the guide 14.
To provide proper seating and aid manipulation of the cut end regions within the guides 16, 26, the scissor type arrangement of arms 11, 21 may be opened as far as possible, such that sliders S1, S2 move further into slot regions 25, 15 and end regions 13, 23 of the arms 11, 21 move apart, which, in turn, moves guide regions 16, 26 apart.
Once the end regions 1, 2 are seated correctly within their respective guides 26, 16, with the cover plates 32 in place the tool may be brought into a condition in which there is a gap between mating surfaces 27, 28, 29 and 17, 18, 19 of the respective guides sufficiently large for the snout region 51 of the nozzle 50 to be inserted therebetween. With the nozzle so attached to a hot air gun the snout 51 is then inserted with locator 57 resting within gap 40 and the snout 51 extending between surfaces 17 and 27 with the turned up end 55 between surfaces 19/28, the turned down end 56 between surfaces 13/29 and the middle region between surfaces 17/27. The air gun is then brought into operation so as to expel hot air through apertures 52 on both upper 53 and lower 54 surfaces of snout 51. The hot air from the apertures 52 melts the extrudate material of the band end regions and, when the material is in a molten state (which takes only a few seconds), the nozzle 50 may be extracted from between the gap formed by surfaces 17, 27 and the two arms 11, 21 may be squeezed together which, in turn, causes the gap between the molten surfaces of the two band end regions 1, 2 to be reduced and brings the molten regions into contact with one another. The arms 11, 21 may be then pressed further together and held in this configuration to compress the material in the join region until the join has cooled somewhat. It will be appreciated from FIGS. 6A to 6C that as pressure is applied by the tool the opposing overhanging regions of the channels 30, 31 force the band end regions to be compressed in the area of the cooperating overhang shown in FIG. 6A. In this way the pressure applied by closing the tool is efficiently applied to the specific area around the join. Once the join has fully cooled, cover plates 32, 33 may be removed by unscrewing thumb wheels 34, 35 and the joined belt may be removed.
It will be appreciated that the abovementioned method may be applied to many different types of belt section and, in the case of "V" sections as described above, the tool is arranged to hold the join area of such sections in an efficiently compressed fashion as an inverted V so that the finished join is perfectly aligned.
A procedure and tool for joining together the ends of circular cross-section transmission belts will now be described with reference to FIGS. 7 to 12. In this discussion, the same basic principles are involved as with the abovedescribed system and similar elements will be denoted by like reference numerals to those above, but are further denoted by a prime. In other words, a first band end region of the circular cross-section transmission belt is denoted by 1'.
Considering initially FIGS. 7 and 8, there is shown a first band end region 1'. Although only one band end region 1' is shown, it will be appreciated that the band end region to which the first band end region is to be joined must be cut in a complementary fashion to the first band end region.
As with the "V" type belts, the belt material comprises, in general, an extrusion of plastics material with an internal reinforcement 3' which may be a single reinforcing member or a plurality of reinforcing members made up of textile fibers, wire strands etc.
End regions of the circular cross-sectional belt are cut in similar fashion to the V-belt shown in FIG. 1 such that a first amount of material represented by the shaded region A' is removed from the belt end region 1' so as to form a stepped area comprising a ledge region 5' on one side of which the reinforcing member 3' is retained along with the extrudate material. The formation of this stepped region is made by performing a number of cuts, comprising a first angled cut 6', a second cut to form the ledge 5' and a third angled cut 7'.
Considering FIG. 7, the broken line F-F' represents the position of the ledge 5' when the circular cross-section transmission belt is viewed end-on from arrow Y.
As with the "V" belts, it should be noted that for both end regions of the circular cross-section belt, the reinforcing member 3' is left largely intact. Where the reinforcing member comprises multiple strands, one or more of those multiple strands may be removed, but a majority remainder is retained at each band end region, so that when a join is made, there is provided an overlapping of reinforcing members to at least some degree.
As before, in order to perform a join, the extrudate material of the band regions adjacent to the join area are locally heated such the material at these boundary regions melts. Once material at the boundary regions is in a molten state, the two end regions are brought together to form a welded join.
Referring now to FIGS. 9A, 9B, 10, 11 and 12, a tool for holding prepared ends of belting material will be described. Again, like or similar elements to those described in relation to the tool for joining V belt material will be denoted by like numerals with an added prime.
Referring to FIGS. 9A and 9B, the tool comprises a pair of pivotally mounted arms 11', 21', the arms having a scissor type action such that when they are squeezed together and rotated about common pivot point 12', their extreme ends 13', 23' move toward one another. Pivotally attached to the extreme ends 13', 23' of arms 11', 21' respectively are provided guide means comprising blocks of material 14', 24' fixedly attached to respective guide regions 16', 26'. Each block of material 14', 24' has a pivotal connection P1', P2', and is also provided with a sliding connection given by movement of sliders S1', S2' fixedly provided on arms 11', 21' and adapted for movement within slots 15', 25' respectively of blocks of material 24', 14'.
The guide regions 16', 26' of the guide means may be attached to the blocks of material 14', 24' by screw fixings or similar or, of course, in other embodiments may be integrally casted or moulded etc. so as to cooperate directly with the arms 11', 21'.
The guide region 16' has an internal channel 30' which is rounded so as to cooperate with the outer periphery of the end region of a circular cross-section transmission belt and the second guide region 26' also has an internal channel 31' of similar formation. These channels are illustrated by broken lines in FIGS. 9A and 9B, but their formation is shown more clearly by referring to FIG. 12 which shows the channel region 31' with a piece of belting material resting in it and held in place by clamping means 32' which will be described in more detail shortly with reference to FIG. 10.
In use, the channels 30, 31 are coverable by removable clamps 32' (which are shown in detail in FIG. 10) these clamps are shown in position in FIGS. 11 and 12, but are absent from FIGS. 9A and 9B for reasons of clarity. The removable clamps 32' are provided so that, when they are in place, the channels formed by these clamps and the channels 30', 31' of the guide regions 16', 26' provide complete support for the two end regions of banding material.
The clamps 32' comprise a threaded thumb wheel member 321', a U-shaped piece of material 322' having an internally threaded hole adapted to cooperate with a threaded member of the thumb wheel 321' and a block of material 323' having a channel 324' formed therein, this channel 325' being of like radius to channels 30', 31'.
Referring now to FIG. 11, there will now be described how the clamps 32' cooperate with the guide regions 16', 26' when they come together to form a gap 40' which serves as a locating means in the same manner as the gap 40 described in relation to FIGS. 3A and 3B. In FIG. 11, the arms 11', 21' are not shown for reasons of clarity.
Joining and welding together of the end regions of a circular cross-section belt will now be described.
Firstly, the prepared belt end regions are inserted into guide regions 16', 26' of the tool of FIGS. 9A to 12. The end regions are inserted such that the cut surface 7' of the band end region 1' sits approximately flush with the angled surface 29' of the guide region 26', the other band end region is arranged in similar fashion with respect to guide region 16'.
To provide proper seating and aid manipulation of the cut end regions within the guides 16', 26', the scissor type arrangement of arms 11', 21' may be opened as far as possible, such that sliders S1', S2'αmove further into slot regions 25', 15' and end regions 13', 23' of the arms 11', 21' move apart, which, in turn, moves guide regions 16', 26' apart.
Once the end regions are seated correctly within their respective guides 26', 16' with the clamps 32' in position, the tool may be brought into a condition in which there is a gap 40' formed, as shown in FIG. 11. This gap 40' is sufficiently large for the snout region 51 of the nozzle 50 to be inserted therebetween. With the nozzle so attached to a hot air gun, the snout 51 is inserted with locator 57 resting within gap 40'. The air gun is then brought into operation so as to expel hot air through apertures 52 on both upper 53 and lower 54 surfaces of snout 51. The hot air from the apertures 52 melts the extrudate material of the band end regions and, when the material is in a molten state, (which takes only a few seconds), the nozzle 50 may be extracted from the gap 40' and pressure maintained on the two arms 11', 21 will cause the molten regions of the band ends to come into contact with one another to form the weld. Once the join has fully cooled, the clamps 32' may be removed by unscrewing thumb wheels 321' and the joined belt may be removed.
Finished joins may be trimmed of flash and then are ready for use.
It will be appreciated that although only round cross-sectional belts and V-shaped belts have been discussed herein, the invention is of application to belts of any given arbitrary cross-section.
The system has many advantages over currently existing systems. Firstly, because the join is made over a large area, it is stronger than other commonly used welded joins. Secondly, because the reinforcing member of each band end is retained, largely in tact, the welding operation joins reinforcing strands from one band end region into the material of the second end region and vice versa and extra strengthening of the join thereby occurs.
Furthermore, join strength relies on the shear strength of the mating surfaces and this is increased.
Furthermore, by utilising a hot air gun with locally applied heating, the band end regions may be brought to a molten state very much quicker than with prior art arrangements which often use a hot knife type instrument to provide surface heating.
The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
|
A band joining system including a method of preparing and making a join in a band, a tool for supporting the band when making the join and an attachment for a hot air gun to facilitate making the join. The tool has first and second arms pivotally attached to one another in a scissor type configuration and having first and second guide means associated with the arms for supporting band end regions during the formation of a join. According to the method, band ends are cut in such a fashion that they fit within guide regions of the guide means and supported in a configuration in which the hot air gun attachment may be interposed between the two band end regions supported in the tool, hot air applied to the band end regions and then compressive force used to bring the molten band end regions into contact with one another to form a welded join. The band end regions are cut such that each band end region retains elements of a central reinforcing member, those elements aiding the formation of a strong join.
| 1
|
FIELD OF THE INVENTION
The invention is in the field of bearing lubrication systems for gearboxes used to drive earth boring machines.
BACKGROUND OF THE INVENTION
A roadheader is an earth-boring machine which experiences high axial and radial loads on and in the frame of the machine. The roadheader includes a cutter head, a gearbox and a motor (prime mover). When the gearing, most notably the ring gear, is affixed to the housing of the gearbox, the axial and radial forces imparted on the cutter head are transmitted to the ring gear through the housing and cause misalignment of the gears and other components. The misalignment causes abnormal gear wear and ultimately destruction of the gears, carriers and other components.
Roadheaders operate in a range of motion with respect to horizontal. In other words, the cutter head of the roadheader and the gearbox affixed thereto may be inclined with respect to horizontal and creating lubrication problems with some of the bearings within the gearbox as the bearings are lifted out of the lubricating oil.
In the prior art, an internal tube requires internal connections which present the potential for leaks. These leaks allow water to enter within the gearbox and cause it to fail. The potential for leaks is increased due to the extreme vibrations that exist within the gearbox as the cutter head cuts into soil and rock. The tube vibrates within the gearbox and the connections leak due to the vibrations.
U.S. Pat. No. 7,935,020 to Jansen et al. issued May 3, 2011, states that: “A drive train for a wind turbine is provided. The wind turbine comprises a low speed shaft connected to blades of the wind turbine and a higher speed shaft connected to a generator. The drive train also includes a bearing that substantially supports the weight of at least the low speed shaft. A compound planetary gear stage is connected to the low speed shaft and the higher speed shaft, and includes a rotating carrier, a nonrotating ring gear, a plurality of planetary gears, and a rotating sun gear. The sun gear is connected to the higher speed shaft.”
U.S. Pat. No. 4,873,894 to Avery et al. issued Oct. 17, 1989, states: “A balanced free-planet drive mechanism includes a reaction ring gear, an output ring gear, an input sun gear arranged along a central axis, and a plurality of floating planet elements individually having a first planet gear engaged with the sun gear, a second planet gear engaged with the output ring gear, and a third planet gear engaged with the reaction ring gear. A required first rolling ring gear resists radially inward movement of the planet elements adjacent the third planet gear, and an optional second rolling ring gear resists radially inward movement of the planet elements adjacent the first planet gears to maintain the planetary elements essentially parallel to the central axis. A plurality of ring segments are connected to the output ring gear and engage a groove in each of the planet elements to maintain the planet elements in a preselected axial position and to transmit relatively low thrust forces. The drive mechanism is easy to assemble in a ground-engaging wheel of a truck or the like, with the output ring gear being connected to rotate with the wheel. The incorporation of the drive mechanism in a wheel eliminates the usual planet carrier and planetary bearings associated with a conventional multi-stage planetary final drive, and is lighter in weight and less costly while fitting compactly within the same general space envelope.”
SUMMARY OF THE INVENTION
Floating Gearbox
When gears are under load, forces within a gear system align the gears and other components of the gear system so that optimum load balancing occurs, that is, the gears align themselves. External forces not generated by the gear system move the gears out of this alignment and thus adversely affect the gear position causing damage and premature wear. The floating gear system of the invention allows gears to retain their most favorable alignment position.
An electric motor drives an input gears via spline connections. The input gear drives an intermediate gear. The intermediate gear drives the shaft which, in turn, drives the first sun gear such that the intermediate gear and the first sun gear rotate together at the same speed. The first sun gear drives a set of first planet gears. Preferably there are three first planet gears. The planet gears are engaged with a static (fixed) ring gear. A first pair of spherical bearings is interposed between each first planet gear and each first planet shaft. The first pair of spherical bearings is separated from each other and provides support for the first planet gear. Each first planet shaft is affixed to the first planetary carrier. The first planet gear forces the first planet carrier to rotate and thus drives second sun. Second sun includes an external spline and a gear.
The second sun gear drives four second planet gears. The second planet gears engage static (rotationally fixed) ring gear. A second pair of spherical bearings is interposed between each second planet gear and each second planet shaft. The second pair of spherical bearings is separated from each other and provides support for the second planet gear. Each second planet shaft is rotatably affixed to the second planetary carrier. The second planet gear forces the second planet carrier to rotate and thus drive the output shaft.
The gears are allowed to float. Both vertical and horizontal forces act on the cutter head. These forces are transmitted through the gearbox and back to the supporting structure. In the present invention, the gears run independent of the housing, that is, they float. The ring gear floats. The ring gear is spaced apart from the housing. A small annular gap exists between the ring gear and the housing, thus deflection due to external forces in the housing doesn't affect the gear alignment because the gears aren't directly attached to the housing. The ring gear has torque passing through it and thus is anchored back (against rotation) to the housing through a spline connection between the ring gear and the cover. The cover is affixed to the housing and the spline connection acts like a hinge. The ring gear and housing deflect independently of each other.
Spline connections in the present invention make the gears float. Splines have small gaps in them. These gaps allow small relative movement between meshing splines and help the gears find a position that best suits them. The spline connections include the connection between ring gear and cover; the second planet carrier and the output shaft; the first carrier and the second sun; and, the first sun gear and the splined shaft, and, the intermediate gear and the splined shaft.
When gears are under load, the forces within the gear system align the gears so that optimum load balancing occurs, that is, the gears align themselves. In the prior art, external forces not generated by the gear system, move the gears out of alignment and thus adversely affect their positions. The present invention allows the planetary gear systems to retain their most favorable alignment positions.
A gearbox which includes a housing having a cover is disclosed. The cover is affixed to the housing. The cover includes an external spline located on a central portion thereof. There are two input gears driven by prime movers, for example, electric motors. The input gears drive an intermediate gear which is known as a drop down gear. The intermediate (drop down) gear includes an internal spline. The splined shaft includes a first external spline and a second exterior spline. The internal spline of the intermediate gear engages the first exterior spline of the shaft rotating the shaft with the intermediate gear. A centrally located tube resides along a first longitudinal axis of the housing. A centrally located adapter also resides along a first longitudinal axis of the housing. The centrally located adapter is affixed to the housing. The centrally located adapter and centrally located tube are stationary. There are two spherical bearings, the shaft input spherical bearing and the shaft output spherical bearing, which enable the components of the gearbox to float within the gearbox thus avoiding deformation and subsequent destruction of the components. The components include the ring gear, a splined shaft, a first planetary system, a second planetary system, and an output shaft. Each of the planetary systems includes a sun gear, a plurality of planet gears, a planet gear carrier, and a plurality of planet gear shafts.
A first shaft input spherical bearing is interposed between the stationary tube and the rotating input shaft. A first sun gear includes an internal spline. The second external spline of the input splined shaft engages the internal spline of the first sun gear driving the sun gear therewith.
A plurality of first planet gears is carried by a first planet gear carrier. Each planet gear is pinned to the first planet gear carrier by a first planet gear shaft. A first pair spherical bearings is interposed between each of the first planet gear shafts and each of the first planet gears. The first sun gear drives the first planet gears. The first planet gear carrier restrains each of the first pair of spherical bearings interposed between the first planet gear and the first planet gear shaft against longitudinal movement. The first planet gear carrier restrains each of the first planet gears with respect to its respective first planet gear shaft holding them against longitudinal movement in their respective planet gear shaft. A ring gear is mounted within the housing and includes an internal spline. The internal spline of the ring gear engages the external spline of the cover affixing the ring gear against rotation with respect to the cover/housing.
The plurality of first planet gears engages the ring gear driving the first planet carrier. The first planet carrier includes an internal output spline. A second sun includes an external spline and a sun gear.
The internal output spline of the first planet carrier drives the external spline of the second sun gear. The plurality of second planet gears engages the ring gear driving the second planet carrier. The gear of the second sun drives the second planet gears which, in turn, drive the second planet carrier. The second planet gears engage the ring gear. A second pair of spherical bearings is interposed between the second planet gear shaft and the second planet gear. The second planet gear carrier restrains the second pair of spherical bearings interposed between each of the second planet gears and the second planet gear shaft against longitudinal movement. The second planet gear carrier restrains the second planet gears with respect to its respective second planet gear shaft against longitudinal movement holding each of them against longitudinal movement. The second planet carrier includes an internal output spline.
The output shaft includes an external spline. The housing, the cover and the output shaft have a longitudinal axis. The internal output spline of the second planet carrier drives the external spline of the output shaft.
A shaft output spherical bearing resides intermediate the output shaft and the cover of the gearbox supporting the output shaft. The shaft output spherical bearing permits angular displacement of the output shaft with respect to the longitudinal axis of the output shaft. The ring gear pivots with respect to the cover/housing. The shaft output spherical bearing enables the ring gear to float within the housing and not engage the housing.
A gearbox in combination with a roadheader is also disclosed. A prime mover, a cutter head, a gearbox are disclosed. The gearbox includes: a housing having an inner surface and an external spline; an input shaft; a first planetary gear system driven by the shaft; and, a second planetary gear system driven by the first planetary gear system. A ring gear includes an internal spline. A first pair of spherical bearings supports the first planetary gear system. A second pair of spherical bearings supports the second planetary gear system. The ring gear includes an outer surface and the outer surface is substantially cylindrically shaped. The outer surface of the ring gear is spaced apart from the inner surface of the housing forming an annular gap therebetween. The internal spline of the ring gear engages the external spline of the housing affixing the ring gear against rotation with respect to the housing. The ring gear is pivotable with respect to the housing. An output shaft is driven by the second planetary gear system. The gearbox is interposed between the prime mover and the cutter head. The prime mover delivers power to the input shaft of the gearbox and the output shaft of the gearbox drives the cutter head.
Lubrication
A bearing lubrication system is disclosed which includes a gearbox housing wherein the gearbox housing includes a planetary gear system, the planetary gear system includes planet gears, an external spline, an interior surface and an exterior surface. Lubricating oil resides in the gearbox housing and the planet gears pass through the lubricating oil in the gearbox housing. The floating ring gear resides within the gearbox housing and the floating ring gear is substantially cylindrically shaped. The floating ring gear includes an inner portion and an outer surface. The inner portion of the floating ring gear includes an internal spline and an internal gear. The internal spline of the floating ring gear engages the external spline of the gearbox housing preventing rotation of the floating ring gear with respect to the housing. The exterior surface of the floating ring gear is radially spaced apart from the interior surface of the gearbox housing forming an annulus between the gearbox housing and the floating ring gear.
The planet gears of the planetary gear system engage the internal gear of the floating ring gear. The internal gear of the floating ring gear includes a first passageway therein for receiving oil from the meshing of the planet gears with the internal gear of the floating ring gear. The first passageway extends through the floating ring gear. The outer surface of the floating ring gear includes first and second grooves therein. First and second O-rings reside in the first and second grooves of the outer surface of the O-rings and seal the annulus formed by the space between the exterior surface of the ring gear and the interior surface of the housing. The gearbox housing includes a second passageway in communication with the annulus. The second passageway in the gearbox housing extends to the exterior surface of the housing. A cover affixed to the housing includes a third passageway in communication with the second passageway of the gearbox. The second passageway and the third passageway are joined together at a joint and the joint is sealed with an O-ring.
The cover includes a void or cavity therein. The third passageway communicates between the joint and the void in the cover. The cover includes a fourth passageway and a circumferential recess. The fourth passageway communicates between the void in the cover and the circumferential recess in the cover. The shaft output spherical bearing is mounted adjacent the circumferential recess in the cover. The lubricating oil is forced and pumped into and through the first passageway through the floating ring gear and into the annulus between the gearbox housing and the floating ring gear. Lubricating oil from the annulus is pumped into and through the second passageway and through the joint between the second and third passageway. Then the oil is pumped through the third passageway into the void/cavity in the cover. Thereafter the oil passes through the fourth passageway between the void in the cover and the circumferential recess in the cover and lubricating the shaft output spherical bearing mounted adjacent the recess.
A bearing lubrication system is disclosed which includes a gearbox housing wherein the gearbox housing includes a planetary gear system, the planetary gear system includes planet gears, an external spline, an interior surface and an exterior surface. The gearbox includes an output shaft and the shaft output spherical bearing is interposed between the output shaft and the cover. Lubricating oil collects in the void and the gearbox tilts at an angle up to 43° with respect to horizontal during operation. A floating ring gear resides within the gearbox housing and is substantially cylindrically shaped. The floating ring gear includes an inner portion and an outer surface. The inner portion of the floating ring gear includes an internal gear. The floating ring gear engages the gearbox housing preventing rotation of the floating ring gear with respect to said housing. The exterior surface of said floating ring gear is radially spaced apart from the interior surface of the gearbox housing forming an annulus between the gearbox housing and the floating ring gear. The planet gears of the planetary gear system engage the internal gear of the floating ring gear. The internal gear of the floating ring gear meshes with the planet gears pumping oil through the floating ring gear, the annulus, the gear box housing, the cover and the shaft output spherical bearing.
The shaft output spherical bearing which resides between the cover/housing and the output shaft has oil pumped to it to ensure that it is lubricated at all times. When the cutter head resides horizontally with respect to the earth, oil is supplied to the shaft output spherical bearing by virtue of the oil within the housing. At this time the shaft output spherical bearing also receives oil from the pumping system of the invention. The cutter head, and thus the gearbox, can tilt substantially with respect to the horizontal axis of the gearbox. The shaft output spherical bearing when inclined is lifted up out of the oil residing in the housing. Oil, or other lubricant, normally fills the housing up to the 50% level based on height. A sight glass is provided in the window which enables the roadheader user to view the oil level in the gearbox. Ring gear and surrounding pieces act, in addition to their normal function, like a pump. In the ring gear, just above the first planet gears, there are three small holes between the teeth of the ring gear. The three holes are spaced 120° apart. As the gear teeth of the first planet gears and the ring gear mesh (engage), oil is forced up into these holes. Oil will then flow to and then through the narrow cavity that is between the ring gear and the housing. O-rings at the ends of the ring gear keep the oil from leaving the volume bounded by the exterior surface of the ring gear and the internal surface of the housing. Oil is then forced though passageways and cavities in the housing and cover so that oil reaches the shaft output spherical bearing, and thus keeps the shaft output spherical bearing lubricated.
The gearbox of the invention is large and deep holes in the housing for a lubrication system are costly and difficult to manufacture. Instead, the invention obviates the need for deep holes. The gap between the ring gear and the housing is adapted to transport oil. Both ends of the ring gear are sealed with the O-rings. This gap provides an oil passage for the majority of the distance—the distance up to the front of the gearbox. The first planet gear pumps the oil used for lubricating the shaft output spherical bearing instead of the second planet gear because the first planet gear rotates much faster than the second planet gear and therefore makes a much more effective pump. After the gap, oil passes through some relatively short length passageways and thereafter falls into a cast cavity/void in the cover. This cast cavity is used in the lubrication system and obviates deep holes. After the cast cavity, oil passes through another short passageway and reaches the shaft output spherical bearing.
Overload Protection
The gearbox has over-torque protection. The input shaft includes a narrowed diametrical portion which acts as a fuse. In the prior art, if excessive force is applied to the cutter head an internal gear component fails. The input shaft acts as a fuse and breaks at the narrowed diametrical portion. When the fuse breaks, the portion of the shaft that is still connected to the electric motor spins harmlessly within a bushing. The bushing prevents the spinning portion of the input shaft from entering the bore in the gear too far. A screw retains the portion of the shaft bearing the external spline. The internal spline of the bore in the input gear remains meshed together with the external spline of the shaft after breakage or fracture of the shaft. This over-torque protection system prevents damage to the ring gear as well as to components of the rest of the gearbox. The two broken portions of the input shaft can easily be replaced.
To prevent damage to the input gear while the outer half of the input shaft is spinning, a bushing permits spinning to occur in a controlled fashion and thus prevent damage to the input gear. In other words, the bushing acts as a shoulder and prevents the input shaft from moving inwardly toward the input gear thus damaging the gear. When the fuse is not broken and the gearbox is running in a normal, proper fashion, the bushing sees no rotation and it radially supports the input shaft. The bushing only functions when the fuse breaks. If any damage occurs to the O-ring when the fuse breaks, it can be easily replaced. The function of the O-rings along the input shaft is to retain grease at the bushing and the spline. The input shaft includes an external spline which mates with an internal spline on the input gear.
An overload protection device in combination with a prime mover and gearbox transmission supplying torque through said gearbox transmission to a load is disclosed. An input shaft includes a bore therethrough enabling affixation of the input shaft to an input gear. The input shaft includes a key for coupling to the prime mover and for rotation therewith. The input shaft also includes an external spline which mates with an internal spline in the bore of the input gear. The prime mover transmits torque to the input shaft which drives the input gear. The input gear includes a bore therein. An internal spline in the bore of the input gear meshes with the external spline of the input shaft. The bore of the input gear includes a shoulder therein, and the bushing resides in the bore of the gear and engages the shoulder of the bore. The input gear of the gearbox transmission drives a planetary gear system which, in turn, supplies power to the load.
The input shaft includes an annular groove which breaks when the load impressed upon the cutting tool of the roadheader is too large. Upon overload of the gearbox transmission, the input shaft breaks at the location of the annular groove. The input shaft includes a bore therein and the annular groove in combination with the bore through the shaft results in a thin section which acts as a fuse. The input shaft is affixed to the input gear against longitudinal movement such that the input shaft will not move longitudinally after the input shaft breaks.
Cooling Cavities
A gearbox, comprising: a housing and a floating gear means for protecting a gear mechanism from damage due to axial and radial forces applied to the gearbox is disclosed. A first cooling compartment and a second cooling compartment are disclosed. The first and second cooling compartments are isolated from the floating gear means. First and second ports supply cooling fluid to the first compartment, and, the third and fourth ports supplying cooling fluid to the second compartment.
It is not possible for cooling water to leak into the gearbox as the gearboxes are sealed with respect to the cooling compartments. Instead, any water leakage falls harmlessly to the ground. Water in the cavities/compartments is isolated from the gearbox by a thick, heat conductible, wall of steel. Cooling cavities/compartments exists at each end of the gearbox, behind the rear plate and the front plate. Plugs are removed from threaded holes, and hoses are attached to the threaded holes for pumping cooling water into and through the cavities/compartments. The cooling water in the cavities soaks up heat generated in the gearbox.
There is a tube that passes through the central portion of the gearbox. When the gearbox is installed in an earth-boring machine, a pipe carrying cooling fluid is installed which passes through this tube and feeds water to the cutter head.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a roadheader including the cutter head, gearbox and prime mover.
FIG. 1A is an enlarged portion of the schematic view of FIG. 1 illustrating the cutter head and gearbox.
FIG. 1B is a perspective view of the gearbox.
FIG. 1C is a front view of the gearbox.
FIG. 1D is a right side view of the gearbox where power is input to the gearbox.
FIG. 1E is a left side view of the gearbox where power is output from the gearbox.
FIG. 1F is a cross-sectional view taken along the lines 1 F- 1 F of FIG. 1D illustrating the first planetary gear system, the second planetary gear system, the floating ring gear, the input to the first planetary gear system, and the output from the second planetary gear system, all of which are supported by the shaft input and output spherical bearings and connected with splines enabling the gear systems and ring gear to float within a fixed housing.
FIG. 1G is an enlarged portion of the cross-sectional view of FIG. 1F illustrating the floating ring gear, the spline connection between the floating ring gear and the cover, and a portion of the lubrication system.
FIG. 1H is an enlarged portion of the cross-sectional view of FIG. 1F illustrating the spline input to the first sun driving the first planetary gear set, the first planet carrier driving the second sun, the second sun driving the second planetary gear set and the second planet carrier driving the output spindle (shaft), all of which are supported by shaft input spherical bearing and the shaft output spherical bearing enabling the gear systems and ring gear to float within a fixed housing.
FIG. 1I is an enlarged portion of the cross-sectional view of FIG. 1F illustrating the shaft input spherical bearing interposed between the centrally located support tube and the splined shaft driven by the intermediate gear.
FIG. 1J is a perspective view of the floating gearbox without the ring gear and without the housing.
FIG. 1K is a perspective view of the floating gearbox with the ring gear shown in an exploded position.
FIG. 1L is a diagrammatic view of an angular spline.
FIG. 1M is a diagrammatic view of an involute spline.
FIG. 2 is a cross-sectional view taken along the lines 2 - 2 of FIG. 1D illustrating the fused input shaft with a splined connection to the input gear which drives the intermediate gear which in turn drives the splined shaft.
FIG. 2A is a front view of the input gear.
FIG. 2B is a cross-sectional view of the input gear illustrating the internal spline for connection with the fused input shaft.
FIG. 2C is a front view of the fused input shaft.
FIG. 3 is a cross-sectional view taken along the lines 3 - 3 of FIG. 1E illustrating the lubrication system and passageways in the ring gear, the housing, and the cover.
FIG. 3A an enlargement of a portion of FIG. 3 illustrating the lubricant passages through the cover and housing.
FIG. 3B is a perspective view of a portion of the cover illustrating the lubricant pathway therethrough.
FIG. 3C is a plan view of the floating ring gear illustrating one of the lubricant passageways therethrough.
FIG. 3D is a cross-sectional view of the floating ring gear illustrating the lubricant passageway therethrough, the housing, the meshing gear and the gap between the ring gear and the housing.
FIG. 4 is a top view of the gearbox illustrating cooling water plugs.
FIG. 4A is a right end view of the gearbox with the cooling water plate removed illustrating the water cavity, the water inlet, the water outlet, and a wall separating the water cavity from the gear systems.
FIG. 4B is the left end view of the gearbox with the cooling water plate removed illustrating the water cavity, the water inlet, the water outlet, and a wall separating the water cavity from the gear systems.
DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic view 100 of a roadheader 7 R including the cutter head 3 , gearbox 9 and prime mover 7 . FIG. 1A is an enlarged portion 100 A of the schematic view of FIG. 1 illustrating the cutter head 3 and gearbox 9 in more detail. As illustrated in FIGS. 1 and 1A , electric motors 7 drive input gears 2 B which in turn drive, via spline connections, input gears 2 A. Input gears 2 A drive intermediate gear 3 A.
Still referring to FIGS. 1 and 1A , a horizontal or axial force 4 is imparted on the cutter head 3 in earth boring operations. The roadheader (earth boring machine) is forced into earthen material which may be very hard. The cutter head 3 includes spikes thereon (not shown) which forcibly cut into the earthen material. All of the axial forces 4 are transmitted through the frame of the cutter head 3 , the coupling frame 6 A, the housing 1 of the gearbox 9 , the cover 2 of the gearbox 9 , and the motor frame 7 A. Similarly, the cutter head is subject to radial force 5 as illustrated in FIGS. 1 and 1A . All of the radial forces are transmitted through the frame of the cutter head 3 , the coupling frame 6 A, the housing 1 of the gearbox 9 , the cover 2 of the gearbox 9 , and the motor frame 7 A. The vertical and horizontal forces are not transmitted to the ring gear, and, therefore, not transmitted to the first and second planetary gear systems. The planetary gear systems within the gearbox are supported by a shaft input spherical bearing and a shaft output spherical bearing enabling the planetary gear systems to float, that is, to self-center and align and to avoid deformation and misalignment caused by forces normally transmitted (in the prior art) to the gear systems by the frame of the gearbox. The shaft input and output spherical bearings, a plurality of meshing internal and external splines, and a plurality of meshing gears permit the planetary gear systems to float, that is, to self-center and align. Tolerance stack up of the components, namely, the various gears, splines, carriers etc. cause the components of a gearbox to find a natural orientation and alignment within the gearbox.
The gears are allowed to float. Vertical and horizontal forces act on the cutter head. These forces are transmitted through the gearbox and back to the supporting structure. In the prior art, the ring gear is fixed to the housing and forces transmitted to the housing cause misalignment of the ring gear and other components of the planetary gear system. This misalignment will cause abnormal alignment, gear wear and damage to the planetary gear system.
In the instant invention the gears run independent of the housing; that is, they float. Ring gear 22 floats as it is separate from the housing 1 . A small annular gap 22 G exists between the ring gear 22 and housing 1 , and, thus forces in the housing 1 do not affect alignment of the gears within the housing.
The ring gear 22 has torque passing through it and is anchored to the housing 1 . This is done through a spline connection 59 , 60 between the ring gear 22 and the cover 2 which acts like a hinge and pivots as indicated by reference numeral 99 . Cover 2 is affixed to housing 1 . Ring gear 22 and housing 1 deflect independently of each other.
Still referring to FIGS. 1 and 1A , the drive shaft 6 A in the roadheader is coupled to the output shaft 28 through a coupling 6 B. Coupling 6 B further isolates and prevents any force from transmission to the output shaft 28 . Coupling 8 couples the input of the electric motor to the input shaft 2 B. Channel 6 C functions as a water conduit through the roadheader to cool the cutter head 3 during operation.
FIG. 1B is a perspective view 100 B of the gearbox 9 illustrating input shafts 2 B, 2 B and bearing retention plates 10 , 10 . Housing 1 , cover 2 and an unnumbered sight glass are illustrated in FIG. 1B . Receptacles 2 R, 2 R of input gears 2 A, 2 A receive input shafts 2 B, 2 B. Referring to FIGS. 1B and 1F , adapter 13 is bolted to housing 1 with screws 13 A as illustrated in FIG. 1F . Further, the rear cooler cap 12 is bolted to housing 1 with screws 12 S. Front cooler cap 25 is affixed to the cover 2 as illustrated in FIG. 1E by screws 11 . Tube 21 is affixed to adapter against rotation by dowel pin 26 as illustrated in FIGS. 1F and 1I .
FIG. 1E is a left side view 100 E of the gearbox 9 where power is output from the gearbox 9 by output shaft 28 and through spline connection 28 S. FIG. 1E further illustrates bearing cover 30 , retainer 36 , and tube 21 .
Referring to FIGS. 1E and 1F , bearing cover 30 is affixed to the cover 2 by screws 30 S and retains the shaft output spherical bearing 27 . Dowel pins 41 are used to correctly orient the cover 2 with respective receptacles in housing 1 . Screws 2 X secure the cover 2 to the housing 1 . Lip seal 31 is interposed between bearing cover 30 and output shaft 28 .
Referring to FIGS. 1F and 1H , the shaft output spherical bearing 27 includes an inner race 271 , and outer race 270 , and rollers 27 R. Shaft output spherical bearing 27 is interposed between output shaft 28 and cover 2 and is longitudinally held in place by bearing cover 30 , a shoulder 28 L on shaft 28 , and a shoulder 2 S of cover 2 . Tube 21 is stationary and affixed to adapter 13 proximate the rear end of the gearbox by dowel 26 and is supported by retainer 36 proximate the front end of the gearbox 9 . Retainer 36 is affixed to output shaft 28 by a screw in a different plane which is not shown. Retainer 36 rotates with output shaft 28 .
Referring to FIG. 1F , bearing 34 is interposed between tube 21 and retainer 36 enabling rotation of the retainer 36 while supporting second planet carrier 5 A. Lip seal 33 is interposed between retainer 36 and tube 21 retaining lubricant for bearing 34 and other components. Retainer 36 retains shaft 28 from extraction. O-ring 61 is retained axially between shaft output spherical bearing 27 and second planet carrier 5 A.
FIG. 1C is a front view 100 C of the gearbox 9 illustrating most of the same principal elements illustrated in FIG. 1B . FIG. 1C illustrates output shaft 28 having an external spline 28 S for mating with coupling 6 B. FIG. 1C further illustrates bearing cover 30 for retention of shaft output spherical bearing 27 which supports output shaft 28 as illustrated in FIG. 1F . Cooling cover plate 12 is also illustrated in FIG. 1D .
FIG. 1D is a right side view 100 D of the gearbox 9 where power is input to the gearbox 9 via input shafts 2 B. Receptacles 2 R receive the input shafts 2 B which are keyed. Bearing covers 10 retain bearings as illustrated in FIG. 2 . Input shafts 2 B include external splines 2 P which mesh with internal splines 2 I in receptacles 2 R. FIG. 3 is a cross-sectional view taken along the lines 3 - 3 of FIG. 1E illustrating the input shaft 2 B and the input gear 2 A.
FIG. 1F is a cross-sectional view 100 F taken along the lines 1 F- 1 F of FIG. 1D illustrating the first planetary gear system, the second planetary gear system, the floating ring gear 22 , the input to the first planetary gear system, and the output from the second planetary gear system 28 , all of which are supported by shaft input and output spherical bearings and connected with splines enabling the gear systems and ring gear to float within the fixed housing. A pair of first spherical bearings 4 C, 4 C is interposed between the first planet gears 4 B and the first planet shaft 4 D supporting the first planet gears 4 B with respect to first planet shaft 4 D. A pair of second spherical bearings 5 C, 5 C is interposed between the second planet gears 5 B and the second planet shaft 5 D supporting the second planet gears 5 D with respect to first planet shaft 5 D. Shaft input spherical bearing 3 C is interposed between tube 21 and splined shaft 3 B supporting the splined shaft with respect to the tube 21 . Tube 21 is affixed to adapter 13 , and adapter is affixed to the housing 1 . Seal 14 is an O-ring seal interposed between the adapter and the housing 1 . Shaft output spherical bearing 27 is interposed between the cover 2 and the output shaft 28 supporting said output shaft with respect to the cover 2 . Cover 2 is affixed to housing 1 by screws 2 X shown in FIG. 1E .
Referring to FIGS. 1F and 1G , each of the pair of spherical bearings 5 C includes an inner race 71 , outer race 73 , and rollers 72 . Referring to FIGS. 1F and 1I , shaft input spherical bearing 3 C includes inner race 77 , outer race 79 , and rollers 78 . Referring to FIGS. 1F and 1H , each of the pair of spherical bearings 4 C includes inner race 74 , outer race 76 , and rollers 75 .
FIG. 1G is an enlarged portion 1000 of the cross-sectional view of FIG. 1F illustrating the floating ring gear 22 , the spline connection 59 , 60 between the floating ring gear 22 and the cover 2 , and a portion of the lubrication system.
Referring to FIGS. 1F and 1G , cover 2 includes an external spline 59 and ring gear 22 includes an internal spline 60 . External spline 59 loosely engages internal spline 60 permitting ring gear 22 to pivot with respect to external spline 59 . Ring gear 22 does not rotate with respect to cover 2 . However, ring gear 22 may pivot or rotate slightly as indicated by arrow 99 . Gap 22 G is an annular gap between the interior surface of the housing 1 and the exterior surface 22 Z of the ring gear 22 . The ring gear is viewable in FIGS. 3B and 3C .
Referring to FIGS. 1F and 1G , ring gear 20 includes teeth 57 which mesh with teeth 58 of the second planet gears 5 B, and, ring gear 20 includes teeth 56 which mesh with teeth 55 of the first planet gears 4 B. Although the teeth mesh as described, there is sufficient play between the teeth to permit the relative rotational movement between the ring gear 20 and the planet gears so as to enable ring gear 20 to pivot as indicated by reference numeral 99 . The amount of pivoting or rotation of the ring gear will, of course, depend on the size of the annular gap 22 G. Further, there may be relative rotational movement between the planet gears 4 B, 5 B and the internal ring gear 20 depending upon the dynamics and loading of the planetary gear systems within the gearbox.
FIG. 1H is an enlarged portion 100 H of the cross-sectional view of FIG. 1F illustrating the spline shaft 3 B input to the first sun 3 E driving the first planetary gear set 4 B, the first planet carrier 4 A driving the second sun 20 , the second sun 20 driving the second planetary gear set 5 B and the second planet carrier 5 A driving the floating output spindle 28 , all of which are supported by shaft input and output spherical bearings 3 C, 27 enabling the gear sets, carriers, suns and ring gear to float within a fixed housing 1 .
Referring to FIGS. 1F and 1H , second sun 20 includes a first external gear 69 having teeth 69 A and an external spline 68 . External spline 68 of second sun 20 meshes with internal spline 67 of first planet carrier 4 A. Teeth 69 A of second sun gear 69 mesh with teeth 70 of planet gear 5 B. Further, second carrier 5 A includes an internal spline 66 which meshes with external spline 65 of output shaft 28 . Internal spline 66 meshes with external spline 65 and there may be some relative rotational movement between the meshed splines. Although the teeth and spline mesh as described, there is sufficient play between the teeth to permit the relative rotational movement between the second sun 20 , the first carrier 4 A, and the second planet gears 5 B so as to enable pivoting as indicated by reference numeral 99 A.
Still referring to FIGS. 1F and 1H , second carrier 5 A includes an internal spline 66 and output shaft 28 includes external spline 65 . Internal spline 66 meshes with output spline 65 . Although the spline meshes as described, there is sufficient play between and in the spline connection to permit relative rotational movement between the second sun 20 , the first carrier 4 A, and the second planet gears 5 B so as to enable pivoting as indicated by reference numeral 99 A.
FIG. 1I is an enlarged portion 100 I of the cross-sectional view of FIG. 1F illustrating shaft input spherical bearing 3 C interposed between the centrally located support tube 21 and the splined shaft 3 B driven by the intermediate gear 3 A. FIG. 1I illustrates retaining rings 3 F holding first sun gear 3 A in place. Shaft input spherical bearing 3 C is positioned between the adaptor 13 and a shoulder on tube 21 . Additionally, bearing 3 C is positioned between the spline shaft 3 B and the retaining rings residing partially in a groove of the splined shaft 3 B. Referring to FIGS. 1F , 1 H, and 1 I, splined shaft 3 B includes external spline 53 meshing with internal spline 54 of intermediate gear 3 A. Splined shaft 3 B includes external spline 51 meshing with internal spline 52 of sun 3 E. Although the spline meshes as described, there is sufficient play therebetween to permit the relative rotational movement between the splined shaft 3 E, first sun 3 E, and intermediate gear 3 A so as to enable pivoting as indicated by reference numerals 99 B and 99 C.
FIG. 1J is a perspective view 100 J of the floating gearbox without the ring gear 20 and without the housing 1 shown. FIG. 1K is a perspective view 100 K of the floating gearbox with the ring gear 20 shown in an exploded position and without the input gears shown. Passageway 22 Z is for lubricant to flow from the interior side of the ring gear and, more specifically, from the interior teeth 56 to the outer surface 22 S. There are three passageways 22 P in the ring gear. Also illustrated well in FIG. 1K is the interior gear 58 of the ring gear 22 and the internal spline 60 . Internal spline 60 meshes with the external spline 59 of cover 2 . Cover 2 is fixed to the housing 1 and prevents rotation of the ring gear 22 with respect to cover 2 and housing 1 .
Referring to FIG. 1J , the input drive shafts 2 B drive input gears 2 A which, in turn, drive intermediate gear 3 A. Intermediate gear 3 A includes an internal spline 53 meshed with spline 54 of shaft 3 B such that spline shaft 3 B rotates with intermediate gear 3 A. Input gears 2 A include teeth 84 which mesh with teeth 85 of intermediate gear 3 A.
The first planetary gear system illustrated in FIGS. 1F , 1 J and 1 K includes a plurality of planet gears 4 B, a first planet carrier 4 A, and, a first sun gear 3 E. Preferably there are three planet gears 4 B and they are retained in place by shaft retainers 17 . The second planetary gear system illustrated in FIGS. 1F , 1 J and 1 K includes a plurality of planet gears 5 B, a second planet carrier 5 A, and a second sun 20 . Preferably there are four planet gears 5 B and they are retained in place by shaft retainers 17 . Second sun 30 is self-centering and is spaced about tube 20 . Washers 20 R, 20 L position second sun 20 between retainer 36 and spline shaft 3 B.
FIG. 1L is a diagrammatic view 100 L of an angular internal spline and an angular external spline with vertical gaps 95 A, 96 A between the internal and external spline teeth. Further, FIG. 1L illustrates a horizontal gap 97 A between the internal and external spline teeth. Sometimes horizontal gap 97 A is called the backlash between the teeth of the mated spline. SW is the space width and TT is the tooth thickness as used in FIGS. 1L and 1M .
FIG. 1M is a diagrammatic view 100 M similar to FIG. 1L using an involute spline tooth profile with vertical spline gaps 95 I, 96 I between the involute internal and external spline teeth. Further, FIG. 1M illustrates a horizontal gap 97 I between the involute internal and external spline teeth. Sometimes horizontal gap 97 I is called the backlash between the teeth of the mated spline.
The gaps just described and illustrated are demonstrative of all of the spline interconnections described herein and enable relative rotational movement between components. Relative rotational movement also occurs between gears. For instance, rotational movement may take place between ring gear 22 and cover 2 , second planet gear 5 B and ring gear 22 , second planet gear 5 B and second sun 20 , second planet carrier 5 A and output shaft 28 , first planet gear 4 B and ring gear 22 , first planet gear 4 B and first sun gear 3 E, first planet carrier 4 A and second sun 20 , first sun gear 3 E and splined shaft 3 B, and, intermediate gear 3 A and splined shaft 3 B.
FIG. 2 is a cross-sectional view 200 taken along the lines 2 - 2 of FIG. 1D illustrating the fused input shaft 2 B with a splined connection 2 I, 2 P to the input gear 2 A which drives the intermediate gear 3 A. Intermediate gear 3 A includes an internal spline 54 which is meshed with external spine 53 of spline shaft 3 B. Splined shaft 3 B rotates with intermediate gear 3 A.
Still referring to FIG. 2 , input gear 2 A is supported by cylindrical bearings 48 , 49 in housing 1 . Seal 40 resides between bearing cover 10 and receptacle 2 R. Bearing cover 10 and input gear shoulder 48 S secure cylindrical bearing 48 in place between the housing and the input gear. Housing shoulder 49 S and shoulder 49 B in input gear 2 A secure cylindrical bearing 49 in place between the housing 1 and the input gear 2 A. FIG. 2A is a front view 200 A of the input gear 2 A illustrating gear teeth 84 and the receptacle portion 2 R. FIG. 2B is a cross-sectional view 200 B of the input gear 2 A illustrating the internal spline 2 I for connection with the fused input shaft. FIG. 2C is a front view 200 C of the fused input shaft 2 B illustrating a fuse portion 82 F, an external spline 2 P, an outer shaft portion 82 C, an inner shaft portion 82 D, and a stepped bore 81 therethrough. A keyway 82 K is illustrated in the shaft portion 82 C. Keyway 82 K mates with a corresponding key of the coupling 8 which transfers power from the electric drive motor 7 to the input shaft 2 B.
Gearbox 9 has over-torque protection. Input shaft 2 B includes a diametrically reduced portion 82 F. The shaft thickness in the region 82 R between the stepped bore 81 and the diametrically reduced portion 82 F is considerably smaller than in other shaft locations 82 C, 82 D. O-rings 2 E, 2 G seal input shaft 2 B against the unwanted intrusion of dirt and for the retention of grease between the seals. Should excessive force be applied to the cutter head 3 , input shaft 2 B functions as a fuse and fractures at the diametrically reduced portion 82 F. When this fracture occurs, a portion of input shaft 2 B is still connected to the coupling 8 and spins harmlessly within bushing 2 C.
Input gear 2 A includes a stepped bore 86 having a first shoulder 86 A and a second shoulder 86 B therein. Bushing 2 C resides in the bore 86 of the receptacle 2 R and engages second shoulder 86 B therein. Input shaft 2 B includes outer shoulder 82 H thereon. Outer shoulder 82 H of input shaft 2 B engages first shoulder 86 A in the bore 86 of receptacle 2 R when the fuse 82 F breaks. It will be noticed that outer shoulder 82 H includes a chamfer 82 Z which matches a corresponding surface on first shoulder 86 A of bore 86 of receptacle 2 R. In the normal condition without the fuse broken, outer shoulder 82 H does not engage first shoulder 86 A in the bore 86 . Bore 81 of the input shaft 2 A is a stepped bore which includes a first shoulder 81 A and a second shoulder 81 B.
Bushing 2 C and shoulders 86 A, 86 B in bore 86 of receptacle portion 2 R of input gear 2 A prevent the diametrically reduced portion 82 F (once broken) from moving inwardly toward the central portion of gear 2 A preventing damage to gear 2 A and/or the internal spline 2 I of the receptacle portion 2 R of gear 2 A. Screw 2 F retains the inner portion 82 D of the shaft 2 B within the receptacle portion 2 R of input gear 2 A. This over-torque protection system prevents damage occurring to ring gear 2 A as well as to the other components of the gearbox. The two broken shaft portions 82 C, 82 D of shaft 2 B are easily replaced.
To prevent damage to gear 2 A while the outer fuse half is spinning, bushing 2 C permits spinning to occur in a controlled fashion and thus prevents damage to the receptacle 2 R of gear 2 A. When fuse 82 F is not broken and the gearbox is running in a normal, proper fashion, bushing 2 C supports shaft 2 B. Bushing 2 C only functions when fuse 82 F breaks or opens. If any damage occurs to the O-ring 2 G when fuse 2 C breaks, it can be easily replaced. The function of the O-rings 2 G, 2 E is to retain grease at the bushing 2 C and the spline 2 P.
FIG. 3 is a cross-sectional view 300 taken along the lines 3 - 3 of FIG. 1E illustrating the lubrication system and passageways in the ring gear 22 , the housing 1 , and the cover 2 . FIG. 3A is an enlargement 300 A of a portion of FIG. 3 illustrating the lubricant passageways through the cover 2 . Gap 22 G is formed as an annulus between ring gear 22 and the interior surface of housing 1 . The geometry of gap 22 G changes with operation of the gearbox, that is, with the pivoting action of the ring gear 22 with respect to cover 2 .
FIG. 3B is a perspective view 300 B of a portion of the cover 2 illustrating the lubricant pathway therethrough by the unnumbered arrows. The arrows with dashed lines indicate the lubricant flow within and through cover 2 .
FIG. 3C is a plan view 300 C of the floating ring gear 22 illustrating the lubricant passageway 22 P therethrough. FIG. 1K illustrates 3 oil passageways 22 P which are separated 120° apart meaning that at least two passageways 22 P may be oriented below the oil line if the housing 1 is filled half full of lubricant. FIG. 3D is a cross-sectional view 300 C of the floating ring gear 22 illustrating the lubricant passageway 22 P, housing 1 , and annular gap 22 G between the ring gear and the housing 1 . Planet gear 4 B is illustrated meshed with ring gear 4 B wherein pumping action of the planet gear forces lubricant into and through passageway 22 P.
The cutter head 3 , and thus the gearbox 9 , can tilt up to a maximum of 43°22′ with respect to horizontal as illustrated by arrow 99 Z in FIG. 1 . The tilt in a downward arc may occur to a minor extent but it will not affect bearing lubrication When gearbox 9 is tilted up it will lifted out of the lubricant (oil). This in turn will cause the bearing to overheat, scorch, and then fail. Ring gear 22 and surrounding pieces, in addition to their normal function, function as an oil pump. In the ring gear 22 , just above planet gear 4 B is a small passageway between the teeth of the ring gear. As the gear teeth mesh, lubricating oil is forced up into this passageway 22 P. First planet gears 4 B were chosen to pump oil instead of second planet gears 5 B because planet gears 4 B spin much faster than second planet gears 5 B and therefore make a much more effective pump. Lubricating oil then flows to and then through the annulus 22 G that is between the ring gear 22 and the housing 1 . O-rings 24 at each end of the ring gear keeps the lubricant under pressure from spilling out. Lubricating oil is then forced though a series of passageways of holes and cavities so that oil reaches shaft output bearing 27 , and thus keeps the shaft output bearing 27 lubricated.
Referring to FIGS. 1G , 3 and 3 A, lubricant is pumped by gear teeth 55 of first planetary gears 4 B through passageways 22 P. There are three passageways 22 P spaced 120° apart as illustrated in FIG. 1K . The lubricant exits passageways 22 P supplying a volume as defined by generally annularly shaped gap 22 G and O-rings 24 , 24 as illustrated in FIG. 1G . When the oil is in the volume as defined it is under pressure and it enters vertical passageway 22 A in housing 1 which, in turn, communicates with horizontal passageway 22 B in housing 1 . Seal 22 S resides in a recess 2 Z in cover 2 . Recess 2 Z is aligned with passageway 22 B in the housing and communicates, horizontally, with a short passageway 2 Y in cover 2 which, in turn, communicates with a vertical passageway 22 C in cover 2 . Vertical passageway 22 C communicates with volume 22 V which is enclosed by front cooler plate 25 . Cooler plate 25 is affixed to cover 2 with screws 11 . As lubricant collects and resides in volume 22 V, it passes into and through necked-down area 22 D where it is communicated to horizontal passageway 22 H. Horizontal passageway 22 H communicates opening 22 R which provides lubricant to shaft output spherical bearing 27 . Lubrication is provided despite the orientation of the gearbox, in other words, if the gear box in inclined, lubrication will continue by virtue of the just-described pumping system.
Referring to FIGS. 4 , 4 A and 4 B, a gearbox, comprising a housing and a floating gear means for protecting a gear mechanism from damage due to axial and radial forces applied to the gearbox is disclosed. A first cooling compartment and a second cooling compartment are disclosed. The first and second cooling compartments are isolated from the floating gear means. First and second ports supply cooling fluid to the first compartment, and, the third and fourth ports supplying cooling fluid to the second compartment. The ports are all identified with the reference numeral 38 in FIG. 4 .
It is not possible for cooling water to leak into the gearbox as the gearboxes are sealed with respect to the cooling compartments. Water in the cooling cavities/compartments 12 C, 25 C is isolated from the gearbox by a thick, heat conductible, wall of steel 12 W, 25 W, respectively. Cooling cavities/compartments 12 C, 25 C exist at each end of the gearbox, behind the rear plate 12 and the front plate 25 .
FIG. 4 is a top view 400 of the gearbox 9 illustrating cooling water plugs 38 , 38 for the supply of cooling water at the ends of the gearbox. FIG. 4 also illustrates the input shafts 2 B, 2 B, cover plate 12 , cover plate 25 , and the output shaft spline 28 S. FIG. 4A is the right end view 400 A of the gearbox with the cooling water plate removed illustrating the water cavity 12 C, the water inlet 121 , the water outlet 120 , and the wall 12 W separating the water cavity 12 C from the gear systems. Wall 12 W is highly thermally conductive. FIG. 4B is the left end view 400 B of the gearbox 9 with the cooling water plate 25 removed illustrating the water cavity 25 C, the water inlet 251 , the water outlet 250 , and a wall 25 W separating the water cavity 25 C from the gear systems. Wall 25 W is also highly thermally conductive. Large amounts of power flow through the gearbox and heat is generated through friction of the gear systems. Referring to FIG. 4 , plugs 37 , 37 are illustrated sealing the oil lubrication drill holes created in the manufacturing process. Plugs 37 , 37 are also illustrated in FIGS. 3 and 3A .
Cooling cavities 12 C, 25 C exist at each end of the gearbox, behind plate 12 and plate 25 , respectively. A portion of cavity 25 C is viewable in FIG. 1F . FIG. 4 is a top view 400 of gearbox 9 . Plugs 38 are illustrated and they are removed from threaded holes, and hoses are attached to those holes in order that cooling water be pumped into the cavities. The cooling water within the cavities 12 C, 25 C removes heat generated in the gearbox. Cavities 12 C, 25 C are completely sealed from the gear systems which reside behind walls 12 W, 25 W, respectively.
There is a water conduit that passes through the central portion of the gearbox. When the gearbox is installed in an earth-boring machine, the water conduit 6 C carrying cooling fluid is installed which passes through this tube and feeds water to the cutter head. In FIGS. 1 and 1A , reference numeral 6 C is used to denote the water conduit 6 C through the gearbox 9 and the cutter head 3 . Water conduit 6 C resides within tube 21 as illustrated in FIG. 1F .
REFERENCE NUMERALS
1 —housing
2 —cover
2 A—input gear
2 B—input shaft
2 C—cylindrical bushing
2 E, 2 G, 14 , 24 —O-ring
2 F—screw/connector affixing input shaft 2 b to input gear 2 A
2 I—internal spline of input gear 2 A
2 P—external spline of input shaft 2 B
2 R—receptacle for input shaft 2 B
2 S—shoulder for retaining bearing
2 X—plurality of screws affixing cover 2 to housing 1
2 Z—recess in cover in which seal 22 S resides
3 —cutter head
3 A—intermediate gear
3 B—splined shaft
3 C—shaft input spherical bearing between tube 21 and shaft 3 B
3 E—sun gear
3 F—retaining ring
4 —horizontal force acting on the cutter head 3
4 A—first planet carrier
4 B—first planet gears
4 C—first pair of spherical bearings between first planet shaft 4 D and first planet gear 4 B
4 D—first planet shafts
5 —vertical force acting on the cutter head 3
5 A—second planet carrier
5 B—second planet gears
5 C—second pair of spherical bearings
5 D—second planet shafts
6 A—coupling frame
6 B—coupling
6 C—water conduit for cooling and lubricating cutting head
7 —electric motor, prime mover, one of two
7 A—motor frame
7 R—roadheader assembly
8 —coupling between motor and input gear
9 —gearbox
10 —bearing cover
11 —headed screw
12 —rear cooler plate/cap
12 S—connector for cooler plate/cap 12
13 —adapter
13 A—connector/screw
17 —planet shaft retainer
20 —second sun having a gear and an external spline
21 —tube
22 —ring gear
22 B—horizontal passageway in housing 1
22 C—vertical passageway in cover 2
22 D—necked down area in cover 2
22 G—gap between ring gear 22 and housing 1
22 H—horizontal passageway in cover 2 in communication with opening 22 r
22 P—port leading to vertical passageway 22 A
22 R—opening in cover 2 providing lubricant to shaft output spherical bearing 27
22 V—volume in cover 2 in which lubricant resides
22 Y—short horizontal passageway in cover 2
22 Z—exterior surface of ring gear 22
24 R—recess for O—ring
25 —front cooler plate/cap
26 —dowel pin
27 —shaft output spherical bearing
271 —inner race
270 —outer race
27 R—rollers
28 —output shaft
28 L—shoulder on shaft 28
28 S—spline on the output shaft
30 —bearing cover
30 S—connector/screw
31 —lip seal
33 —lip seal
34 , 48 , 49 —bearing
36 —retainer
37 —plug in housing
38 —port plug in housing which is removed for cooling water connections
38 T—threaded connection for cooling water
39 —port plug in housing for the addition of oil to the gearbox 9
40 —seal
41 —dowel pins aligning cover 2 with respect to housing 1
48 B—shoulder
48 S—input gear shoulder
49 S—housing shoulder
51 —external spline of spline shaft 3 b meshing with spline 52 of first sun 3 E
52 —internal spline of first sun 3 E
53 —external spline meshing with internal spline 54 of intermediate gear 3 A
54 —internal spline of intermediate gear 3 A
55 —first planet gear teeth
56 —internal ring gear mating with planet gear teeth 55 of first planet gear 4 B
57 —internal ring gear mating with planet teeth 58 of second planet gear 5 B
58 —second planet gear teeth
59 —external spline of the cover 2
60 —internal spline of the ring gear 20
61 —retaining ring which retains output shaft 28
65 —external spline of output shaft 28
66 —internal spline of second planet carrier 5 A
67 —internal spline of first planet carrier 4 A
68 —external spline of second sun 20
69 —external gear of second sun 20
69 A—output teeth of the second sun 20
70 —teeth of second planet gear 5 B
71 —inner race of spherical bearing 5 C
72 —roller bearings of spherical bearing 5 C
73 —outer race of spherical bearing 5 C
74 —inner race of spherical bearing 4 C
75 —roller of spherical bearing 4 C
76 —outer race of spherical bearing 4 C
77 —inner race of shaft input spherical bearing 3 C
78 —roller of shaft input spherical bearing 3 C
79 —outer race of shaft input spherical bearing 3 C
80 —shaft seal between second carrier 5 A and cover 2
81 —stepped bore in input shaft 2 B
81 A—first shoulder in bore of input shaft 2 B
81 B—second shoulder in bore of input shaft 2 B
82 C—outer portion of the input shaft 2 B
82 D—inner portion of the input shaft 2 B
82 H—outer shoulder on input shaft 2 A
82 F—annular groove, fused portion
82 R—thin section between annular groove and the stepped bore 81 in input shaft 2 B
82 Z—chamfer on shoulder 82 H
84 —teeth of input gear 2 A
85 —teeth of intermediate gear 3 A
86 —bore in receptacle portion 2 R of input gear 2 A
86 A—first shoulder in bore 86 engaging shoulder 82 H of input shaft 2 B
86 B—second shoulder in bore 85 engaging bushing 2 C
95 A—gap between internal angular spline and external angular spline
96 A—gap between internal angular spline and external angular spline
97 A—gap, backlash, between internal angular spline and external angular spline
95 I—gap between internal involute spline and external involute spline
96 I—gap between internal involute spline and external involute spline
97 I—gap, backlash, between internal involute spline and external involute spline
99 —arrow indicating relative rotation of ring gear 22 , housing 1 , and second planet gears 5 B
99 A—arrow indicating relative rotation of second planet gear 5 B and second sun 20
99 B—arrow indicating relative rotation of first sun gear 3 E and splined shaft 3 B
99 C—arrow indicating relative rotation of intermediate gear 3 A and spline shaft 3 B
99 D—arrow indicating relative rotation of second carrier 5 A and output shaft 28
99 E—arrow indicating relative rotation of first planet gear 4 B, ring gear 20 and housing 1
99 Z—arrow indicating rotation of the roadheader
100 —schematic view of a roadheader including the cutter head, gearbox and prime mover
100 A—enlarged portion of the schematic view of FIG. 1 illustrating the cutter head and gearbox
100 B—perspective view of the gearbox
100 C—front view of the gearbox
100 D—right side view of the gearbox where power is input to the gearbox
100 E—left side view of the gearbox where power is output from the gearbox.
100 E—cross-sectional view taken along the lines 1 F- 1 F of FIG. 1D illustrating the first planetary gear system, the second planetary gear system, the floating ring gear, the input to the first planetary gear system, and the output from the second planetary gear system, all of which are supported by shaft input and output spherical bearings enabling the gear systems and ring gear to float within a fixed housing
100 G—enlarged portion of the cross-sectional view of FIG. 1F illustrating the floating ring gear, the spline connection between the floating ring gear and the cover, and a portion of the lubrication system
100 H—enlarged portion of the cross-sectional view of FIG. 1F illustrating the spline input to the first sun driving the first planetary gear set, the first planet carrier driving the second sun, the second sun driving the second planetary gear set and the second planet carrier driving the output spindle, all of which are supported by the shaft input and output spherical bearings enabling the gear systems and ring gear to float within a fixed housing
100 I—enlarged portion of the cross-sectional view of FIG. 1F illustrating a shaft input spherical bearing interposed between the centrally located support tube and the splined shaft driven by the intermediate gear
100 J—perspective view of the floating gearbox without the ring gear and without the housing
100 K—perspective view of the floating gearbox with the ring gear shown in an exploded position
100 L—diagrammatic view of an angular spline
100 M—diagrammatic view of an involute spline
200 —cross-sectional view taken along the lines 2 - 2 of FIG. 1D illustrating the fused input shaft with a splined connection to the input gear which drives the intermediate gear which in turn drives the splined shaft
200 A—a front view of the input gear
200 B—cross-sectional view of the input gear illustrating the internal spline for connection with the fused input shaft
200 C—front view of the fused input shaft
300 —cross-section taken along the lines 3 - 3 of FIG. 1E illustrating the lubrication system and passageways in the ring gear, the housing, and the cover
300 A—enlargement of a portion of FIG. 3 illustrating the lubricant passages through the cover and housing.
300 B—perspective view of a portion of the cover illustrating the lubricant passages through the cover
300 C—plan view of the floating ring gear illustrating the lubricant passageway therethrough
300 D—cross-sectional view of the floating ring gear illustrating the lubricant passageway therethrough
400 —top view of the gearbox illustrating cooling water plugs
400 A—right end view of the gearbox with the cooling water plate removed illustrating the water cavity, the water inlet, the water outlet, and a wall separating the water cavity from the gear systems
400 B—left end view of the gearbox with the cooling water plate removed illustrating the water cavity, the water inlet, the water outlet, and a wall separating the water cavity from the gear systems
TT—tooth thickness
SW—space width
The invention has been set forth by way of example only and those skilled in the art will recognize that changes may be made to the examples provided herein without departing from the spirit and the scope of the appended claims.
|
Lubricating oil is forced and pumped into and through the first passageway through the floating ring gear and into the annulus between the gearbox housing and the floating ring gear. Lubricating oil from the annulus is pumped into and through the second passageway and through the joint between the second and third passageway, and through the third passageway into the void in the cover. Thereafter the oil passes through the fourth passageway between the void in the cover and the circumferential recess in the cover and lubricating the bearing mounted adjacent the recess in the cover/housing.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates to covers that enclose the bed area of a pickup truck. Tonneau covers are usually hard or soft covers that enclose bed of a pickup truck and protect that area from rain, snow and other weather elements.
SUMMARY OF THE INVENTION
The present invention is a pickup-truck bed cover which incorporates elements of both low-profile tonneau covers and solid-wall canopies. This convertible design transforms from several inches flat to a full height canopy in seconds—all while providing solid-wall, insulated security in either the expanded or collapsed position. In addition, the cover is designed to be safely driven down the road while either expanded or collapsed.
In the collapsed position, this cover provides outstanding driver visibility and a sleek low-profile appearance. It is preferably constructed of aluminum tread-plate, which provides a durable and attractive finish that compliments trucks of any color. Although the cover is only a few inches high in the collapsed position, in the expanded position it provides nearly four feet of interior height and cargo capacity superior to that of many fixed canopies.
There are five main components to the design: the frame, top cover, right sidewall, left sidewall and rear door. The sidewalls and rear door stow inside and under the top cover. The top cover pivots open which allows access to un-stow the rear door. The sides then pivot up to form the canopy. This design maintains the ability to store cargo below the bed sill height in either configuration, with access through the truck rear tailgate or canopy rear door.
The cover is generally rectangular in shape. It is several inches wider than the open bed of the pickup-truck. A preferably “U” shaped frame is affixed to the truck bed—along both sides and across the front of the bed. One half of a hinge rests along each of these three sides. The hinge along the forward edge of the frame attaches to the forward edge of the top cover and allows the cover to pivot open. Hinges along the left and right sides of the frame are attached to the left and right sidewall panels and allow each sidewall to pivot to a vertical position.
The left and right sides of the top cover have straight and level lower edges which are bent 90 degrees outward to rest on the upper edges of the truck bed. The top of the top cover is flat and level, parallel to the lower edges of the top cover sides. There is a slope at the front of the top cover beginning at the lower forward corner progressing upward and aft. This slope allows the cover to pivot open without intersecting the cab or rear window of the truck. The slope is of such an angle that it is generally vertical when the cover is in the expanded position.
On the aft portion of the top cover, there is another slope. This slope tapers from the upper surface of the top cover aft and downward to the rear edge of the cover. The slope is of such an angle that it is directly horizontal in the expanded position. This slope allows the aft portion of the cover to taper for better driver visibility and aerodynamics, yet provides a flat and level design element when expanded.
Two gas-filled lift struts are positioned inside the top cover. One end of each strut is attached near the forward side of the frame, and the other end is attached to the inner surface of the top cover side. These struts are located in such a position and geometry as to assist in raising open the cover and holding it up. The sidewalls are designed with the lift struts positioned between the inner panels of the sidewalls, and the sides of the top cover, which allows the lift struts to be hidden from view (from both the inside and the outside) when the sidewalls are expanded.
Attached to the upper surface of the top cover are two tiedown rails. These provide several hardpoints to secure oversize items carried on top of the cover. The bolts that attach these rails to the top cover also bolt through to the internal bracing in the roof of the top cover.
All components of this design overlap each other in both the expanded and collapsed positions to keep water out. A piece of flashing is located at the forward edge of each rail which prevents water from entering near the forward edge of the sides. Additional water intrusion is prevented by a series of seals. This overlapping component design, however, provide an inherent deterrent to leaks well beyond the dependence on seals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear perspective view of the convertible pickup canopy of the present invention, the convertible pickup canopy shown in an expanded condition and attached to a bed of a pickup truck;
FIG. 1A is a rear perspective view of a frame of the convertible pickup canopy, the frame coupled to rails of a truck bed;
FIG. 2 is a rear perspective view of the convertible pickup canopy of the present invention, the convertible pickup canopy shown in an expanded condition, with a rear access door opened;
FIG. 3 is a rear perspective view of the convertible pickup canopy of the present invention, the convertible pickup canopy shown in an expanded condition, with a rear access door opened, and a left side panel collapsed;
FIG. 4 is a rear perspective view of the convertible pickup canopy of the present invention, the convertible pickup canopy shown in an expanded condition, with a rear access door opened, and the left and a right side panel collapsed;
FIG. 5 is a rear perspective view of the convertible pickup canopy of the present invention, the convertible pickup canopy shown in an expanded condition, with a rear access door stowed, and the left and a right side panel collapsed;
FIG. 6 is a rear perspective view of the convertible pickup canopy of the present invention, the convertible pickup canopy shown in a collapsed condition;
FIG. 7 is a rear perspective view of the convertible pickup canopy of the present invention, the convertible pickup canopy shown in a collapsed condition and the top cover removed.
FIG. 8 is a perspective view of interior components of the convertible pickup canopy.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
Referring now to FIG. 1 , is a rear perspective view of a convertible pickup canopy 10 of the present invention is shown, the convertible pickup canopy 10 shown in an expanded condition and attached to a bed of a pickup truck.
There are five main components to the design: the frame 11 (discussed with reference to FIG. 1A below), top cover 12 , right sidewall 24 , left sidewall 24 and rear door 28 . The sidewalls 24 and rear door 28 stow inside and under the top cover 12 as will be described later. The top cover 12 pivots open which allows access to un-stow the rear door 28 as will be described later. The sides 24 then pivot up to form the canopy. This design maintains the ability to store cargo below the bed sill height in either configuration, with access through the truck rear tailgate or canopy rear door.
The top cover 12 is preferably equipped with tiedown rails 14 . The tiedown rails 14 provide several hardpoints to secure oversize items carried on top of the cover. Bolts (not shown) attach tiedown rails 14 to the top cover 12 .
A plurality of windows 16 are optionally provided on the top cover 12 , and sidewalls 24 . Handles 18 are also provided on various locations, preferably the rear door 28 and a rear portion 38 of the top cover 12 for movement, lifting or lowering of those parts.
Left and right sides 26 of the top cover 12 have preferably straight and level lower edges which are bent 90 degrees outward to rest on rails 2 of the truck bed. The top portion 12 B of the top cover 12 is preferably flat and level, parallel to the lower edges of the top cover sides 26 . There is preferably a slope 12 C at the front of the top cover 12 beginning at the lower forward corner progressing upward and aft. This slope 12 C allows the cover to pivot open without intersecting the cab or rear window of the truck. The slope 12 C is preferably of such an angle that it is directly vertical when the cover 10 is in the expanded position.
On the aft portion of the top cover 12 , there is another slope 12 A. This slope 12 A tapers from top portion 12 B of the top cover 12 aft and downward to the rear edge of the cover 10 . The slope 12 A is of such an angle that it is preferably horizontal in the raised position. This slope 12 A allows the aft portion of the cover to taper for better driver visibility and aerodynamics, yet provides a flat and level design element when raised.
Two preferably gas-filled lift struts 22 (only one is visible in FIG. 1 ) are positioned inside the top cover 12 . One end of each strut 22 is attached near the forward side of the frame 11 , and the other end is attached to inner surfaces of the top cover sides 26 . These struts 22 are located in such a position and geometry as to assist in raising open the cover 10 and holding it up. The sidewalls 26 are designed with the lift struts 22 positioned between the inner panels of the sidewalls 26 , and the sides of the top cover 12 , which allows the lift struts 22 to be hidden from view (from both the inside and the outside) when the sidewalls 24 are raised.
Referring now to FIG. 1A , a rear perspective view of the frame 11 of the convertible pickup canopy 10 is shown, the frame 11 coupled to rails 2 of a truck bed. The frame 11 is affixed to the truck bed—along both side rails 2 and across the front rail 2 of the bed. Half hinges 30 (an example shown in detail in FIG. 8 ) rest along each of the three sides of the frame 11 . The hinge 30 along the forward edge of the frame attaches to the forward edge of the top cover 12 and allows the cover to pivot open. Hinges 30 along the left and right sides of the frame are attached to the left and right sidewall panels and allow each sidewall 24 to pivot to a vertical position for placing the cover 10 in its expanded condition. Flashings 20 are provided coupled to the frame 11 and providing a surface for struts 22 to affix to, and to prevent water from entering the truck bed near the forward edge of the frame 11 .
Referring now to FIG. 2 , a rear perspective view of the convertible pickup canopy 10 of the present invention is shown, the convertible pickup canopy 10 shown in an expanded condition, with a rear access door 28 opened. As can be seen from this view, two additional struts 22 are coupled between the sidewalls 24 and a top portion of the rear access door 28 , allowing and assisting the rear access door 28 to pivot and remain opened if desired. Preferably, the portion of the struts 22 that attach to the access door 28 are removably coupled with the sidewalls 24 , to allow the canopy 10 to enter its collapsed condition, as will be described later.
FIGS. 3-7 demonstrate the conversion of the canopy 10 from its expanded to its collapsed condition.
Referring now to FIG. 3 , a rear perspective view of the convertible pickup canopy 10 of the present invention is shown, the convertible pickup canopy 10 shown in an expanded condition, with the rear access door opened 28 . It can be seen that the strut 22 attached to the left sidewall 24 has been detached from the left sidewall 24 , allowing the left sidewall 24 to rotate about hinge 30 (example of hinge 30 shown in FIG. 8 ) into a substantially horizontal position hovering over the bed of the pickup truck.
From this view, it is evident that the sidewalls 24 are shaped complimentary along their top edge to the profile of the top cover 12 , notably where the surfaces 12 A and 12 B of the top cover 12 are slanted. Similarly, the profile of the sidewalls 24 are shaped complimentary to the two-plane profile of the rear access panel 28 . This allows for a tight fit and aids structural stability of the convertible pickup canopy 10 .
Referring now to FIG. 4 both the left and a right side panels have been collapsed by detaching struts 22 from the sidewalls 24 . The sidewalls 24 now both lie in their collapsed condition over the bed of the truck.
Referring now to FIG. 5 , the rear door 28 has been rotated about a hinge (not shown) and tucked under the top cover 12 . It is noted also that the shape of the rear door 28 is complimentary with the profile of the top cover 12 such that when the top cover 12 becomes lowered, the rear door 28 will be sandwiched between the sidewalls 24 , already lying in their substantially horizontal collapsed condition and the top cover 12 .
Referring now to FIG. 6 , after collapsing the sidewalls 24 and the rear door 28 , the top cover 12 can be pulled downward, rotating about struts 22 and placing the convertible pickup canopy 10 in its fully collapsed condition.
Referring now to FIG. 7 is a rear perspective view of the convertible pickup canopy 10 of the present invention, the convertible pickup canopy 10 shown in a collapsed condition and the top cover removed. Latching mechanisms (such as shown in FIG. 8 ) can be provided to ensure that the top cover 12 remains collapsed when intended.
Referring now to FIG. 8 is a perspective view of interior components of the convertible pickup canopy 10 . This view shows the canopy 10 in a position as in FIG. 2 , with the canopy 10 in an expanded condition, with sidewall 24 shown vertical and top cover 12 secured thereto. A latch 57 is provided to secure sidewalls 24 with the top cover 12 with sidewall 24 in the expanded condition. The latch 57 is detached for placing the canopy 10 in the collapsed condition. Also shown is strut 22 which is coupled between rear door 28 and sidewall 24 as shown in FIG. 2 . As can be seen, hinge 30 allows rear door 28 to pivot open as shown in FIG. 2 .
The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
|
A convertible pickup canopy is disclosed, the canopy having left and right sidewalls hingedly coupled with a frame member. The frame member is coupled with rails of the bed of a pickup truck, and allow the sidewalls and a rear door to expand to support a top cover, and to collapse to allow the top cover to travel in a lower profile.
| 1
|
CROSS REFERENCE
This application is a continuation in part of pending application Ser. No. 820,467 filed Aug. 1, 1977, abandoned.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention is a solar absorber for use to heat hot water by means of the sun's rays and designed to be mounted on the roofs of buildings, the solar absorber elements being mounted in the form of a pyramid, with the base of the pyramid designed to conform to the contour of a roof. In the first form of my invention, finned copper absorbing elements are connected in series, with the absorber having one heat sensor electrically connected to one water valve and water circulator, with the cold water circulating around the entire absorber. In my modified absorber, the heat absorbing elements are pressed waterway bonded copper, aluminum or stainless steel or alternatively are made of copper tubing bonded to copper or aluminum heat transfer flat surfaces. Each panel is equipped with its own heat sensor which is electrically connected through a control panel to a zone water valve and to a water circulator, so that water is circulating through only those panels which are exposed to the sun.
(2) Description of the Prior Art
Most commercially available hot water solar absorbers available for home use are flat plate absorbers. However, in a majority of existing homes, flat bed absorbers are not adaptable to the roof angle or to the north-east-south-west orientation of the building. In homes where the ridge pole of the roof runs in a north-south direction, a conglomeration of odd angle brackets would be required to mount the flat bed absorbers in such a way as to be moderately effective in catching the sun's rays. Most solar contractors do not want to construct these ungainly types of arrangements and very few homeowners would consent to have such ugly structures on their roofs. Further, known types of solar absorbers do not permit the economical installation of these devices on a great many homes.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a hot water solar absorber having an upper part shaped as a pyramid and a lower part or base made with either a flat surface for mounting on flat roofs or a wedged shaped base for mounting on peaked roofs.
The heat absorbing elements themselves are those which are well known in the art, the invention being the form, arrangement and connection of the known types of absorbing elements into the upward extending faces of a pyramid, thus providing a single fixed unit, in which one or more of the faces will take the sun's rays throughout the day. The pyramid, unlike a flat plate collector, will take the full morning sun at almost right angles to the east side. At midday the absorber will take the full sun on the west with angle absorption on the south and west. An exception would be in far northern latitudes where the noon sun would not strike the north side. It is therefore a further object of this invention to provide an all directional, self-supporting unit which requires no external brackets and which can be used on substantially all buildings regardless of latitude or the directional orientation of the building.
Another object of this invention is to provide a very efficient solar absorber. Tests indicate that the use of finned copper absorbing elements provide up to several times the amount of absorbing surface on a square foot to square foot basis as compared to flat plate collectors, without the need for added baffles to prevent internal convection.
In the modified form of my invention the heat absorbing elements are pressed waterway bonded copper, aluminum or stainless steel or alternatively are made of copper tubing bonded to copper or aluminum heat transfer flat surfaces. Panels of these absorbing elements can be manufactured ready to install and have been found to be easy to handle and efficient.
Another object of this invention is to provide a solar absorber which is relatively easy to mount and to maintain.
These and various other objects and advantages of this invention will be more fully apparent from a consideration of the following description, drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the hot water solar absorber according to this invention showing the device mounted on a house having a peaked roof. FIG. 2 is a perspective view of the invention showing it mounted on a house having a flat roof.
FIG. 3 is a top plan view.
FIG. 4 is a side perspective view of the absorber showing the placement of the absorbing elements.
FIG. 5 is a sectional view taken on line 5--5 of FIG. 4.
FIG. 6 is a bottom plan view of the base of the absorber designed for use on flat roofs.
FIG. 7 is a bottom plan view of the base of the absorber designed for use on peaked roofs.
FIG. 8 is a perspective view of a modified version of this invention showing the device mounted on a house having a peaked roof.
FIG. 9 is a perspective view of a modified version of the invention showing it mounted on a house having a flat roof.
FIG. 10 is a top plan view of the device shown in FIG. 8.
FIG. 11 is a side perspective view of the device shown in FIG. 8.
FIG. 12 is a sectional view taken on line 12--12 of FIG. 11.
FIG. 13 is a schematic diagram of the heat sensor electrical connections and water line connections of the device shown in FIG. 8.
FIG. 14 is a sectional view of the device shown in FIG. 8 showing the attachment to the roof of a building.
FIG. 15 is a bottom plan view of the device shown in FIG. 8 designed for use on flat roofs.
FIG. 16 is a bottom plan view of the device shown in FIG. 8 designed for use on peaked roofs.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now specifically to the drawings, the numeral 10 designates the heat absorber. The heat absorber is constructed by connecting a plurality of heat absorber elements 13 to form a triangular shaped lateral face 14 or panel extending upwardly from a base 15. A plurality of triangular faces 14 are connected along their upward extending or lateral edges 12 by a flashing strip 16 to form a pyramid having an upward extending vertex 17.
A typical absorber panel 14 is shown in FIG. 4. A sectional view of a part of a typical absorber panel 14 is shown in FIG. 5. A sheet of plywood 18 is covered with a sheet of foam insulating material 19 on its inside face. The outer surface of the plywood sheet is covered with sheet aluminum 20. The absorber elements 13 are mounted on the outer face of the sheet aluminum 20. The absorber elements 13 may be constructed of finned copper, pressed copper or stainless steel tubing or they may be made by using teflon baffles over aluminum, copper or stainless steel tubing. In FIG. 5 the copper tubing is indicated by numeral 21 and the fins by numeral 27. The absorber elements 13 are then covered with a protective sheet 22 made of glass, double glass, plastic, teflon or fiberglass. The absorber elements 13 and the sheet aluminum 20 are sprayed with an absorption enhancing coating such as 3M Nextel or an equivalent spray coating (not shown in drawings).
The absorber panel shown in FIG. 5 may be constructed with 1/2" (1.2 cm.) plywood sheet, 11/2" (3.7 cm.) foam insulation, and 3/4" (2 cm.) copper convector aluminum finned tubes, although it is obvious that other sizes may be used with satisfactory results.
In testing various absorber elements, it has been found that when using finned copper absorber elements, convection under the glass is greatly reduced, thus preventing re-radiation on a side not receiving the direct rays of the sun. An advantage of using a finned tube absorber element is that a great number of fins will always be facing the sun's direct angle and there will not be as much of a re-radiating effect as from a flat surface in the morning and evening.
The tubes 21 of the absorber element 13 are connected in series at the lateral edges 12 of the triangular panel faces 14 by pipe elbows (not shown) to form a continuous run of tubing from the lower part of the pyramid to an area near the vertex 17, as shown in FIG. 3. The pipe elbows pass through holes 28 formed in the flashing strips 16 mounted on the lateral edges of the panel faces. The flashing 16 is also used to support the protective sheets 22 of glass, plastic, teflon or fiberglass which cover the absorber elements 13.
The absorber elements 13 are connected to a cold water inlet pipe 25 and a hot water outlet pipe 26 by well known plumbing techniques, with a heat sensor electrically connected to open the cold water valve and to activate a water circulator, the hot water thereafter being pumped into a storage tank or heating system for house heating or domestic hot water. A standard type air eliminator 51 is mounted in the hot water line toward the top of the pyramid (shown in FIG. 11).
A plurality of heat absorber elements 13 as described are formed and arranged in predetermined sizes to form a triangular lateral face 14 or panel when connected, a plurality of such lateral faces being arranged and connected to form a pyramid. The device shown in the drawings, which is my preferred form, is a four sided or quadrilateral regular pyramid, all of the lateral faces being congruent isosceles triangles. However, it is obvious that the device can be constructed with three or more equal lateral faces or it may be formed with three or more faces having lateral edges of unequal length to form a pyramid which tilts toward a predetermined desired direction.
The size of the faces of the pyramid will vary according to the requirements of the dwelling. Further, the angles formed by the lateral edges of the pyramid may vary with the latitude in which the device will be used, but generally the base angles of the pyramid will be approximately 51 degrees.
The base 15 of the pyramid is formed to fit the configuration of the roof of the building 11 on which the solar absorber will be placed. As shown in FIG. 1, the base 15a is wedge-shaped to fit onto a peaked roof, the angle of the wedge depending on the shape of the roof. Foam rubber can be attached to the edges of the wedge-shaped base to provide a unit which can be mounted on peaked tile roofs. Heretofore it has been practically impossible to mount a solar heater on a peaked tile roof. A plan view of an equilateral wedge is shown in FIG. 7. The base 15b as shown in FIGS. 2 and 6 is a flat surface designed to rest on flat roofs. In either case, after the device is hoisted onto the roof of a building it is affixed in place by brackets which are not shown in the drawings.
A modified version of my invention is shown in FIGS. 8 through 14, where the numeral 30 designates the modified heat absorber and with similar parts identified by the same numerals as above. Preformed triangular shaped heat absorber panels 31 of predetermined size, extend upwardly from a base 32 having side walls 52 which are mitered to conform to the contours of a roof of a building 11.
A sectional view of a part of a typical absorber panel 31 is shown in FIG. 12. The heat absorbing elements 33 are triangular sheets preformed to have water lines running through a flat heat transfer surface, such as pressed waterway bonded copper, aluminum or stainless steel or alternatively copper tubing bonded to copper or aluminum heat transfer flat surfaces. In the drawings, the pressed or bonded tubing or waterway is indicated by the numeral 45. Each obsorber element 33 is covered on the outer face with a protective heat transmitting sheet 22 made of glass, double glass, plastic, teflon or fiberglass. The protective sheet may be transparent or translucent and tinted. Each absorber element 33 is backed by a sheet of insulation material 19 such as 11/2 inch (3.7 cm.) foam insulation, which is backed by a sheet of aluminum 20.
The components of the heat absorber panel 31 are connected along their upwardly extending or lateral edges 12 by a slide down corner locking extrusion 34 having a corner strip 39 formed with inward facing projections 39a at the ends and a center support 38 formed with two outward facing projections 38a at the forward end, the corner projections and center support projections being formed to interlock. Three pairs of separate extrusions 35, 36, 37 extend outwardly from the center support at a predetermined angle to form three pairs of channels into which the lateral edges of two sheets of protective material 22, absorber elements 33 and the insulation 19 backed by aluminum sheeting 20 are fitted, respectively. As is well known in the art, the projections 39a of the corner strips 39 are interlocked with the projections 38a of the center support 38, bringing together two panels with the corner strip forming the angle corner of each lateral edge of the pyramid.
A heat sensor 40 is operably mounted in the face of each absorber element 33. The lower end of the copper water heating tubing in each heat absorbing element 33 is connected to its own cold water line 41 which in turn is connected to a zone water valve 42 located in a control panel 43 installed in one side wall 52 of the base 32 of the heat absorber. Each heat sensor 40 is electrically connected through a control panel 43 to one water valve 42 and to a water circulator 44. When the sun hits an absorber panel 31 the heat sensor 40 operates to open both the water valve 42 controlling the water flow to the particular panel and the water circulator 44. Cold water passes through the copper tubing or waterways 45 of the heat absorbing elements 33 and warm water is collected at the point near the top of the pyramid in a hot water collection pipe 46 or manifold which is connected in series to the waterway lines 45 of the other heat absorber elements. The hot water then drains down through a single hot water outlet line 26 to a storage tank 48. The process is shown schematically in FIG. 13 wherein electrical connections are indicated by the numeral 49.
An air eliminator 51 is mounted in the hot water collection pipe 46 and functions to vent any air that is in the water lines.
It has been found that for a four sided heat absorber, four 24 volt zone valves and a 1/20th horsepower circulating pump operate in a satisfactory manner.
The independent operation of each heat absorbing panel increases the efficiency of the heat absorber as water is not being pumped through a panel which is not being warmed by the sun, where the warm water would tend to lose some of its heat. When the sun is high in the sky, all of the heat sensors would be activated and all the panels will operate. When the sun is low in the sky, the heat sensor in the shade cuts out and closes the water valve to the shaded panel. The water circulator operates until the last sensor cuts off.
The vertex of the absorber panels is cut off to form an opening 54 at the top of the pyramid which is covered with a removable metal cap 50, preferably made of aluminum. The cap 50 can be removed to gain access to the piping inside the pyramid.
The base 32 of the pyramid has side walls and an open top to which the absorber panels are attached by clips (not shown). The bottom of the base can be flat 32a or wedge shaped 32-b as described above and as shown in perspective in FIGS. 8 and 9 and in plan view in FIGS. 15 and 16. My preferred form is a square base and a four sided regular pyramid, but as discussed above the device may be constructed in other ways.
A control box or panel 43, which is installed in one of the side walls 52 of the base, contains all of the water and electrical connections. All of the plumbing and electrical connections are concealed. The panel has a door 53 to protect the valves and electrical connections. In practice, the control panel is installed and all inside piping done with the exception of the last panel. The final connections are then made at the control panel and through the removable cap.
The modified device is very simple to install, as shown in FIG. 14. A metal plate 55 is mounted across the opening 54 at the top of the absorber panels 31. Matching holes 56, 57 are drilled through the roof of a house 11 and the metal plate 55, respectively. A long threaded rod 58 is passed through the roof 11 and metal plate 55 and the threaded rod is fastened in place by standard means, such as a stud plate, washer and nut, shown generally by the numberal 59. Three other openings are drilled through the roof, namely an opening 60 for the passage of the cold water line 25, an opening 61 for the passage of the electrical lines 49 and an opening 62 for the passage of the hot water outlet 26. The same method can be used for flat or pitched roofs.
It will thus be seen that I have provided a new and improved all directional, hot water solar absorber.
|
A solar absorber to be mounted on the roofs of buildings, the absorber having the form of a pyramid with the heat absorbing elements mounted across the upward extending faces of the pyramid and the base formed to conform to the contour of the roof so that the solar absorber may be fixedly mounted on the roof of a building.
In a modified form of my invention each face of the pyramid is independently equipped with a heat sensor which is electrically connected to a water valve and water circulator so that water circulates only through the faces exposed to sunlight.
| 5
|
BACKGROUND
This invention concerns a foldable modular structure for a fast-erecting tent or similar shelter.
The invention relates particularly to tents designed for emergency situations and military use. In this particular type of application, it is required that tents have a relatively small volume when they are disassembled, and that they can be erected and deployed quickly whilst providing shelter capable of resisting harsh weather conditions.
Generally a tent consists of a structure supporting a canvas, said structure being dismountable, and consisting to this effect of a frame assembled by slotting together tubular sections, which may be articulated with each other.
Structures are already known that comprise a succession of parallel roof poles forming trusses, linked two by two by connecting bars notably constituting purlins. These connecting bars are slotted together with said roof poles, and to enable the roof poles to be moved closer together and/or apart, these bars be formed of two profiled section members articulated with each other and lockable lengthwise to form a rigid bar or purlin.
With EP1493886 in particular, a rapidly erectable, modular and foldable structure for tents is known, which consists of an assembly of tubular sections, enabling in particular at least two opposing arches to be formed, linked by at least two purlins, including one ridge purlin. Said ridge purlin in this case consists of the abutment of two profiled sections, each fastened, moreover, at the other end to a ridge part on each of said arches, said end comprising, firstly, pivoting means enabling it to pivot on said ridge part around an axis perpendicular to the plane of the arch, whilst indexing means angularly limit said pivoting and, secondly, pivoting means enable the rotation of said end around a transverse axis parallel to the plane of the arch, in order to enable said profiled section to fold parallel to said arch. The abutment of the two profiled sections of the ridge purlin is achieved by interlocking means capable of immobilising the axial rotation of one section in relation to the other according to the angular positions of the latter defined by said indexing means. Due to the limiting of the rotation around an axis perpendicular to the plane of the arches, of each of the sections in relation to the respective arches with which they are linked, and due to the immobilising of the pivoting in relation of the two sections when erecting the structure, such a structure makes it possible to maintain the ridge purlin formed by the assembly of the two sections in a fixed position.
This system is satisfactory, although it requires relatively precise indexing means to ensure good immobilisation of the pivoting of the ridge purlin without interfering with the abutting operations when erecting the structure.
SUMMARY
The purpose of this invention is to solve the problems mentioned above, and it aims in particular to propose a foldable modular structure that is simpler and more robust in design than earlier systems.
With these aims in mind, the invention concerns a foldable modular structure for a fast-erecting tent or similar shelter, consisting of the assembly of profiled sections, generally of the tubular type, intended to support a canvas, said profiled sections forming, in particular, at least two opposing arches linked by at least two purlins, including one ridge purlin.
According to the invention, the structure is characterised in that a first end of said ridge purlin is linked by a hinge to a first ridge part on a first of said arches, said hinge comprising, on the one hand, first pivoting means allowing said ridge purlin to pivot according to a transverse axis, parallel to the plane of the arch, in order to allow the purlin to fold parallel to said arch, and on the other hand, second pivoting means allowing the ridge purlin to pivot according to an axis perpendicular to the plane of the arch, and the second end of the ridge purlin comprises linking means for linking with a second ridge part on the second of said arches, said linking means being arranged to provide a dismountable but rigid link between the ridge purlin and said second linking part.
By a dismountable but rigid link, it is understood here a link immobilising the ridge purlin on the second linking part when the structure is erected and in use, but separable during the disassembly operations during routine use of the structure, that is to say when the tent is dismantled, and that with no need for any tools.
Thus, when the structure is folded away for transport, the ridge purlin can, thanks to the dual-pivoting joint means at its first end which form a sort of swivel joint, be folded against a profiled section forming the first arch. And, when the structure is deployed, the dismountable rigid link of the second end of the ridge purlin to the second arch is capable of immobilising the ridge purlin pivoting with respect to the arches, according to a longitudinal axis of said ridge purlin. Thereby the distance between the arches is maintained, whilst the dismountable rigid link also guarantees the optimum positioning of the ridge purlin to provide the best mechanical flexural strength under the loads to which it is subjected when the tent is in use.
Typically, the ridge purlin has a generally elongated rectangular cross section, and the ridge purlin will therefore be immobilised in rotation in a position where its cross section extends vertically, offering the best mechanical resistance to vertical loads.
According to a preferred embodiment, the ridge purlin is telescopic, making it possible to reduce its length in order to place it, when in the retracted position, against one of the rafters constituting the arch, without exceeding the length of that rafter. It will be noted incidentally that, to make the structure more compact when it is folded away, whilst still allowing for large dimensions when it is deployed, said rafters may also be telescopic. When the structure is deployed, the ridge purlin is extended so that its length corresponds to the distance between the arches, which is, moreover, determined by the length of the other purlins, as will be seen below.
So that the ridge purlin is telescopic as indicated above, it comprises, preferentially, two tubular sections sliding one inside the other, and locking means are provided to lock said sliding sections one onto the other. These locking means may typically be pin-type locking devices, according to a principle that is well known elsewhere, resiliently mounted to be retractable into the inner section and able to engage, when the telescopic purlin is extended, in a hole in the outer section, thereby locking the two sections in position.
According to another particular embodiment, the hinge connecting the ridge purlin to the first ridge part comprises a clevis, integral with the end of the ridge purlin, pivotably mounted on an intermediate swivel pin according to an axis parallel to the plane of the arch, the intermediate swivel pin being pivotably mounted on the first ridge part according to an axis perpendicular to the plane of the arch. This embodiment achieves the two pivoting movements required of the ridge purlin in relation to the first arch in a simple way.
According to another particular embodiment, the linking means linking the ridge purlin to the second ridge part comprise a fixed bush linked rigidly to the second ridge part and having a vertical axis, and a lug, integral with the second end of the ridge purlin, extending perpendicular to the longitudinal direction of the ridge purlin and in the longitudinal direction of the cross section of the latter, and arranged to engage slidingly downwards into said bush.
When the structure is deployed, this lug is simply inserted into said bush to achieve at once the linking of the two arches and the immobilization of the pivoting of the ridge purlin around its own longitudinal axis. The weight of the ridge purlin and the tent canvas supported by the latter is sufficient to hold the lug in place in the bush.
According to yet another particular embodiment, each of the arches consists of a ridge part and two rafters, preferentially telescopic, attached to said ridge part according to separated axes perpendicular to the plane of the arch, the pivoting of the rafters being limited by stops provided in said ridge part. These embodiments allow the rafters to be folded one against the other when folding away the structure, thereby ensuring the compactness of the folded structure.
Also preferentially, the ridge parts comprise means of centering them one with the other in order to maintain them in their relative position when the structure is folded away, which maintains the ridge parts and the rafters in their relative positions as long as the structure is not deployed.
The secondary purlin or purlins that link the two arches together in addition to the ridge purlin, preferentially consist of two profiled sections pivotably attached on one hand to each other and also to their respective arches, according to parallel axes of rotation, so as to allow one of said sections to be folded onto the other, thereby bringing together two neighbouring arches. The axes of rotation of the profiled sections are perpendicular to the general direction of the rafters forming the arches, so that said sections can be folded against the rafters and parallel to them.
The joint linking the two profiled sections forming a purlin comprises blocking means allowing the two sections to kept aligned after deployment, said blocking means comprising, preferentially, a tubular latch arranged to slide over said sections and to be able to cover the joint and the ends of the two sections adjacent to said joint, thereby immobilising said sections in aligned respective position.
Other features and advantages will appear in the description that follows of a foldable modular structure for a fast-erecting tent according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings enclosed:
FIG. 1 is a perspective view of the structure according to the invention, in the transport position, prior to any deployment,
FIG. 2 shows the first phase of erection, with the deployment of the rafters forming the arches,
FIG. 3 shows the next stage of erection, with the deployment of the eave purlins,
FIGS. 4 and 5 show in detail the hinge of the profiled sections constituting said eave purlins, in the folded and deployed positions respectively,
FIG. 6 shows the structure after complete deployment of the eave purlins, before deploying the ridge purlin,
FIG. 7 shows in detail the link between the ridge purlin and the first ridge part,
FIG. 8 is a view of the first ridge part on its own,
FIG. 9 is a view of the second ridge part on its own,
FIG. 10 illustrates the beginning of the deployment of the ridge purlin,
FIGS. 11 and 12 illustrate the connection of the ridge purlin onto the second arch,
FIG. 13 shows the structure after complete deployment of the eave purlins and the ridge purlin,
FIG. 14 shows the complete structure, with its legs, ready to receive the tent canvas.
DETAILED DESCRIPTION
The structure according to the invention illustrated in the different drawings comprises three arches: two end arches 1 and a central arch 2 , each in the shape of an inverted V and consisting of a ridge part 10 , 20 , onto which are attached, pivoting according to axes of rotation A perpendicular to the plane of the arch, two rafters, 11 and 12 , and 21 and 22 , respectively. The pivoting of the rafters on the ridge parts is limited by stops 101 , 201 provided on said ridge parts so as to achieve the desired angle of the V formed by the rafters.
Each rafter comprises at its opposite end to the ridge part, an angle part 13 , 23 arranged to connect firstly the legs 3 , and secondly, the eave purlins.
Arches 1 and 2 are connected by three purlins, one ridge purlin 4 which extends between the two ridge parts 10 , 20 of the neighbouring arches 1 , 2 , and two eave purlins 5 which are also connected pivotably with the angle parts 13 , 23 .
The eave purlins 5 consist of two profiled sections 51 , 52 pivotably attached, on the one hand, to each other, and on the other hand to their respective arches 1 , 2 , according to parallel axes of rotation A 1 to A 4 , as can be seen in FIG. 3 , so as to allow said sections 51 , 52 to be folded one over the other and therefore two neighbouring arches to be moved closer together or apart. The profiled sections 51 , 52 are attached to each other by means of a linking part 53 , which can be seen better in FIGS. 4 and 5 . This linking part 53 , onto which the profiled sections 51 , 52 are pivotably mounted according to axes A 2 , A 3 , parallel to and distant from each other so as to allow the sections to be folded parallel one against the other, also comprises two stops 531 arranged to limit the relative pivoting of the sections in the direction of moving them apart, at a position in which the two sections are in alignment, as shown in FIG. 5 . A latch 54 , in the form of a tubular member slidingly mounted with a simple functional clearance onto one of the sections, can then be slid into a position where it covers the articulation area including the ends of the two sections 51 , 52 and the linking part 53 , and can be immobilised in translation, thereby blocking the two sections in an aligned position, as can be seen in FIG. 6 in particular.
It will also be noted that the axes of rotation A 1 and A 4 of the two profiled sections on the angle parts 13 , 23 are orthogonal to the rafters 11 , 12 , 21 , 22 , so that, in the folded position, the sections are folded against said rafters, parallel to them, as shown in FIGS. 1 and 2 .
The ridge purlin 4 consists of two profiled sections 41 , 42 of generally rectangular cross section, sliding one inside the other so that the ridge purlin is telescopic; and it comprises means of locking the two sections 41 , 42 both in the retracted position, to hold the ridge purlin in this retracted position when the structure is folded away, and in the extended position, when the purlin is connecting the two arches 1 , 2 . These locking means may in particular be pin-type locking devices 43 , of a type already known for locking sliding telescopic members.
The ridge purlin 4 is fastened at one end onto a first arch, for example arch 1 , by means of a concurrent axis hinge system 6 allowing first of all the ridge purlin 4 to pivot in relation to the arch 1 according to an axis A 5 parallel to the plane of said arch, and according to an axis A 6 orthogonal to said plane of the arch, which allows the ridge purlin to be brought against one of the rafters 11 , 12 when the structure is folded away, and, alternatively, when the structure is deployed, to place said purlin 4 perpendicular to the plane of the arch 1 , to connect the second arch 2 to it, the pivoting according to axis A 6 allowing the ridge purlin 4 to be placed in the position where it offers the best resistance to the vertical loads, that is to say with its rectangular cross section, and therefore axis A 5 , oriented vertically. The hinge system 6 typically comprises a swivel pin 61 pivotably mounted according to axis A 6 on the ridge part 10 , and the end of the ridge purlin 4 comprises a clevis 44 pivotably mounted on said swivel pin according to axis A 5 .
The ridge purlin 4 comprises at its other end a connecting piece 45 comprising a lug 46 which extends perpendicular to the ridge purlin and is oriented according to the largest direction of the cross section of said purlin, that is to say parallel to axis A 5 . The lug is also dimensioned to engage by sliding vertically, as shown in FIG. 11 , into a bush 25 rigidly linked to the ridge part 20 and whose axis A 7 is vertical when the structure is erected. The fixed bush 25 may be made of one piece with the ridge part 20 . Thus when the lug 46 is slotted into the bush 25 , on the one hand the ridge purlin rigidly connects the two ridge parts 10 , 20 , and on the other hand said slotting together prevents the ridge purlin from pivoting according to its longitudinal axis, thereby maintaining it in the optimum position for the strength of the structure.
In addition, the fixed bush 25 has a centering stud 251 , extending orthogonally to axis A 7 and in the general plane of the ridge part 20 and with dimensions that allow it to engage in a hole 611 provided to this effect in the swivel pin 61 , when the structure is folded away, the ridge parts 10 and 20 being positioned one against the other, as shown in FIG. 1 . Thus, during the first stage of unfolding the structure, illustrated by FIG. 2 , the different ridge parts remain positioned in alignment, avoiding them moving over each other, which could otherwise cause the different components of the structure to move respectively in an uncontrolled way. Thanks to this system of centering the different ridge parts, the deployment and erection of the structure is notably facilitated. In a quite equivalent way, the centering stud could be formed on the swivel pin 61 , cooperating with a hole provided in the fixed bush.
The structure is erected as follows: starting from the folded position of the structure shown in FIG. 1 , we begin by deploying the rafters 11 , 12 , 21 , 22 by pivoting them on the ridge parts 10 , 20 , in the directions F 1 , until the rafters are brought up against the stops 101 , 201 , in the position shown in FIG. 2 , the ridge parts then being held in place in relation to each other by the studs 251 engaged in the holes 611 .
We continue to deploy the structure by opening the arches 1 , 2 , as shown by the arrows F 2 in FIG. 3 . This opening movement is accompanied by the pivoting, in directions F 3 , of the profiled sections 51 , 52 constituting the eave purlins 5 , until said sections are in alignment, this alignment being achieved furthermore by said sections coming up against the stops 531 in the linking parts 53 . The latches 54 are then slid in direction F 4 until the profiled sections 51 , 52 are held together in said aligned position.
The ridge purlin 4 , which until now was still in its position up against a rafter, is deployed by pivoting it around axis A 5 , in direction F 5 , and by pivoting it on itself around axis A 6 in direction F 6 , to bring the ridge purlin perpendicular to the plane of arch 1 , its cross section extending vertically. The ridge purlin is extended by relatively sliding the profiled sections 41 , 42 that constitute it, in direction F 7 , until these sections are locked into the extended position of the ridge purlin, whose second end is then connected to the ridge part 20 of the second arch by engaging the lug 46 in the bush 25 .
The structure in now in the state illustrated in FIG. 13 . If the rafters are also telescopic, then we now bring them into their extended position, then we connect the legs 3 onto the angle parts 13 and 23 to complete the erection of the structure, which is now ready to receive the tent canvas.
Folding the structure away, of course takes place by carrying out the operations in reverse order.
The structure in the example that has just been described has three arches, but of course the same system can be used for structures with two arches or with more than three arches.
Intermediate secondary purlins could also be used to reinforce the support provided for the canvas, located between the ridge purlin and the eave purlins.
In similar structures, it is also possible to make the purlins other than the ridge purlin, or at least some of the other purlins, in a similar way to what has been described for the ridge purlin.
The rafters 11 , 12 , 21 , 22 , can also be telescopic, to increase the width of the structure, whilst still having a folded structure with a small volume. In this case, it will also be possible to use as means of locking for the rafters in the deployed position, and in the retracted position, pin-type locking devices similar to the locking device 43 used on the ridge purlin, or other locking devices of known types used to lock sliding telescopic members in position.
Although preferentially the profiled sections used have a rectangular cross section, which is generally optimal for reasons of mechanical strength, it is also possible to use sections with a different cross section, as long as, for the telescopic members at least, they are able to slide one inside the other without any relative rotation according to their longitudinal axis.
|
A foldable modular structure for a fast-erecting shelter comprising the assembly of profiled sections that form at least two opposing arches linked by at least two purlins, including one ridge purlin. A first end of the ridge purlin is linked by a hinge to a first ridge part of a first arch, said hinge comprising first pivoting means allowing said ridge purlin to pivot on a transverse axis, parallel to the plane of the arch, in order to allow the purlin to fold parallel to said arch, and second pivoting means allowing the ridge purlin to pivot on an axis perpendicular to the plane of the arch, and the second end of the ridge purlin comprises linking means for linking with a second ridge part of a second arch, said linking means being arranged to provide a dismountable but rigid link between the ridge purlin and said second linking part.
| 4
|
FIELD OF THE INVENTION
[0001] The present invention relates to the field of image processing. More specifically, the present invention relates to a virtual level for a digital camera.
BACKGROUND OF THE INVENTION
[0002] Digital cameras have been used to acquire images for many years. Digital cameras typically record captured images in a particular format on a storage device. The stored images are able to be processed or modified by a user.
[0003] Some types of digital cameras include built in orientation sensors. An orientation sensor is used to determine if the user has the camera in regular landscape mode or if the camera has been rotated to take a picture in the portrait mode. The inclusion of the orientation sensor allows the images to be displayed on a display in the correct orientation.
[0004] In spite of orientation sensors, it is common to acquire an image with a camera tilted to an angle. In some circumstances, it is beneficial to correct the tilt/angle so that the image appears untilted. One implementation of tilt correction involves identifying vertical or horizontal objects within an image and determining the orientation error associated with the objects and rotating the image to eliminate the orientation error.
SUMMARY OF THE INVENTION:
[0005] A method of and apparatus for generating a reference line or a virtual level enables tilt correction of an image. A user is able to utilize the reference line which is directly overlaid on top of an existing edge (line) of the image to see how an image should be oriented for the objects within the image to be level. The user is able to then correct the tilt of the image as desired using the reference line for assistance.
[0006] In one aspect, a method of assisting a user in orienting an image programmed in a memory on a device comprises estimating a tilt angle and generating a reference line based on the tilt angle. Estimating the tilt angle further comprises computing a gradient feature, implementing line segment tracking, estimating a line segment and estimating an orientation deviation. Computing the gradient feature further comprises estimating a gradient, adaptive noise filtering, non-maximum suppression and thinning Implementing line segment tracking further comprises locating segment junctions using a neighborhood look-up table and tracking edges between junction points. Tracking edges between junction points further comprises scanning a gradient image starting at a non-zero edge point, following an edge segment through its neighborhood, stopping tracking at a junction, assigning each segment a unique identification, iterating until all of the points are tracked and removing any edge segment that is short or isolated. Estimating the line segment further comprises filtering edge length and estimating linear segments from approximately vertical and horizontal lines. Estimating the orientation deviation further comprises computing an optimal balance between deviations from all line segments. Estimating the orientation deviation further comprises image content analysis and segment analysis. Image content analysis further comprises filtering segments according to location in the image. Segment analysis uses vertical segments if more than one vertical segment is present; otherwise, horizontal segments are used if more than one horizontal segment is present and the total length is more than the total vertical length; otherwise, the average of the vertical and horizontal segment length is used. Generating the reference line includes displaying the reference line on a display of the device. Generating the reference line occurs during image acquisition. Alternatively, generating the reference line occurs after image acquisition. The device is selected from the group consisting of a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television and a home entertainment system.
[0007] In another aspect, a method of assisting a user in orienting an image programmed in a memory on a device comprises estimating a tilt angle comprising implementing linear structure estimation for estimating orientation preference and generating a reference line based on the tilt angle. Implementing linear structure estimation further comprises computing a gradient feature, implementing line segment tracking, estimating a line segment and estimating an orientation deviation. The device is selected from the group consisting of a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television and a home entertainment system.
[0008] In another aspect, a system programmed in a memory on a device comprises a gradient feature module configured for computing a gradient feature, a line segment tracking module operatively coupled to the gradient feature module, the line segment tracking module configured for implementing line segment tracking, a line segment estimating module operatively coupled to the line segment tracking module, the line segment estimating module configured for estimating a line segment, an orientation deviation module operatively coupled to the line segment estimating module, the orientation deviation module configured for estimating an orientation deviation and a reference line generation module operatively coupled to the orientation deviation module, the reference line generation module configured for generating a reference line based on the orientation deviation. The device is selected from the group consisting of a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television and a home entertainment system.
[0009] In another aspect, a device comprises a memory for storing an application, the application configured for estimating a tilt angle and generating a reference line based on the tilt angle and a processing component coupled to the memory, the processing component configured for processing the application. Estimating the tilt angle further comprises computing a gradient feature, implementing line segment tracking, estimating a line segment and estimating an orientation deviation. The device is selected from the group consisting of a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television and a home entertainment system.
[0010] In another aspect, a camera comprises a lens, a sensor configured for acquiring an image through the lens, a memory for storing an application, the application configured for estimating a tilt angle comprising computing a gradient feature, implementing line segment tracking, estimating a line segment and estimating an orientation deviation and generating a reference line based on the tilt angle and a processing component coupled to the memory, the processing component configured for processing the application. The reference line is overlaid and displayed on a display to allow a user to correct tilt in the image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates a flowchart of a method of estimating a tilt angle of an image according to some embodiments.
[0012] FIG. 2 illustrates a block diagram of an exemplary computing device configured to generate a reference line according to some embodiments.
[0013] FIG. 3 shows exemplary before and after images with tilt correction according to some embodiments.
[0014] FIG. 4 shows exemplary before and after images with tilt correction using a reference line according to some embodiments.
[0015] FIG. 5 shows exemplary before and after images with tilt correction using a reference line according to some embodiments.
[0016] FIG. 6 illustrates a flowchart of a method of generating a reference line according to some embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] A preferred orientation of an object and the deviation of the current orientation from the preferred orientation is determined by tilt image analysis without object recognition. This process is also able to be aided by using a reference line. Tilt image analysis includes several steps such as gradient feature computation, line segment tracking, line segment estimation and orientation deviation estimation. Tilt image analysis is further described in U.S. Patent Application Serial No. Atty Docket No. Sony-37400, filed ______, and entitled, APPARATUS FOR AUTOMATIC ESTIMATE OF THE ANGLE IN TILTED IMAGES FOR LEVEL CORRECTION, which is incorporated by reference herein.
[0018] FIG. 1 illustrates a flowchart of a method of estimating a tilt angle of an image. In the step 100 , the image is down sampled. In some embodiments, down sampling brings the image to a maximum of 600 pixels in either length or width using bicubic interpolation. In some embodiments, a different method of down sampling is implemented. In some embodiments, a different number of maximum pixels is implemented. In some embodiments, the step 100 is skipped, and down sampling is not implemented.
[0019] In the step 102 , a gradient feature is computed. Computing the gradient feature includes gradient estimation, adaptive noise filtering, non-maximum suppression and thinning. In the gradient estimation a directional derivative of a Guassian is further computed.
[0000]
[
∂
G
σ
∂
x
,
∂
G
σ
∂
y
]
,
G
σ
=
1
2
πσ
-
(
x
2
+
y
2
)
/
2
σ
2
[0000] The gradient magnitude is computed by:
[0000]
I
g
(
x
,
y
)
=
[
(
∂
G
σ
∂
x
*
I
)
2
+
(
∂
G
σ
∂
y
*
I
)
2
]
1
/
2
[0000] In some embodiments, an edge gradient is filtered by adaptive noise filtering. The image gradient is further processed by non-maximum suppression. Non-maximum suppression is applied to suppress a pixel whose gradient is not locally a maximum:
[0000]
I
g
(
x
,
y
)
=
{
I
g
(
x
,
y
)
if
I
g
(
x
,
y
)
>
I
g
(
x
′
,
y
′
)
&
I
g
(
x
,
y
)
>
I
g
(
x
″
,
y
″
)
0
otherwise
[0000] A pixel is labeled an “edge” if its gradient is above a high threshold. The pixel is labeled as a “non-edge” if its gradient is below a low threshold. For a pixel between the high and low thresholds, the pixel is labeled an “edge” if it is connected with an “edge” pixel.
[0020] Thinning is also implemented to estimate a single pixel width from double or triple maximum edge points. After thinning, the edge with a single pixel width is used in the next step.
[0021] In the step 104 , line segment tracking is implemented. Line segment tracking includes locating segment junctions by a neighborhood look-up table algorithm. Line segment tracking also includes tracking edges between junction points including scanning a gradient image starting at a non-zero edge point, following an edge segment through its neighborhood, stop tracking at the junction, assigning each segment a unique identification, iterating until all of the points are tracked and removing any edge segment that is short or isolated. Resulting edge lists are used in the next step.
[0022] In the step 106 , a line segment is estimated. Estimating the line segment includes edge length filtering using Euclidean 2-norm. Estimating the line segment also includes estimating linear segments from approximately vertical and horizontal lines by filtering a minimum length (l >l min ), fitting by straight line segments and considering only lines close to vertical or horizontal orientation (θ<θ max ).
[0023] In some embodiments, line segment estimation includes a two-scale method with higher precision but increased complexity. The two-scale method includes edge gradient detection with statistical noise filtering at two levels. At the first level (or level 0), short line segments are identified. At the second level (or level 1), long line segments are searched, cued by the short segments. The orientation deviation is then computed at level 1.
[0024] In the step 108 , orientation deviation is estimated using the line segments. Orientation deviation estimation includes computing angle deviation where:
[0000]
δθ
i
=
{
θ
i
-
ϕ
,
θ
i
-
ϕ
≤
θ
max
0
,
θ
i
>
θ
max
,
ϕ
=
0
,
π
/
2
[0000] The optimal balance is computed from the line segments determined in the step 106 .
[0000]
ΔΘ
0
,
π
/
2
=
∑
i
w
i
δθ
i
,
w
i
=
l
i
∑
i
l
i
[0025] Image content analysis filters segments according to their locations in the image. Segments within “ignored” zones along an image boundary do not contribute to the final estimation. Segment analysis uses vertical segments if more than one vertical segment is present.
[0026] Otherwise, horizontal segments are used if more than one horizontal segment is present and their total length is more than the total vertical length. Otherwise, the average of the vertical and horizontal segment length is used.
[0027] View parameters ΔΘ are estimated from the optimal linear balance:
[0000] ΔΘ= f ( d 0 , d π/2 )=β 0 ΔΘ 0 +β π/2 ΔΘ π/2
[0000] where β 0 ,β π/2 are determined by the image content analysis and segment analysis.
In some embodiments, after the view parameters are estimated, the image is rotated by the amount of orientation deviation so that the tilt is removed.
[0028] FIG. 2 illustrates a block diagram of an exemplary computing device 200 configured to generate a reference line (also referred to as a virtual level) according to some embodiments. The computing device 200 is able to be used to acquire, store, compute, communicate and/or display information such as images and videos. For example, a computing device 200 is able to acquire and store an image. The reference line generation method is able to be used to generate a reference line to be used to correct the tilt of the image on the device 200 . In general, a hardware structure suitable for implementing the computing device 200 includes a network interface 202 , a memory 204 , a processor 206 , I/O device(s) 208 , a bus 210 and a storage device 212 . The choice of processor is not critical as long as a suitable processor with sufficient speed is chosen. The memory 204 is able to be any conventional computer memory known in the art. The storage device 212 is able to include a hard drive, CDROM, CDRW, DVD, DVDRW, flash memory card or any other storage device. The computing device 200 is able to include one or more network interfaces 202 . An example of a network interface includes a network card connected to an Ethernet or other type of LAN. The I/O device(s) 208 are able to include one or more of the following: keyboard, mouse, monitor, display, printer, modem, touchscreen, button interface and other devices. Tilt angle estimation application(s) 230 used to perform the tilt angle estimation method are likely to be stored in the storage device 212 and memory 204 and processed as applications are typically processed. More or less components shown in FIG. 2 are able to be included in the computing device 200 . In some embodiments, reference line generation hardware 220 is included. Although the computing device 200 in FIG. 2 includes applications 230 and hardware 220 for reference line generation, the reference line generation method is able to be implemented on a computing device in hardware, firmware, software or any combination thereof.
[0029] In some embodiments, the reference line generation application(s) 230 include several applications and/or modules. In some embodiments, the reference line generation application(s) 230 include tilt angle estimation applications and modules. A gradient feature module 232 is configured for computing a gradient feature. A line segment tracking module 234 is configured for implementing line segment tracking A line segment estimating module 236 is configured for estimating a line segment. An orientation deviation module 238 is configured for estimating an orientation deviation. A tilt correction module 240 is configured for tilting an image based on the orientation deviation. A planar inference module 242 is configured for implementing planar structure estimation. A reference line generation module 244 is configured for generating a reference line. Fewer or additional modules are able to be included as well.
[0030] Examples of suitable computing devices include a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television, a home entertainment system or any other suitable computing device.
[0031] A specific example of a computing device implementing reference line generation is a camera which includes a lens, a sensor such as a Charge-Coupled Device (CCD) or Complementary Metal Oxide Semiconductor (CMOS), a storage component such as a hard drive or a flash memory, a processing component and other standard image acquisition components. The camera functions as any other camera, for example, when a user presses a button to acquire an image, the lens, sensor and processor function together to acquire the desired image. The reference line generation method is able to be used in conjunction with the standard functionality of the camera to ensure that the image has a proper configuration.
[0032] FIG. 3 shows exemplary before and after images with tilt correction according to some embodiments. A first image 300 is shown as taken by a user. The first image 300 is tilted with the building, tree and sky at a significant angle. A second image 302 is shown after being corrected for the tilt. The correction shows the building, tree and sky in a configuration that such a scene would generally appear.
[0033] FIG. 4 shows exemplary before and after images with tilt correction using a reference line according to some embodiments. A device is able to automatically estimate a tilted angle of a scene as described herein. The device is also able to provide a reference line 400 directly overlaying an image or showing on a viewfinder or another display to assist a user. In some embodiments, the reference line 400 is able to be determined using the tilt angle estimation implementation described herein. In some embodiments, the reference line 400 is able to be determined using another implementation. The reference line 400 is able to appear while the photograph is being taken or after the photograph has been taken and when the user is displaying the photograph (e.g. on a camera or in photo editing software). The reference line 400 is able to be utilized in a digital camera so that a user is able to manually correct for the tilt, or the camera is able to automatically correct the level without user involvement. The reference line 400 is displayed partially on or near an object or scene that generally has a similar directionality/position. For example, in FIG. 4 , the horizon, where the water meets the sky, the water is generally horizontally across. The reference line 400 is positioned very close to the horizon so that a user is able to line up the horizon with the reference line 400 to correct the tilt of the image. In some embodiments, the reference line 400 includes a quality or feature to distinguish it from the scene in the image. For example, the line is able to be semi-transparent, dotted, dashed, solid, a bright color, a color not found within the image, multi-colored and/or any other quality. The reference line 400 is able to be implemented in any manner, such as in a software module. The reference line 400 shown in FIG. 4 assists in correcting for tilt based on a horizontal line.
[0034] FIG. 5 shows exemplary before and after images with tilt correction using a reference line according to some embodiments. In addition to being able to place a horizontal reference line 400 as shown in FIG. 4 , a vertical reference line 500 is able to be used. For example, in FIG. 5 , a reference line 500 is used based on a post in the scene.
[0035] FIG. 6 illustrates a flowchart of a method of generating a reference line according to some embodiments. In the step 600 , a tilt angle of an image is estimated. The tilt angle is able to be estimated using any implementation such as tilt angle estimation described herein. In the step 602 , an existing edge (line) is located in the image as a reference line. In the step 604 , a guide (or new reference line) is generated based on the reference line and the estimated tilt angle. For example, a longer, stronger or clearer edge is located in the image. The new reference line is able to be used as a guide. When the new reference line is generated, the new reference line is displayed on a display so that the user is able to use the new reference line to adjust the image tilt so that the image appears in a desired orientation. The user is able to use any implementation to adjust the image tilt including, but not limited to, a button, a lever, a key, a touchpad/touchscreen and/or any other input implementation. For example, a user sees that the image is tilted based on the new reference line, and the user is able to press an auto-correct button to correct the tilt. In another example, a user recognizes the tilt based on the reference line and then presses a touchscreen icon to rotate the image n degrees (e.g. 1, 2 or any other amount) which is repeated until the tilt is corrected.
[0036] To utilize a reference line or virtual level, a user acquires an image such as by a digital camera, and then while the image is acquired or after the image is acquired, the image angle is able to be corrected using the reference line. For example, before/while an image is being acquired, the reference line is displayed, and the user is able to rotate the camera so that the image is acquired with a desired orientation, or after an image is acquired, a user is able to process the image and correct the tilt using the reference line. In some embodiments, the camera automatically implements the reference line, and in some embodiments, a user manually selects to implement the reference line. In some embodiments, the reference line is able to be implemented on another device such as a computer after the image is downloaded from the camera to the computer. On the computer, the reference line is able to be utilized manually or automatically. By using the reference line, the user is able to more easily recognize the appropriate positioning of the scene.
[0037] In operation, the reference line is able to be used to correct tilting of an image without object recognition. The tilt angle estimation computes a gradient feature, tracks line segments, estimates line segments and then estimates orientation deviation, which is then used to generate the reference line. The image is then able to be corrected based on the orientation deviation and the reference line. Using this process, an image is able to be corrected so that the image is configured appropriately without an undesired tilt. The tilt angle estimation and reference line are able to correctly compensate for a tilted image so that even if the image contains images that are leaning or angled, the correct configuration will still be obtained.
[0038] When taking a picture with a digital capturing device, the reference line is able to generate functionality similar to a hardware level. The image is analyzed to estimate a tilted angle deviated from a preferred angle (e.g. the user's intention). Then, an appropriate edge in the image is chosen as a reference line. A corrected reference line, based on the estimated tilted angle) is overlaid on the reference line of the image as a guide for the user. The user is then able to tilt the capturing device (e.g. camera) to match the edge (reference line) with the corrected reference line (guide), and then press the shutter for a well-balanced image.
[0039] In some embodiments, media able to utilize the method described herein includes but is not limited to images, videos and other data.
Embodiments of Reference Line Generation
[0000]
1. A method of assisting a user in orienting an image programmed in a memory on a device comprising:
[0041] a. estimating a tilt angle; and
[0042] b. generating a reference line based on the tilt angle.
2. The method of clause 1 wherein estimating the tilt angle further comprises:
[0044] a. computing a gradient feature;
[0045] b. implementing line segment tracking;
[0046] c. estimating a line segment; and
[0047] d. estimating an orientation deviation.
3. The method of clause 2 wherein computing the gradient feature further comprises:
[0049] a. estimating a gradient;
[0050] b. adaptive noise filtering;
[0051] c. non-maximum suppression; and
[0052] d. thinning
4. The method of clause 2 wherein implementing line segment tracking further comprises:
[0054] a. locating segment junctions using a neighborhood look-up table; and
[0055] b. tracking edges between junction points.
5. The method of clause 4 wherein tracking edges between junction points further comprises:
[0057] a. scanning a gradient image starting at a non-zero point;
[0058] b. following an edge segment through its neighborhood;
[0059] c. stopping tracking at a junction;
[0060] d. assigning each segment a unique identification;
[0061] e. iterating until all of the points are tracked; and
[0062] f. removing any edge segment that is short or isolated.
6. The method of clause 2 wherein estimating the line segment further comprises:
[0064] a. filtering edge length; and
[0065] b. estimating linear segments from approximately vertical and horizontal lines.
7. The method of clause 2 wherein estimating the orientation deviation further comprises computing an optimal balance between deviations from all line segments. 8. The method of clause 2 wherein estimating the orientation deviation further comprises:
[0068] a. image content analysis; and
[0069] b. segment analysis.
9. The method of clause 8 wherein image content analysis further comprises filtering segments according to location in the image. 10. The method of clause 8 wherein segment analysis uses vertical segments if more than one vertical segment is present; otherwise, horizontal segments are used if more than one horizontal segment is present and the total length is more than the total vertical length; otherwise, the average of the vertical and horizontal segment length is used. 11. The method of clause 1 wherein generating the reference line includes displaying the reference line on a display of the device. 12. The method of clause 1 wherein generating the reference line occurs during image acquisition. 13. The method of clause 1 wherein generating the reference line occurs after image acquisition. 14. The method of clause 1 wherein the device is selected from the group consisting of a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television and a home entertainment system. 15. A method of assisting a user in orienting an image programmed in a memory on a device comprising:
[0077] a. estimating a tilt angle comprising:
i. implementing linear structure estimation; ii. estimating a planar structure; and iii. combining linear segments from the linear structure estimation and superpixels from estimating the planar structure for estimating orientation preference; and
[0081] b. generating a reference line based on the tilt angle.
16. The method of clause 15 wherein implementing linear structure estimation further comprises:
[0083] a. computing a gradient feature;
[0084] b. implementing line segment tracking;
[0085] c. estimating a line segment; and
[0086] d. estimating an orientation deviation.
17. The method of clause 15 wherein the device is selected from the group consisting of a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television and a home entertainment system. 18. A system programmed in a memory on a device comprising:
[0089] a. a gradient feature module configured for computing a gradient feature;
[0090] b. a line segment tracking module operatively coupled to the gradient feature module, the line segment tracking module configured for implementing line segment tracking;
[0091] c. a line segment estimating module operatively coupled to the line segment tracking module, the line segment estimating module configured for estimating a line segment;
[0092] d. an orientation deviation module operatively coupled to the line segment estimating module, the orientation deviation module configured for estimating an orientation deviation; and
[0093] e. a reference line generation module operatively coupled to the orientation deviation module, the reference line generation module configured for generating a reference line based on the orientation deviation.
19. The system of clause 18 wherein the device is selected from the group consisting of a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television and a home entertainment system. 20. A device comprising:
[0096] a. a memory for storing an application, the application configured for:
i. estimating a tilt angle; and ii. generating a reference line based on the tilt angle; and
[0099] b. a processing component coupled to the memory, the processing component configured for processing the application.
21. The device of clause 20 wherein estimating the tilt angle further comprises:
[0101] a. computing a gradient feature;
[0102] b. implementing line segment tracking;
[0103] c. estimating a line segment; and
[0104] d. estimating an orientation deviation.
22. The device of clause 20 wherein the device is selected from the group consisting of a personal computer, a laptop computer, a computer workstation, a server, a mainframe computer, a handheld computer, a personal digital assistant, a cellular/mobile telephone, a smart appliance, a gaming console, a digital camera, a digital camcorder, a camera phone, an iPod®, a video player, a DVD writer/player, a television and a home entertainment system. 23. A camera comprising:
[0107] a. a lens;
[0108] b. a sensor configured for acquiring an image through the lens;
[0109] c. a memory for storing an application, the application configured for:
i. estimating a tilt angle comprising:
(1) computing a gradient feature; (2) implementing line segment tracking; (3) estimating a line segment; and (4) estimating an orientation deviation; and
ii. generating a reference line based on the tilt angle; and
[0116] d. a processing component coupled to the memory, the processing component configured for processing the application.
24. The camera of clause 23 wherein the reference line is displayed on a display to allow a user to correct tilt in the image.
[0118] The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It will be readily apparent to one skilled in the art that other various modifications may be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention as defined by the claims.
|
A method of and apparatus for generating a reference line or a virtual level enables tilt correction of an image. A user is able to utilize the reference line to see how an image should be oriented for the objects within the image to be level. The user is able to then correct the tilt of the image as desired using the reference line for assistance.
| 6
|
RELATED APPLICATIONS
[0001] This application claims the domestic benefit under Title 35 of the United States Code §119(e) of U.S. Provisional Patent Application Ser. No. 61/880,892, entitled “Method and System for Defining an Offlinable View/Controller Graph,” filed Sep. 21, 2013, which is hereby incorporated by reference in its entirety and for all purposes as if completely and fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] Enterprise applications provide valuable services to businesses. For example, enterprise applications provide customer relationship management (CRM), resource planning, human resource management, etc. The present invention will be described with reference to an example CRM that provides sales and marketing services, it being understood that the present invention should not be limited thereto.
[0003] CRM is a widely implemented strategy for managing a company's interaction with customers. CRM services can be accessed through mobile devices (e.g., smart phones or tablet computers). The present invention will be described with reference to providing CRM services to users via their mobile devices, it being understood the present invention should not be limited thereto.
SUMMARY
[0004] A method and system for defining an offlinable view/controller graph is disclosed. In one embodiment of the method, a first view definition is received from a server via data communication link, wherein the first view definition comprises a first identifier. The first view definition is stored in memory at a location identified by a first universal resource locator (URL). The first URL is mapped to the first identifier in a table.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present invention may be better understood, and its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
[0006] FIG. 1 is a block diagram illustrating relevant components of an example system that employs mobile CRM.
[0007] FIG. 2 is a block diagram of relevant components of an example server employed in FIG. 1 .
[0008] FIG. 3 graphically illustrates an example page displayed on a mobile device employed in FIG. 1 .
[0009] FIG. 4 graphically illustrates an example page displayed on a mobile device employed in FIG. 1 .
[0010] FIG. 5 graphically illustrates an example page displayed on a mobile device employed in FIG. 1 .
[0011] FIG. 6 is a block diagram illustrating relevant components of an example mobile device.
[0012] FIGS. 7A-7C graphically illustrates an example view table stored in the mobile device employed of FIG. 6 .
[0013] FIG. 8 is a flow chart illustrating relevant aspects of a process implemented by the mobile device of FIG. 6 .
[0014] FIG. 9 graphically illustrates an example page displayed on a mobile device employed in FIG. 1 .
[0015] FIG. 10 graphically illustrates an example page displayed on a mobile device employed in FIG. 1 .
[0016] The use of the same reference symbols in different drawings indicates similar or identical items.
DETAILED DESCRIPTION
[0017] Today's sales workforce is more mobile than ever. To better aid the mobile sales workforce, many companies employ mobile CRM, which enables users to more efficiently use CRM services such as creating, reviewing, and/or updating sales opportunities, sales accounts, contacts, etc., through user interfaces or “views” displayed on mobile devices.
[0018] FIG. 1 illustrates in block diagram form, relevant components of an example system 100 that provides mobile CRM. System 100 includes a mobile device (e.g., smart phone) 104 in wireless data communication with a CRM executing on server 106 . Services provided by the CRM can be accessed through views displayed by mobile device 104 .
[0019] In one embodiment, the CRM implements a model-view-controller architecture. The CRM includes a single, state driven application that contains multiple page definitions, which form the basis of views that can be are displayed by mobile device 104 . In response to receiving a view request from mobile device 104 , the CRM merges or binds view components (e.g., account names, contact names, etc.) from a logical data model with a selected page definition, the result of which is sent to the mobile device 104 as a view definition in a reply after additional processing (e.g., rendering, URI insertion, and/or serialization). Mobile device 104 receives and renders the view definition for display. For purposes of explanation, this disclosure presumes that any view definition received by a mobile device contains merged view components (e.g., account names, contact names, etc.) in condition for rendering and subsequent display. Mobile device may perform preprocessing (e.g., deserialization) before the view definition is rendered for subsequent display.
[0020] With continuing reference to FIG. 1 , FIG. 2 illustrates an example of server 106 with relevant components shown in block diagram form. Memory 202 stores an application definition for the CRM. The application definition includes page definitions, some of which are represented in memory 202 . The “Springboard” page definition can be used to render a springboard view for display on a mobile device, which enables user access to mini-applications or high level business objects within the logical data model. The “Accounts,” “Opportunities,” and “Contacts” page definitions can be used to render views for display on mobile devices that present names of accounts, opportunities, and contacts, respectively, in a list pattern. The “Account,” “Opportunity,” and “Contact” page definitions can be used to render views for display that provide detailed information for an account, opportunity, and contact, respectively, in a form. The “Account Form,” “Opportunity Form,” and “Contact Form” page definitions can be used to render views for display that provide information from an account, opportunity, and contact, respectively, in a user editable form. Other page definitions in memory 202 are contemplated. In general, page definitions can be used to render logical data model 204 into a form suitable for interaction by a user of a mobile device via views displayed thereon. In one sense, logical data model 204 provides access to business objects including accounts, contacts, opportunities, etc., some of which are shown in FIG. 2 .
[0021] The application definition in memory 202 can be implemented as a state driven application that is built using Java Server Faces (JSF) technology, it being understood the present invention should not be limited thereto. JSF provides standard, reusable components for creating pages for views. JSF provides useful, special tags to enhance view definitions. As will be more fully described below, the present invention can extend JSF (or a similar technology for building a state driven application) with a new feature that enables insertion of a new type of tag (e.g. URIs) into view definitions before the view definitions are sent to mobile devices. These new tags, as will be more fully described below, enable multiple features. For example, the tags allow mobile devices to display views when the mobile devices are “offline” or lack data communication with the CRM.
[0022] Control logic 206 , which may take form in instructions executing on a processor, is in data communication with the application definition. Control logic 206 can receive a view request from mobile device 104 via interface 208 . In response to receiving the view request, control logic 206 may access the application definition in memory 202 or a view navigation stack (not shown) to select an appropriate page definition for creating the reply. The page definition can be selected based on information contained in the view request in addition to other information.
[0023] The page definition contains metadata that can be used to retrieve view components (e.g., account names, contact names, etc.) needed from logical data model 204 . Control logic 206 can make calls to logical data model 204 to retrieve the needed view components. Control logic 206 can then bind or merge the selected page definition with the retrieved components, the result of which is transmitted to the requesting mobile device as a view definition in a reply after some additional processing. FIGS. 3-5 illustrate example views that are displayed by mobile device 104 in response to receiving replies from the CRM.
[0024] With continuing reference to FIG. 2 , FIG. 3 illustrates an example view 302 that is displayed on a touch sensitive screen 300 of mobile device 104 in response to a user's initial invocation of a mobile session with the CRM. More particularly, when the user invokes the mobile session, mobile device 104 generates and sends a request for a springboard view. In response to receiving the request, control logic 206 selects the springboard page definition in memory 202 . After some processing, control logic 206 sends the springboard view definition to the mobile device in a reply. Mobile device 104 receives and subsequently displays view 302 with actionable springboard view components 306 - 310 in response.
[0025] When springboard view 302 is displayed on mobile device 104 , the user can request additional, related views for display on mobile device 104 via activation of components 306 - 310 . To illustrate, the user can activate “Contacts” in order to retrieve a list of the contacts from the CRM. In response to activation of Contacts, mobile device 104 generates and sends a request for the contacts view to the CRM. View requests may include a session identification or other information that uniquely identifies the session between the CRM and mobile device 104 . The CRM and/or control logic 206 can use session identifications to manage view navigation stacks for respective mobile devices, which in turn can be used to select the proper page definition and components needed to form the reply.
[0026] Continuing with the illustrated example, control logic 206 receives the contacts list view request from mobile device 104 , and in response selects the contacts page definition from memory 202 . Control logic 206 selects and merges view components (e.g., contact names) from model 204 that are needed for the reply. The component selection may be based on information in the selected page definition and/or other information. In the current example, control logic 206 selects contact names that are identified directly or indirectly by the contact page definition. Components selected and retrieved are merged by control logic 206 with the contacts page definition, the result of which is transmitted to mobile device 104 as a contacts view definition after some additional processing. This additional processing may include, but should not be limited to, control logic 206 selectively adding view URIs and/or target view URIs based on the contents of the merged page definition or a rendered, merged page definition. A portion of an example contacts view definition sent to mobile device 104 is provided below.
[0000]
Contacts View Definition
<<page title=“Contacts” viewUri=“view:/contacts#list”>
<list>
<entry action=“contacts?_ctrl.state=zxy1&source=abc”
targetUri=“view:/contacts/101#detail”
>Labron James</entry>
<entry action=“contacts?_ctrl.state=zxy1&source=def”
targetUri=“view:/contacts/102#detail”
>Mark Adams</entry>
<entry action=“contacts?_ctrl.state=zxy1&source=ghi”
targetUri=“view:/contacts/102#detail”
>Peter Chu</entry>
<entry action=“contacts?_ctrl.state=zxy1&source=jkl”
targetUri=“view:/contacts/102#detail”
>Sally Ride</entry>
. . .
</list>
</page>
[0027] FIG. 4 shows an example “Contacts” view 402 displayed by mobile device 104 after it receives the reply from CRM. Like other views presented in a list pattern, view 402 illustrates contact names in a list. Many components displayed in a view are actionable. For example, the “Labron James” component can be user activated (e.g., “clicked”) to request a corresponding view that provides contact details for Labron James. In response to activation, mobile device 104 generates and sends a request for the Labron James detail view to the CRM. Control logic 206 receives this request, and selects the Contact page definition based on information in the request. Control logic 206 selects components (e.g., the account associated with the contact) identified directly or indirectly by the Contact page definition. The selected components are merged with the Contact page definition, URIs are added, and the result is transmitted to mobile device 104 after some additional processing. A portion of an example contact view definition for Labron James received by mobile device 104 is provided below.
[0000]
Labron James Contact View Definition
<page title=“Contact” subtitle=“Labron James”
viewUri=“view:/contacts/101#detail”>
<form>
<entry label=“Name”>Labron James</entry>
<entry label=“Account” action=“contact?_ctrl.state=zxy2&source=abc”
targetUri=“view:/accounts/201#detail”>Acme Bike Corp.</entry>
. . .
</form>
</page>
[0028] Like the contacts view definition example, the contact view definition example includes view and target view URIs. As will be more fully described, mobile devices, like mobile device 104 , can store view definitions from the CRM, like the contacts and LaBron James contact view definition examples above, in local memory to enable offline rendering and display of views. The view and target view URIs provide a graph or relationship between views, view components and view definitions so that a user can navigate between and views on his mobile device even when the user's mobile device is offline. Target view URIs are linked to actionable components within view definitions. When a user clicks a displayed view component while the mobile device is offline, a view definition identified by a target view URI and linked to the displayed view component, can be retrieved from local memory and subsequently rendered for display.
[0029] FIG. 5 shows an example of the Labron James contact view 502 displayed by mobile device 104 after it receives and renders the reply from the CRM. View 502 illustrates detail contact components displayed in a form format. View 502 has a look and feel of other views displayed by mobile device 104 such as the view 402 shown in FIG. 4 . For example, both views 402 and 502 include a “Back” button that can be used to backward navigate to a prior view. If the Back button of view 502 is activated, mobile device 104 will generate and send a back request to the CRM. In one embodiment, the same generic back request is sent by mobile device 104 whenever any back button in any view is activated. In response to the back request, the control logic 206 can pop the last item off the view navigation stack, which item includes information related to view 502 . Then, control logic 206 can recreate the reply that resulted in view 402 , using the page definition (e.g., Contacts page definition) in the most recently added stack item, and components from the model. The reply is recreated for subsequent transmission to the mobile device 104 . The redisplay of the view should be the same except for any component from the logical data model that has changed in the interim.
[0030] Most of the time, mobile devices such as mobile device 104 shown in FIG. 1 are in data communication with the CRM such as the CRM executing on server 106 . While “online” or in data communication, mobile device can receive view definitions from the CRM. However, data communication between the CRM and a mobile device may be interrupted either voluntarily or involuntarily. For example, mobile device 104 may have a feature (e.g., “airplane mode”) that allows the user to disable wireless communication, or the mobile device may be too far away from a communication tower to exchange radio signal communications. Mobile device users prefer to have access to CRM data and services when their mobile devices are voluntarily or involuntarily offline.
[0031] FIG. 6 illustrates relevant components of mobile device 104 that enables offline access to CRM data and/or services. More particularly, FIG. 6 shows, in block diagram form, a view request handler 604 in data communication with a view controller 602 and a mobile CRM client 606 . In one embodiment, components 602 - 606 may take form in instructions executing on one or more processors of mobile device 104 . Additionally, FIG. 6 shows a memory subsystem 610 that is configured to store a file system 612 and a data store 614 . In one embodiment, data store 614 may take form in a database that stores one or more tables such as a view table more fully described below.
[0032] Mobile CMR client 606 generates requests for views, such as the request for the contacts view mentioned above, in response to user activation of displayed, actionable view components. Request handler 604 receives the requests and is configured to forward the requests to the CRM if the mobile device 104 is online or in data communication with the server 106 . Otherwise, request handler 604 forwards the view requests to view controller 602 as will be more fully described below.
[0033] If the mobile device is online, view controller 602 is configured to receive a request reply from server 106 that contains a view definition such as the contacts view definition example above. View controller 602 stores a copy of the view definition in file system 612 , and links the view URI for the view definition to the stored copy. In one embodiment, view controller 602 creates and/or accesses a view table within data store 614 that maps view URIs to respective URLs or addresses for view definitions stored in file system 612 . View controller 602 is also configured to provide view definitions to mobile CRM client 606 on request when mobile device 104 is in the offline mode as will be more fully described below.
[0034] FIG. 7A illustrates an example view table 700 contained within data store 614 . This view table contains entries that map view URIs to file system URLs, which identify respective locations within file system 612 where view definitions are stored. The view table shown in FIG. 7A is accessible by the view controller. As shown in the example of FIG. 7A , view table 700 includes four entries, only one of which maps a URI to a file system URL. For purposes of explanation, FIG. 7A represents the state of view table 700 prior to mobile device 104 requesting the contacts view definition and the Labron James contact view definition set forth above.
[0035] FIG. 8 illustrates an example process employed by the view controller 602 and request handler 604 to enable offline access to CRM data and/or services. The process begins when a user of mobile device 104 activates (e.g., clicks) a displayed, actionable view component of a rendered view definition. The view component may be linked to a separate view definition via a target view URI in the rendered view definition. In response to user activation, the mobile CRM client 606 generates a view request corresponding to the activated view component. If the activated view component is linked to a target view URI, the URI from the rendered view definition may be included in the request generated by the mobile CRM client 606 .
[0036] Request handler 604 receives the view request and determines whether mobile device 104 operates in the online mode. If mobile device 104 is operating in the online mode, the process proceeds to step 805 where handler 604 sends the request to the CRM. In response view controller 602 will receive a reply from CRM that contains a view definition as shown in step 806 . The view definition should contain and is identified by a unique view URI. The view definition may also contain one or more target view URIs that link components (e.g., contacts) in the view definition to respective view definitions.
[0037] The view definition received in step 806 is subsequently processed by view controller 602 . More particularly, view controller 602 accesses the view table 700 to determine whether it contains the view URI for the view definition. If the view table lacks an entry containing the view URI, view controller 602 creates a new entry, and adds the view URI to the new entry. The view definition received in step 806 is stored, in one embodiment, in a file identified by a unique URL within file system 612 . The view controller 602 maps this URL to the view URI in the new entry of the view table as shown in step 820 . In one embodiment, certain views do not warrant storage in the mobile device, and as a result view storage on the mobile device is selective. For example views showing up to date stock prices or weather reports are not stored.
[0038] If the view controller 602 determines in step 810 that the view table contains the view URI for the received view definition and a mapped URL thereto, thus indicating file system 612 contains a prior version of the view definition received in step 806 , the prior version of the view definition stored at the URL is overwritten with the view definition received in step 806 . On the other hand if the view table 700 contains the view URI for the view definition received in step 806 , but the view URI in the table is not mapped to a URL, then the view definition received in step 806 is stored in file system 612 at a unique URL in step 822 . View table 700 is then updated with the URL of step 822 . The view definition received in step 806 may contain one or more target view URIs. Although not shown in FIG. 8 , view controller 602 creates a new entry in view table 700 for each target view URI that is not present in the view table.
[0039] After step 818 , 820 , or 824 the view definition received from the CRM in step 806 is sent to the mobile CRM client 606 for rendering and subsequent display on the mobile device 104 , and the process of FIG. 8 ends.
[0040] Mobile device 104 may be in the offline mode when the request handler 604 receives the view request from the mobile CRM client 606 . If the mobile device is in the offline mode, then the request handler 604 forwards the view request to view controller 602 . This request should contain a view URI (i.e., the target view URI) mapped in the rendered view definition to the view component that was activated in step 802 . View controller 602 accesses table 700 to read the URL that is mapped to the view URI. File system 612 is accessed to read the view definition at the URL, which is then forwarded to mobile CRM client 606 as shown in 832 for rendering and display. Thereafter, the process ends.
[0041] FIG. 7A illustrates the example view table prior to mobile device 104 receiving the example contacts list view definition and the example Labron James contact view definition. FIG. 7B illustrates changes made by view controller 602 to the view table shown in FIG. 7A in accordance with the process of FIG. 8 after mobile device 104 receives the example contacts view definition. Entry 5, which maps the view URI (i.e., view:\\contacts#list) for the example contacts list view definition and the URL (i.e., file:\\...contacts#list) for the example view definition stored in file system, illustrates the result of view controller 602 creating a new entry in accordance with step 820 . Entries 6-9, which contain the target view URIs of the example contacts view definition, illustrates the result of view controller 602 creating new entries for target view URIs contained in the example contacts view definition.
[0042] FIG. 7C illustrates changes made by view controller 602 to the view table shown in FIG. 7B after the mobile device receives and processes the example Labron James contact view definition in accordance with the process of FIG. 8 . As can be seen, entry 6 has been updated to include the URL where the LaBron James contact definition file is stored.
[0043] With continuing reference to FIGS. 7C and 8 , FIGS. 9 and 10 illustrate example views that are displayed by mobile device 104 when operating in the offline mode. Although not indicated in FIG. 7C , the file system of mobile device 104 stores a view definition for the springboard view shown in FIG. 3 . This view definition can be rendered and displayed on mobile device 104 that is similar to that shown in FIG. 3 while mobile device 104 is in the offline mode. The user of mobile device 104 can activate the Contacts view component (see FIG. 3 ) of the springboard while mobile device 104 is in the offline mode. In response, the mobile CRM client 606 generates a request for the contacts view definition. This request will include the view URI (i.e., view://contacts#list) that is linked to the contacts view component within the rendered springboard view definition. Since mobile device 104 is offline, request handler 604 will forward the request from the mobile CRM client to the view controller 602 in accordance with the process shown in FIG. 8 . In response, view controller 602 accesses view table 700 shown in FIG. 7C to read the URL (i.e., file:\\...contacts#list) that is mapped to the view URI (i.e., view://contacts#list) of the request. View controller 602 initiates a process to retrieve the contacts view definition stored at the mapped URL, which is eventually forwarded to mobile CRM client 606 for rendering and display. In one embodiment, however, before the view definition is forwarded to the mobile CRM 602 , view controller 602 can analyze the contacts view definition to identify which of its target view URIs, if any, are mapped to respective URLs in view table 700 . View controller 602 can update the contacts view definition to indicate those target view URIs that are mapped to URLs within the view table before the view definition is sent to the mobile CRM client 606 . Mobile CRM client 606 renders and displays the contacts view as shown in FIG. 9 . When displaying the contacts view definition, mobile CRM client 606 will visually identify those view components that are actionable based upon corresponding target view URIs that were previously identified by view controller 602 as mapped to URLs. In one embodiment, view components that are actionable are bolded in the resulting view displayed by the mobile device 104 . In the example shown in FIG. 9 , the LaBron James contact view component is bolded, thus indicating that this component is actionable in the offline mode.
[0044] In response to a user activating an actionable component such as the LaBron James component displayed in FIG. 9 , the mobile CRM 606 acting in accordance with the process shown in FIG. 8 generates a view request for the LaBron James contact definition view. This request will include the view URI (i.e., view://contacts/101#detail) for the request contact view definition, which is linked to the “LaBron James” component within the contacts view definition rendered for display. Since mobile device 104 is offline, this request is provided to view controller 602 , which in turn initiates a process that reads the LaBron James contact view from the file system definition at the mapped URL (i.e., file://...contacts/101#detail). The contact view definition is forwarded to the mobile CRM client for subsequent rendering and display. FIG. 10 illustrates the LaBron James contact view displayed by mobile device 104 while mobile device 104 is in the offline mode.
[0045] Although the invention has been described in connection with several embodiments, the invention is not intended to be limited to the specific forms set forth herein. On the contrary, it is intended to cover such alternatives, modifications, and equivalents as can be reasonably included within the scope of the invention as defined by the appended claims.
|
A method and system for defining an offlinable view/controller graph. In one embodiment of the method a first view definition is received from a server via data communication link, wherein the first view definition comprises a first identifier. The first view definition is stored in memory at a location identified by a first universal resource locator (URL). The first URL is mapped to the first identifier in a table.
| 6
|
BACKGROUND OF THE INVENTION
[0001] This invention relates to fertilizer compositions that have been developed to increase nutrients required by humans and/or domesticated animals in food plants, which is easily tailored for application to particular agricultural land, deficient in specific human/domesticated animal nutrients. In this respect, the invention is a delivery system that can be easily adjusted to deliver human/domesticated animal nutrients that have been determined to be deficient, in a determined appropriate amount to increase the amount of the nutrients in food plants in order to alleviate or eliminate the deficiency in the human/domesticated animal diet. The compositions include plant growth fertilizers that promote plant growth in addition to the delivered human/domesticated animal nutrients.
[0002] Additionally, the invention includes processes of making the fertilizer compositions containing animal nutrients.
[0003] The invention further includes methods of alleviating or eliminating deficiencies in animal nutrients by means of increasing the amounts of the nutrients in food plants.
[0004] On a worldwide basis, the demand for the present fertilizer containing animal nutrients is tremendous, as emphasized in the following excerpts regarding deficiencies of iodine, iron, zinc and vitamin A, from the World Health Organization, World Health Report 2002.
[0005] Iodine deficiency has been associated with mental retardation and brain damage, lower mean birth weight and increased infant mortality, hearing impairment, impaired motor skills, and neurological dysfunction. Over 2.2 billion people in the world may be at risk for iodine deficiency, and estimates suggest over one billion experience some degree of goiter. Globally, iodine deficiency disorders were estimated to result in 2.5 million Disability Adjusted Life Years (“DAYLs,” i.e., the sum of years of potential life lost due to premature mortality and the years of productive life lost due to disability) which is 0.2% of total global DAYLs. Approximately 25% of this burden occurred in Africa, 17% in South-East Asia and 16% in the Eastern Mediterranean.
[0006] Iron deficiency is one of the most prevalent nutrient deficiencies in the world, affecting an estimated two billion people. Young children and pregnant and postpartum women are the most commonly and severely affected because of the high iron demands of infant growth and pregnancy. Iron deficiency may, however, occur throughout the life span where diets are based mostly on staple foods with little meat intake or people are exposed to infections that cause blood loss (primarily hookworm disease and urinary schistosomiasis). About one-fifth of prenatal mortality and one-tenth of maternal mortality in developing countries is attributable to iron deficiency. There is also a growing body of evidence indicating that iron deficiency anemia in early childhood reduces intelligence in mid-childhood. There is also evidence that iron deficiency decreases fitness and aerobic work capacity through mechanisms that include oxygen transport and respiratory efficiency within the muscle. In total, 0.8 million (1.5%) of deaths worldwide are attributable to iron deficiency, 1.3% of all male deaths and 1.8% of all female deaths. Attributable DALYs are even greater, amounting to the loss of about 35 million healthy life years (2.4% of global DALYs). Of these DALYs, 12.5 million (36%) occurred in South-East Asia, 4.3 million (12.4%) in the Western Pacific, and 10.1 million (29%) in Africa.
[0007] Zinc deficiency is largely related to inadequate intake or absorption of zinc from the diet. Zinc requirements for dietary intake are adjusted upward for populations in which animal products (the best sources of zinc) are limited, and in which plant sources of zinc are high in phytates (strong chelators). It is estimated that zinc deficiency affects about one-third of the world's population, with estimates ranging from 4% to 73% across regions. Mild to moderate zinc deficiency is quite common throughout the world. Worldwide, zinc deficiency is responsible for approximately 16% of lower respiratory tract infections, 18% of malaria and 10% of diarrheal disease. The highest attributable fractions for lower respiratory tract infection occurred in Africa, the Americans, the Eastern Mediterranean and South-East Asia (18-22%); likewise, the attributable fractions for diarrheal diseases were high in these four regions (11-13%). Attributable fractions for malaria were highest in Africa and the Eastern Mediterranean (10-22%). In total, 1.4% (0.8 million) of deaths worldwide were attributable to zinc deficiency: 1.4% in males and 1.5% in females. Attributable DALYs were higher, with zinc deficiency accounting for about 2.9% of worldwide loss of healthy life years. Of this disease burden, amounting to 28 million DALYs worldwide, 34.2% occurred in South-East Asia, and 49.1% in Africa.
[0008] Vitamin A is an essential nutrient required for maintaining eye health and vision, growth, immune function, and survival. Severe vitamin A deficiency can be identified by the classic eye signs of xerophthalmia, such as corneal lesions. Milder vitamin A deficiency is far more common. Vitamin A deficiency causes visual impairment in many parts of the developing world and is the leading cause of acquired blindness in children. Children under five years of age and women of reproductive age are at highest risk of this nutritional deficiency and its adverse health consequences. Globally, approximately 21% of all children suffer from vitamin A deficiency (defined as low serum retinol concentrations), with the highest prevalence of deficiency, and the largest number affected in South-East Asia (78%) and in Africa (63%). There is a similar pattern for women affected by night blindness during pregnancy, with a global prevalence of approximately 5% and the highest prevalence among women living in Asia and Africa where maternal mortality rates are also high. It is estimated that vitamin A deficiency also caused about 16% of worldwide burden resulting from malaria and 18% resulting from diarrheal diseases. Attributable fractions for both diseases were 16-20% in Africa. In South-East Asia, about 11% of malaria was attributed to vitamin A deficiency. About 10% of maternal DALYs worldwide were attributed to vitamin A deficiency, again with the proportion highest in South-East Asia and Africa. Other outcomes potentially associated with vitamin A deficiency are fetal loss, low birth weight, preterm birth and infant mortality. In total, about 0.8 million (1.4%) of deaths worldwide result from vitamin A deficiency, 1.1% in males and 1.7% in females. Attributable DALYs are higher: 1.8% of global disease burden. Over 4-6% of all disease burden in Africa was estimated to result from vitamin A deficiency.
[0009] Thus, much of the world's population is lacking in micronutrients and iodine, which can cause a variety of illness or death. This is generally a direct result of consuming food crops that were grown in micronutrient and/or iodine deficient soils. Primary micronutrients which may be deficient include iron, zinc, copper, magnesium and selenium. Food crops grown in deficient soils not only have reduced crop yields, but also have low micronutrient and/or iodine content needed for human health.
[0010] A quick acting and cost effective method to alleviate this problem is to use enriched fertilizers containing micronutrients and/or iodine as well as vitamins and other beneficial additives. These human nutrients are transferred from the soil, through plant uptake, to the edible fruit, vegetable, seed, leaves, stalk or other portion of the food crop plant. Similarly, domesticated animals that have nutrient deficiencies will have improved health and productively by consuming food plants that have received increased amounts of the deficient nutrients. Moreover, human consumption of the nutrient healthy animals will increase human health. The present invention employs a new and particularly effective means of providing selected types and amounts of animal nutrients to food crops and concurrently providing plant nutrients for crop high yield.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention is directed towards a new and entirely unexpected fertilizer composition wherein a core particle is composed of selected types and amounts of animal micronutrients, iodine and/or vitamins which is coated with plant growth fertilizer, particularly urea as a nitrogen plant nutrient, but may also include other plant nutrients of, for example, phosphorus and potassium. Thus, a combined animal nutrient and plant nutrient fertilizer may be tailored and applied to agricultural areas to fulfill the specific needs of animal (particularly human) and food plant (crop) nutrition. The core packet of selected animal nutrients may be produced with only a small coating of urea as an intermediate product for future processing or such intermediate product may be further processed substantially in a continuous manner to the final fertilizer product. For convenience only, hereafter, nutrients for increased health of humans and domestic animals will be referred to as human nutrients and nutrients for increased food plant will be referred to as plant nutrients.
[0012] The physical structure of the present fertilizer product is novel and the process of the present invention that was developed for making the product, including the nutrient core packet and one or more coatings, includes novel granulation steps.
[0013] The present invention further includes a method of delivering human/domesticated animal nutrients that have been determined to be deficient, in a determined appropriate amount to increase the amount of the nutrients in crops, in order to alleviate or eliminate the deficiency in the human/domesticated animal diet.
DETAILED DESCRIPTION OF THE INVENTION
[0014] While in the manufacture of fertilizers, the granulation of urea is known, the simple addition of micronutrients, iodine, or other essential nutrients to a urea granulation process can potentially cause processing problems such as agglomeration, dusting, excess moisture and low production rate. Physical properties of the resulting urea granules can also be affected such as reduced particle strength, dust formation, caking in storage, or more susceptibility to humidity. Further, additives, such as human nutrient compounds, can also be damaged from the high urea melt temperature (275 to 290 F).
[0015] The present invention particularly relates to a new delivery system for incorporating micronutrients and/or iodine or any other beneficial materials into fertilizers to provide highly effective availability of the nutrients to crop plants and uptake of the nutrients into the plant. The delivery system consists of a core packet comprised of animal nutrients (nutrients in the broad sense of substances in food that aid in healthy growth and health maintenance of animals). The core packet particles are produced by granulating (e.g. drum granulation) the nutrient core ingredients, optionally with a binder (e.g., monoammonium phosphate (MAP)). On a dry basis the binder is 0.3 to 0.9% by wt. and preferably 0.5 to 0.7% by wt. The resulting core packet particle size is in the range of 0.7 mm to 1.5 mm and preferably in the range of 0.9 mm to 1.2 mm in diameter depending on the desired additive concentration.
[0016] The core particles are over coated with urea. This first coating of urea is to build up the particle size for improved processing by such means as a high or even low flow fluid bed reactor to produce the fertilizer product granules. The size of core particles with the first coating of urea is 0.9 to 1.5 mm and preferably 1.0 to 1.2 mm. The core particles with urea overcoat is an intermediate product, which may be stored or processed substantially immediately to a final fertilizer granular product.
[0017] The core particles with first coating of urea are introduced to a urea granulation process, to be coated a second time with urea and optionally including other plant macronutrients such as phosphorus and potassium to yield the fertilizer granular product. The fertilizer granules each contain a core packet particle near the center of the granule. The final product granule size ranges from 2.50 to 3.60 mm and preferably 2.5 to 2.8 mm.
[0018] The urea employed in the coating may optionally be substituted or supplemented with coating materials selected from the group consisting of ureaform, water soluble urea formaldehyde polymer, water insoluble urea formaldehyde polymer, methylene urea, methylene diurea, dimethylenetriurea and urea formaldehyde.
[0019] The plant macronutrient compounds include the following:
[0020] 1) nitrogen compounds selected from the group consisting of urea, ammonia, ammonium nitrate, ammonium sulfate, calcium nitrate, diammonium phosphate, monoammonium phosphate, potassium nitrate and sodium nitrate;
[0021] 2) phosphorous compounds selected from the group consisting of diammonium phosphate, monoammonium phosphate, monopotassium phosphate, dipotassium phosphate, tetrapotassium pyrophosphate, and potassium metaphosphate.
[0022] 3) potassium compounds selected from the group consisting of potassium chloride, potassium nitrate, potassium sulfate, monopotassium phosphate, dipotassium phosphate, tetrapotassium pyrophosphate, and potassium metaphosphate.
[0023] The core packet particles may be manufactured as an intermediate product for later coating with urea or a tailored urea-macronutrient formulation for application to a specific agricultural area, worldwide. The fertilizer product granules may optionally receive an outer coating of a substance having reduced solubility or otherwise of slower degradation to provide a slow or controlled release of the fertilizer, e.g., sulfur or polymer coatings.
[0024] Micronutrient sources include iron sulfate, iron oxides, chelated iron, zinc sulfate, iron nitrate, zinc oxide, chelated zinc, copper oxide, copper sulfate, copper nitrate, magnesium nitrate, magnesium sulfate, magnesium oxide, selenium sulfate and selenium oxide. Iodine sources include potassium iodide or sodium iodide. The proportion of total micronutrients in the fertilizer product range from 0.01 to 10.0% by wt. and preferably range from 0.1 to 5.0% by wt. Core packet particles prepared for regions that have iodine deficient soils typically contain 0.01 to 5% by wt. iodine, and more preferably contain 0.01 to 1.0% by wt. Core packet particles typically contain 0.01 to 10% wt. zinc and more preferably 0.01 to 5% wt. zinc. Core packet particle typically contain 0.01 to 10% wt iron and more preferably contain 0.01 to 4% wt. iron.
[0025] Core packet particles may also include a vitamin-mineral composition to alleviate or eliminate human vitamin deficiencies. One or more vitamins are selected from such vitamins as vitamins A, C, D, E and K, thiamin, riboflavin, niacin, vitamin B6 and B12, folic acid (vitamin B9), pantothenic acid (vitamin B5) and biotin (vitamin B7). In addition to the previously disclosed mineral nutrients of iron, zinc and iodine additional mineral nutrients are selected from calcium, phosphorus, magnesium, selenium, copper, manganese, chromium, molybdenum, chloride, potassium, boron, nickel, silicon, tin, vanadium, and carotenoids such as lutien, and lycopene.
[0026] See Table 1 for an exemplary list of components and exemplary amounts as may constitute a complete human multivitamin.
[0000]
TABLE 1
Vitamin-Mineral Composition
“Equate (Tm) Complete Multivitamin”
Supplement Facts
Serving Size: 1 Tablet
Amount Per Serving:
% DV
Vitamin A (29% as Beta Carotene)
3500
I.U.
70%
Vitamin C
90
mg
150%
Vitamin D
400
I.U.
100%
Vitamin E
30
I.U.
100%
Vitamin K
25
mcg
31%
Thiamin (Vit. B1)
1.5
mg
100%
Riboflavin (Vit. B2)
1.7
mg
100%
Niacin
20
mg
100%
Vitamin B6
2
mg
100%
Folic Acid
500
mcg
125%
Vitamin B12
6
mcg
100%
Biotin
30
mcg
10%
Pantothenic Acid
10
mg
100%
Calcium
200
mg
20%
Iron
18
mg
100%
Phosphorus
109
mg
11%
Iodine
150
mcg
100%
Magnesium
100
mg
25%
Zinc
11
mg
73%
Selenium
55
mcg
79%
Copper
0.9
mg
45%
Manganese
2.3
mg
115%
Chromium
35
mcg
29%
Molybdenum
45
mcg
60%
Chloride
72
mg
2%
Potassium
80
mg
2%
Boron
150
mcg
**
Nickel
5
mcg
**
Silicon
2
mg
**
Tin
10
mcg
**
Vanadium
10
mcg
**
Lutein ‡( Tagetes erecta ) (flower)
250
mcg
**
Lycopene
300
mcg
**
** Daily Value (DV) not established.
Other Ingredients:
[0027] Dicalcium Phosphate, Magnesium Oxide, Potassium Chloride, Calcium Carbonate, Cellulose, Ascorbic Acid, Ferrous Fumarate, Corn Starch, dl-Alpha Tocopheryl Acetate, Niacinamide, Polyvinyl Alcohol, Gelatin, Croscarmellose Sodium, d-Calcium Pantothenate, Crospovidone, Zinc Oxide, Magnesium Stearate, Titanium Dioxide, Polyethylene Glycol, Talc, Manganese Sulfate, Silicon Dioxide, Acacia, Maltodextrin, Hypromellose, Pyridoxine Hydrocholride, Glucose, Cupric Sulfate, Riboflavin, Thiamine Mononitrate, Vitamin A Acetate, Boric Acid, Sucrose, Folic Acid, Beta Carotene, Yellow 6 Lake, Chromium, Picolinate Lycopene, Lutein, Potassium Iodide, Sodium Selenate, Sodium Molydate, Tricalcium Phosphate, Sodium Asorbate, Tocopherols, Red 40 Lake, Phytonadione, Biotin, Sodium Metavanadate, Nickelous Sulfate, Stannous Chloride, Cholecalciferol, Cyanocobalamin, Ascorbyl Palmitate
[0028] There is substantial flexibility in the manufacture of the core packets to specifically tailor products to be produced for different agricultural areas of the world, which have varying soil and weather conditions. The present fertilizer products containing nutrient core packets can be produced by a number of typical fertilizer manufacturing processes including fluid bed granulation, drum granulation, and pan granulation. While the unit operations comprise typical fertilizer manufacturing processes, the combination of operations is novel to produce the product of the present invention.
[0029] The micronutrient core packet particles are primarily formed by granulating a fine powder (or fine crystals) of various micronutrients and/or iodine using a binder such as corn syrup (e.g., 20-30% fructose or 3-9% dry basis), other sugars (such as sucrose), starches, lignosulfonates (such as calcium or potassium or ammonium lignosulfonates), PVA (polyvinyl acetate), methyl cellulose, MAP (monoammonium phosphate) and any other binders commonly used for granulation. Binder content ranges from 1 to 10% by wt. and preferably ranges from 3 to 6% by wt. The granulation method for preparing the core packets is selected from commonly used techniques such as drum granulation, pan granulation, pin-mixer, extrusion, compaction, fluid bed granulation and prilling. The core packet particles are pre-coated by processes for example of drum granulation, pan granulation or fluid bed granulation, with a small amount of urea (5 to 25% by wt.) to give the particle a sufficient size to be further processed, immediately or later in a urea production facility (by such means as drum granulation, pan granulation or fluid bed granulation), to prevent particle damage or entrainment in a process air stream causing removal from the granulator.
[0030] If the raw material for the nutrient compound is in (fine) powder form, then granulation is required in order to increase the nutrient core particle size to the desired size before coating with urea. Alternatively, if the raw nutrient material is in a larger form, e.g. crystals, then granulation is not necessary and the raw nutrient material is only screened to result in the desired nutrient core particle size.
[0031] The resulting nutrient core particles are then sprayed with melted urea and granulated to result in a granulated nutrient core fertilizer final product or intermediate product. If an intermediate product, a second coating of urea is sprayed on the intermediate granules, followed by further granulation to the final twice coated product. In both cases, after spraying with melted urea and granulation, the resulting granules are cooled. In a commercial process, the granules would be cooled in a fluid bed cooler.
EXAMPLES
[0032] Samples of the product of the present application were generally made employing the following protocol.
[0033] Samples of fertilizer granular products were produced comprised of core packet particles composed of a binder and compounds containing the desired nutrients with over-coatings of urea. For one exemplary example, for core packet particles, the binder is mono-ammonium phosphate (MAP) and/or corn syrup, and human nutrients are potassium iodide, zinc sulfate, iron sulfate and a vitamin-mineral composition.
[0034] The core packet particles were produced by granulating powdered nutrient compounds (and optionally other nutrient constituents) with the binder to form the core packet particles which were then screened to a specific size or range of sizes.
[0035] Alternatively, the particles of single powdered nutrient compound (or other nutrient constituent) were not granulated but were instead only screened to select a specific size or range of sizes to be the core packet particles.
[0036] Whether produced by granulation with subsequent screening or resulting from only screening, the core packet particles were over-coated with urea.
[0037] Industrial grade urea was melted and sprayed to overcoat the core packet particles. The urea over-coating drum was 20″ in diameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″ apart inside the drum to assist in forming a falling curtain during melt spray granulation. The same type of drum was used to make the core packet particles except that the drum contained no flights. The stainless steel granulation drum was mounted on a variable speed base.
[0038] Approximately 1 pound of core packet particles was placed inside the drum to form a falling curtain. The drum speed during granulation was 35-40 rpm. The sample fertilizer granules were produced by this process. After granulation, the granules were allowed to cool.
[0039] Product samples were made with the constituents and amounts shown in Table 2. The samples are designated by product number NP3-16. Note that these samples were all produced based on the volume of the final product granule. For exemplary purposes the desired final product size was a mean particle size of 2.80 mm. With this product size fixed the nutrient core size was adjusted to vary the iron, zinc, and iodine content. In examples employing iron, zinc or iodine, the compound was screened or granulated and then screened, and then the iron, zinc or iodine content was determined by volume of the nutrient core in relation to the final product size. This resulted in amounts of constituents in the sample compositions to be stated on a percent weight basis, estimated plus/minus 10-15%.
[0040] While the samples of the Examples were produced in this manner, on a full scale production basis the nutrient cores would be screened or granulated and then screened just as in the examples, but the cores would be metered in the process on a percent weight basis.
[0041] The following are examples, representative of making product samples.
Example 1. (Product NP-3, NP-4, and NP-5)
[0042] Samples were produced containing 1, 3, and 5% iron from iron sulfate core packet. Iron sulfate crystals were screened to a pre-determined size prior to being over-coated with urea. Sample NP-3 contained 5% iron was produced by screening the iron sulfate crystals to 1.7 to 2.0 mm. Sample NP-4 contained 3% iron was produced by screening the iron sulfate crystals to 1.4 to 1.7 mm. Sample NP-5 contained 1% iron was produced by screening the iron sulfate crystals to 1.0 to 1.2 mm.
[0043] Approximately 1 pound of each core material was placed inside the drum to form a falling curtain. The urea over-coating drum was 20″ in diameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″ apart inside the drum to assist in forming a falling curtain during melt spray granulation. The stainless steel granulation drum was mounted on a variable speed base. The drum speed during granulation was 35-40 rpm. Industrial grade urea was melted and sprayed to overcoat the core packet and produce a final product size of 2.8 mm.
Example 2. (NP-6)
[0044] A sample was produced containing 1% iron from an iron EDTA (ethylene diamine tetra acetic acid) core packet. Iron EDTA nutrient cores were produced by first granulating powdered iron EDTA with 6-7% corn syrup in a lab scale pan granulator. Sample NP-6 contained 1% iron that was produced by screening the granulated core to a particle size of 1.0 to 1.4 mm.
[0045] Approximately 1 pound of nutrient core material was placed inside the drum to form a falling curtain. The urea over-coating drum was 20″ in diameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″ apart inside the drum to assist in forming a falling curtain during melt spray granulation. The stainless steel granulation drum was mounted on a variable speed base. The drum speed during granulation was 35-40 rpm. Industrial grade urea was melted and sprayed to overcoat the core packet and produce a final product size of 2.8 mm.
Example 3. (NP-7)
[0046] A sample was produced containing 1% zinc from a zinc EDTA core packet. Zinc EDTA nutrient cores were produced by first granulating powdered zinc EDTA with 6-7% corn syrup in a lab scale pan granulator. Sample NP-7 contained 1% zinc that was produced by screening the granulated core to a particle size of 1.0 to 1.4 mm.
[0047] Approximately 1 pound of core material was placed inside the drum to form a falling curtain. The urea over-coating drum was 20″ in diameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″ apart inside the drum to assist in forming a falling curtain during melt spray granulation. The stainless steel granulation drum was mounted on a variable speed base. The drum speed during granulation was 35-40 rpm. Industrial grade urea was melted and sprayed to overcoat the core packet and produce a final product size of 2.8 mm.
Example 4. (NP-8, NP-9, and NP-10)
[0048] Samples were produced containing 1, 3, and 5% zinc from zinc sulfate core packet. Zinc sulfate nutrient cores were produced by first granulating powdered zinc sulfate with 6-7% corn syrup in a lab scale pan granulator. Sample NP-8 containing 5% zinc was produced by screening the granulated zinc sulfate to 1.4 to 1.7 mm. Sample NP-9 contained 3% zinc was produced by screening the granulated zinc sulfate to 1.2 to 1.4 mm. Sample NP-10 contained 5% zinc was produced by screening the granulated zinc sulfate to 0.7 to 1.0 mm.
[0049] Approximately 1 pound of each nutrient core material was placed inside the drum to form a falling curtain. The urea over-coating drum was 20″ in diameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″ apart inside the drum to assist in forming a falling curtain during melt spray granulation. The stainless steel granulation drum was mounted on a variable speed base. The drum speed during granulation was 35-40 rpm. Industrial grade urea was melted and sprayed to overcoat the core packet and produce a final product size of 2.8 mm.
Example 5. (NP-11, NP-12, and NP-13)
[0050] Samples were produced containing 1, 3, and 5% iodine from potassium iodide core packet. Potassium iodide crystals were screened to a pre-determined size prior to being over-coated with urea. Sample NP-11 contained 5% iodine was produced by screening the potassium iodide crystals to 1.0 to 1.2 mm. Sample NP-12 contained 3% iodine was produced by screening the potassium iodide crystals to 0.8 to 1.0 mm. Sample NP-13 contained 1% iodine was produced by screening the potassium iodide crystals to 0.6 to 0.7 mm.
[0051] Approximately 1 pound of each nutrient core material was placed inside the drum to form a falling curtain. The urea over-coating drum was 20″ in diameter, 5″ wide, 2″ deep, with forty-1″ lifting flights mounted 1½″ apart inside the drum to assist in forming a falling curtain during melt spray granulation. The stainless steel granulation drum was mounted on a variable speed base. The drum speed during granulation was 35-40 rpm. Industrial grade urea was melted and sprayed to overcoat the core packet and produce a final product size of 2.8 mm.
[0000]
TABLE 2
Product Examples of Nutrient Core Packet
Nutrient
Product #
Composition (%)
Nutrient Source
Product Compostion (%)
NP 7
1% Zn
Zinc EDTA
6.9% Zinc EDTA, 93.1% Urea
NP 10
1% Zn
Zinc Sulfate
2.8% Zinc Sulfate, 97.2% Urea
NP 9
3% Zn
Zinc Sulfate
8.5% Zinc Sulfate, 91.5% Urea
NP 8
5% Zn
Zinc Sulfate
14.1% Zinc Sulfate, 85.9% Urea
NP 6
1% Fe
Iron EDTA
7.5% Iron EDTA, 92.5% Urea
NP 5
1% Fe
Iron Sulfate
5.0% Iron Sulfate, 95% Urea+
NP 4
3% Fe
Iron Sulfate
10% Iron Sulfate, 90% Urea+
NP 3
5% Fe
Iron Sulfate
15% Iron Sulfate, 85% Urea+
NP 13
1% I
Potassium Iodide
1.3% Potassium Iodide, 98.7% Urea+
NP 12
3% I
Potassium Iodide
3.9% Potassium Iodide, 96.1% Urea+
NP 11
5% I
Potassium Iodide
6.5% Potassium Iodide, 93.5% Urea+
NP 14
1% Vitamin A
Gel Capsules
90% Urea, 1% Vitamin A, 9% Inert
NP 15
1% Zn, 1% Fe
Zinc Sulfate, Iron Sulfate
2.8% Zinc Sulfate, 5.0% Iron Sulfate, 92.2% Urea
NP 16
2% Zn, 2% Fe
Zinc Sulfate, Iron Sulfate
5.6% Zinc Sulfate, 10% Iron Sulfate, 84.4% Urea
Notes:
1) MAP—Monoammonium Phosphate
2) EDTA—ethylenediaminetetra acetic acid
3) Zn—Zinc
4) Fe—Iron
5) I—Iodine
6) B—Boron
7) N—Nitrogen
8) P—Phorphous
+Binder of Corn Syrup was employed to granulate core constitutents
Example 6. Zinc Uptake in Spinach Plants from Application of Fertilizer Containing Animal Nutrient Core Packet
[0052] In this example tests were performed to quantify the incorporation of zinc in a common spinach variety (Bloomsdale Long-Standing) employing compositions of the present invention. The tests quantified the increase in leaf zinc content due to application of compositions of the present invention containing zinc. The impact of the present compositions on spinach biomass increase was not the primary objective. In addition to applications of the present compositions to soil, for comparative purposes, foliar application of zinc solutions were applied to spinach leaves. Direct foliar applications provide an indication of potentially maximum amounts of zinc uptake into the leaves. A list of the sample products of the present application is shown in Table 2.
[0053] Materials and Methods
1. Soil
[0054] 8 kg Greenville loam (fine, kaolinitic, thermic Rhodic Kandiudults), pH=6.2, organic matter=1.4%, CEC=5.2 cmol kg −1 . The soil has been depleted of nutrients by previous cropping of tomatoes and cabbage.
2. Experimental Units
[0055] The spinach was grown in 8-kg pots. Each pot was transplanted with two spinach seedlings on Mar. 5, 2010.
3. Blanket Fertilizer Rates—Basal
[0056] All fertilizer materials were laboratory grade reagents to avoid contamination and antagonistic interaction with Zn, Fe and/or I.
[0057] Nitrogen: 250 mg N kg −1 or 2 g N pot −1 . All N was applied basally and incorporated into the top 10 cm of the soil.
[0058] Phosphorus: 100 mg P kg −1 or 0.8 g P pot −1 applied as monocalcium phosphate (all basal and incorporated into the entire 8 kg of soil).
[0059] Potassium: 415 mg K kg −1 or 3.3 g K pot −1 applied as potassium sulfate (all basal and incorporated into the entire 8 kg of soil).
[0060] Magnesium: 30 mg Mg kg −1 or 0.24 g Mg pot −1 applied as MgSO 4 .7H 2 O (all basal and incorporated into the entire 8 kg of soil).
[0061] Calcium: Monocalcium phosphate (MCP) applied for P.
[0062] Sulfer: From sulfate of potash (SOP) and MgSO 4 .
[0063] Micronutrients: As per treatment (see Table 3).
4. Basal Zn Fertilizer Rates
[0064] Zinc: 20 mg Zn kg −1 or 0.16 g Zn pot −1 applied as ZnSO 4 .7H 2 O solution on topsoil just prior to transplanting for three treatments only (Table 3).
5. Foliar Rates for Zn, Fe, I and Vitamin a
[0065] Foliar applications were used in treatments that have a foliar component as indicated in Table 3.
6. Experimental Design
[0066] Randomized complete block with 40 treatments and three replications for a total of 120 experimental units.
7. Crop Data Analysis
[0067] The fresh and dried weight of spinach leaves was determined and analyzed for N, P, K, Zn, Fe and I.
[0000]
TABLE 3
Treatment Description
Basal
Foliar
Treatment
Treatment
N Prod
SOP
MCP
MgSO 4
ZnSO 4
Zn
KI
Fe
Vit A
No.
Description
(g)
(ppm)
1
Urea + 5Zn
4.31
8
3.25
2.46
0.00
5
2
Urea + 10Zn
4.31
8
3.25
2.46
0.00
10
3
Urea + 20Zn
4.31
8
3.25
2.46
0.00
20
4
Urea + 40Zn
4.31
8
3.25
2.46
0.00
40
5
Urea + 60Zn
4.31
8
3.25
2.46
0.00
60
6
Urea + 10KI
4.31
8
3.25
2.46
0.00
10
7
Urea + 20KI
4.31
8
3.25
2.46
0.00
20
8
Urea + 30KI
4.31
8
3.25
2.46
0.00
30
9
Urea + 40KI
4.31
8
3.25
2.46
0.00
40
10
Urea + 100Fe
4.31
8
3.25
2.46
0.00
100
11
Urea + 300Fe
4.31
8
3.25
2.46
0.00
300
12
Urea + 100 Vit A
4.31
8
3.25
2.46
0.00
100
13
Urea + 200 Vit A
4.31
8
3.25
2.46
0.00
200
14
Urea
4.31
8
3.25
2.46
0.00
0
0
0
0
15
NP3
4.77
8
3.25
2.46
0.00
16
NP4
4.88
8
3.25
2.46
0.00
17
NP5
4.74
8
3.25
2.46
0.00
18
NP6
4.82
8
3.25
2.46
0.00
19
NP7
4.74
8
3.25
2.46
0.00
20
NP8
4.95
8
3.25
2.46
0.00
21
NP9
4.72
8
3.25
2.46
0.00
22
NP10
4.61
8
3.25
2.46
0.00
23
NP11
5.30
7.78
3.25
2.46
0.00
24
NP12
5.23
7.79
3.25
2.46
0.00
25
NP13
4.74
7.93
3.25
2.46
0.00
26
NP14
4.66
8.00
3.25
2.46
0.00
27
NP15
5.00
8.00
3.25
2.46
0.00
28
NP16
4.72
8.00
3.25
2.46
0.00
29
NP17 (void)
4.95
7.98
3.25
2.46
0.00
30
NP1 (void)
5.29
8.00
2.83
2.46
0.00
31
NP2 (void)
4.91
7.97
2.94
2.46
0.00
32
NP4 + FOL
4.88
8
3.25
2.46
0.00
12.62
33
NP6 + FOL
4.82
8
3.25
2.46
0.00
4.15
34
NP8 + FOL
4.95
8
3.25
2.46
0.00
19.11
35
NP9 + FOL
4.72
8
3.25
2.46
0.00
9.98
36
NP12 + FOL
5.23
7.79
3.25
2.46
0.00
34.87
37
NP13 + FOL
4.74
7.93
3.25
2.46
0.00
11.61
38
NP4 + 20 ppm Zn
4.88
8
3.25
2.46
0.70
39
NP12 + 20 ppm Zn
5.23
7.79
3.25
2.46
0.70
40
NP13 + 20 ppm Zn
4.74
7.93
3.25
2.46
0.70
Results and Discussion
Zinc Response on Spinach Dry Matter Production
[0068] With Fe seed-core we had a poor response to Fe application in terms of yield because The soil used for these tests had a sufficient amount of iron and thus did not require any application of Fe fertilization. The addition of the iron product samples resulted in too much iron and had a negative impact on the spinach plants. The amount of iodine in the iodine product samples were too high and had a negative impact on the spinach plants. The types and amounts of nutrients in the products of the present invention can be adjusted to supply the amount of nutrient within the range of increasing nutrients within the plant and less than the inhibitory amount of nutrient. This experiment was not planned to provide for such adjustment to initial soil nutrient content and spinach maximum tolerance to the nutrient.
[0069] The positive results of the present zinc sample applications with spinach (spinach enrichment with zinc) shows that the present nutrient core products supplies the needed nutrient to the crop when applied directly to the soil. The positive enrichment results of the zinc product samples with spinach are representative of the validity of the present approach and would reasonably have a similarly positive result using iron, iodine and other nutrients based on soil characteristics and crop plant requirements. Plants can be enriched with nutrient content (e.g. Zn content in spinach) employing the present nutrient core fertilizer products as long as application amounts do not have a negative impact on growth. Hence, there is no need to prove the nutrient core products for each individual nutrient.
[0070] Due to the negative impact of I and Fe, particularly at higher application rates, the results for Zn sample application presented in Table 4 are for treatments without Fe and I. All foliar Zn applications led to a significant increase in spinach dry matter production (Table 4). Soil application of Zn product samples was not as effective causing no significant (positive or negative) response on spinach dry matter production. However, the combination of soil application of product samples and foliar applications of iron, zinc or iodine (see Table 3, Treatments 32-37) resulted in increased dry matter production. The samples NP 4, NP 12, and NP 13 contained iron or iodine products used in Treatments 38-40 and did not have any Zn. Accordingly, 20 ppm Zn was applied to the soil (basal), but the iron and iodine apparently had the aforementioned negative effect.
[0071] Since the soil used for this experiment was not deficient in Zn for plant growth, it was expected that soil application of Zn product samples did not result in any significant response for dry matter production.
Zinc Fertilization Effect on Spinach Zn Concentration
[0072] There was a significant increase in the Zn concentration of spinach leaf with Zn application whether applied as foliar, soil applied product samples or the combination of soil and foliar applications (Table 4). The spinach leaf Zn concentration without any Zn application was 42 ppm. Standard Zn concentration for spinach leaf is about 40-45 ppm. Based on the leaf Zn concentration, the employed soil not Zn deficient, supplied an adequate amount of Zn for spinach growth.
[0000]
TABLE 4
Effect of Foliar and Soil Zn Application on Spinach Dry Matter
Production and Tissue Zn Content
Method of
Total Dry Matter
Zn Concentration
Treatment
Application
(g pot −1 )
(% increase)
(ppm)
(% increase)
0 ppm Zn
—
12.82
0
42.0
0
5 ppm Zn
Foliar
16.70
30.3*
121.5
189.4
10 ppm Zn
Foliar
15.17
18.3*
195.8
366.2
20 ppm Zn
Foliar
15.14
18.1*
403.2
860.1
40 ppm Zn
Foliar
15.19
18.5*
730.8
1,640.4
60 ppm Zn
Foliar
15.94
24.3*
1,067.3
2,441.9
NP7 (6.9% Zn EDTA)
Soil
11.2
−12.5
219.9
423.7
NP8 (14.1% ZnSO 4 )
Soil
12.74
−0.6
188.9
349.9
NP9 (8.5% ZnSO 4 )
Soil
12.09
−5.7
147.8
252.0
NP10 (2.8% ZnSO 4 )
Soil
13.06
1.9
98.4
134.4
NP8 + 19 ppm Zn
Soil + Foliar
13.98
9.0
429.3
922.5
NP9 + 10 ppm Zn
Soil + Foliar
14.47
12.9*
258.4
515.4
*Significant difference in spinach dry weight. All Zn-fertilized spinach plants had significantly higher tissue Zn concentration.
[0073] However, additional application of Zn (soil alone (product samples), foliar alone and combination of soil and foliar) resulted in Zn enrichment of the spinach, with spinach concentration at two to 25 times higher than the standard. For example, at 60 ppm Zn foliar application, the spinach tissue Zn concentration was 1,067 ppm compared to 42 ppm without any Zn application. Soil application of Zn with Zn product samples (NP 7-10) resulted in significant increases in tissue Zn concentration—from 2.3 to 5.2 times higher than with the control, zero amount Zn treatment. As the concentration of Zn applied as ZnSO 4 in the Zn product samples NP 10, 9, 8 increased (calculated as percent zinc: from 0.9% to 1.7% to 3.1%), the corresponding increase in leaf tissue Zn concentration was 98 ppm, 148 ppm and 189 ppm (Table 4). When the zinc product sample NP 7 having Zn as Zn EDTA (calculated as 0.8% zinc), was applied, a resulting plant tissue Zn concentration of 220 ppm was achieved. Zinc EDTA as the Zn source in the nutrient core for Zn product was more effective than ZnSO 4 in increasing Zn tissue content in spinach (Table 4).
[0074] None of the treatments with Zn application alone resulted in a significant decline in spinach dry matter. The high tissue Zn concentration resulting in this experiment was not at the expense of reduced dry matter production.
Effect of Zinc Application on Zinc Uptake by Spinach
[0075] The positive effect of Zn application as foliar, soil or combination is reflected in the higher Zn uptake by spinach in all treatments compared to the standard—0 ppm Zn treatment (Table 5). The results clearly show that a common spinach variety can accumulate Zn without any negative impact on dry matter production but with potential nutritional and health benefits to humans. The nutrient core Zn product was an effective Zn nutrient core fertilizer for soil application resulting in Zn enriched plants.
[0000]
TABLE 5
Effect of Zn Application as Foliar, on Soil or in Combination on Zn
Uptake by Spinach
Method of
Zn Uptake
Treatment
Application
(mg/pot)
0 ppm Zn
—
0.52
5 ppm Zn
Foliar
2.02
10 ppm Zn
Foliar
2.96
20 ppm Zn
Foliar
6.11
40 ppm Zn
Foliar
10.89
60 ppm Zn
Foliar
17.74
NP7 (6.9% Zn EDTA)
Soil
2.45
NP8 (14.1% ZnSO 4 )
Soil
2.33
NP9 (8.5% ZnSO 4 )
Soil
1.77
NP10 (2.8% ZnSO 4 )
Soil
1.25
NP8 + 19 ppm Zn
Soil + Foliar
5.98
NP9 + 10 ppm Zn
Soil + Foliar
3.65
NP15 (2.8% ZnSO 4 , 5% FeSO 4 )
Soil
1.28
[0076] Table 5 also shows that due to Fe toxicity in the NP15 product, it was possible to get a significantly higher Zn concentration, significantly lower dry matter and yet higher Zn uptake than with 0 ppm Zn treatment. However, such practice would not be commercially feasible (increased cost due to micronutrient and with lower yield).
CONCLUSIONS
[0077] The results from this study, summarized in Table 4, clearly show that both application of the Zn core nutrient fertilizer products and Zn foliar application resulted in Zn enrichment of spinach.
[0078] Application the Zn core nutrient fertilizer products and Zn foliar application resulted in a several-fold increase in Zn concentration in spinach leaf and increased uptake of Zn compared to the standard treatment (no Zn application), even though the soil was not Zn-deficient. Zn foliar applications resulted in higher spinach growth and higher Zn content than soil application. For leafy vegetables, the greater effectiveness with foliar application is expected. However, for cereals, the effectiveness of foliar application may not be as great due to greater losses (leaf contact), cost of application and translocation of Zn from leaves to grains. Zn EDTA was more effective than ZnSO 4 as a Zn source in soil applied Zn nutrient core product.
[0079] While only a few exemplary embodiments of this invention have been described in detail, those skilled in the art will recognize that there are many possible variations and modifications which may be made in the exemplary embodiments while yet retaining many of the novel and advantageous features of this invention. Accordingly, it is intended that the following claims cover all such modifications and variations.
|
A fertilizer supplying animal nutrients including a core particle having an outer surface and comprising compounds containing animal nutrients, and a coating of urea on the outer surface of the core particle, and further a process of making the fertilizer including the steps of: screening animal nutrient core particles comprising a powdered substance containing an animal nutrient, to a preselected particle size; spraying melted urea onto the surface of the nutrient core particles to produce a coating on the nutrient core particles; granulating the nutrient core particles with sprayed melted urea to produce nutrient core granules; and cooling the nutrient core granules.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is generally related to floating structures offshore for oil and gas production and, more particularly, to a riser keel joint assembly for such structures.
2. General Background
All floating systems used by the Oil and Gas Industry to recover hydrocarbons from seafloor sites in offshore waters have risers of some type connecting the well termination at the seafloor to the floating system at the surface. One particular type of riser, the independently supported, top-tensioned riser, extends vertically from the seafloor to the floating system and is directly supported either by buoyancy modules (cans) or other means (e.g., tensioners) that can support the weight of the riser and accommodate the relative movement between that riser and the floating platform when the platform responds to metocean environments. This type of riser has been used by both Spar platforms and Tension Leg Platforms. Where the platform hull is a mono-column-or these risers pass close by the hull structure, some kind of special section of riser is required at the keel of the hull to accommodate the bending loads where the riser leaves the support of the platform and this section also has to accommodate the relative vertical movement between the riser and the hull.
The special riser joint at the keel of the hull and which is addressed by this invention is commonly referred to as the Keel Joint. This section is reinforced to carry the bending loads imposed on the riser by the pitch/heel motions of the hull relative to the riser as well as the bearing and wear loads imposed on the riser by the vertical and lateral motions of the hull relative to the riser.
The functions of a keel joint are straightforward and include:
Reinforcing the bending capacity of the riser by a significant amount so it can have adequate strength and adequate fatigue life (lower stress ranges).
Permitting the riser pipe to curve compliantly as the hull keel moves horizontally relative to the fixed end of the riser at the seafloor.
Bearing on the guides in the hull both to transfer the load to the hull through the keel joint outer surface, instead of through the riser pipe itself, and to incur the wear from friction forces as the riser slides axially against the guides in the hull.
There are several versions of keel joints in the known art.
One type has a larger diameter sleeve, centralized around the riser pipe and attached directly to it with rubber spacers at each end which are vulcanized to both the riser and the sleeve in the annular space. This type of joint supports the riser at the two locations of the rubber and delivers the lateral load from these two locations through the sleeve to the guide locations(s). The rubber provides the flexibility for the riser itself to rotate. In this version, the keel joint is an integral part of the riser string itself.
Another type has the riser in a sleeve similar to the above type but the sleeve is attached to the riser by bolting at each end. For this purpose, the riser is fabricated with machined bumps and flanges at each end both to attach to the sleeve and to the continuing sections of riser at each end. Riser rotation is limited by the flexibility of the sleeve and the riser pipe itself beyond either end of the sleeve resulting in a rather stiff system in bending.
Another type has the riser centralized in a larger diameter pipe called a stem. The stem is suspended directly from the buoyancy module at the top of the riser. The stem performs the same function as the sleeve in the aforementioned example but in this version the riser is not connected to the stem but only centralized within it using a ball type centralizer that allows the riser to pivot and curve relative to the stem.
SUMMARY OF THE INVENTION
The invention addresses the needs in the known art. What is provided is a tapered riser joint that is connected to a larger diameter outer sleeve through a connection that allows the tapered section and outer sleeve to function as one unit. Working as one unit, fewer and smaller parts are required than when similar pieces are configured to function separately. In the combined design, the outer sleeve provides the required sliding interface between the riser and the guide at the keel of the hull while also providing some of the bending compliance needed to transition from the riser supported in the hull to the riser unsupported below the hull. Also in this design, the tapered section provides the remaining bending compliance needed for the transition.
The connection between the tapered and sleeve sections is a forged, machined ring plate welded to the bottom end of the sleeve which provides a base for either bolted or threaded type attachment points for the tapered riser joint below the ring plate and the internal riser joint that continues to the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention reference should be made to the following description, taken in conjunction with the accompanying drawings in which like parts are given like reference numerals, and wherein:
FIG. 1 is an elevation view that illustrates the preferred embodiment of the installed invention.
FIG. 2 is a detailed view of the circled area indicated by the number 2 in FIG. 1 .
FIG. 3 is an alternate embodiment of the circled area indicated by the number 2 in FIG. 1 .
FIG. 4 is an elevation view of an alternate embodiment of the invention.
FIG. 5 is a detailed view of the circle area indicated by the number 5 in FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, it is seen in FIG. 1 that the invention is generally indicated by the numeral 10 . The riser keel joint assembly 10 is generally comprised of a single tapered riser joint 12 , a sleeve 14 , and an internal riser joint 16 installed on a floating offshore structure 11 .
Tapered riser joint 12 is connected to the sleeve 14 and internal riser joint 16 at a connecting flange 18 .
The internal riser joint 16 may be formed from one or more riser joints, depending upon the length of riser required relative to the sleeve 14 . When a second internal riser joint 15 is required, a mechanical joint 17 is used to connect the joints 15 and 16 . The sleeve 14 may also be extended through the use of a mechanical connector 19 when its total length is over the drilling rig length handling limitations during riser installation. The internal riser joint 16 / 15 is provided with a centralizer 20 near the upper end of sleeve 14 . Mechanical joints and centralizers are generally known in the industry. The sleeve 14 is laterally supported by guides 13 at two elevations in the keel region of the offshore structure 11 so the guides 13 develop a moment resisting couple acting on the sleeve 14 .
FIG. 2 illustrates the details of the preferred connecting flange 18 . A threaded flange 22 is rigidly attached to sleeve 14 by any suitable means such as welding. Flange 22 has a central, threaded bore that is sized to receive the threaded end 24 of internal riser joint 16 . Flange 22 is also provided with threaded bores 26 which receive pre-tension bolts 28 when attaching tapered riser joint 12 to the flange 22 . Nuts 30 on the pre-tension bolts 28 secure the tapered riser joint 12 in place. Tapered riser joint 12 is provided with a suitable flange 23 such as an API 6A flange at the upper end to accomplish the connection. A gasket 32 is inserted between the flanges to maintain the internal pressure and seal at the connection of the two risers. The gasket 32 is preferably a pressure energized ring gasket. The tapered profile of threaded flange 22 provides the welding access to the outer sleeve 14 . The overall shop assembly length, including the tapered riser joint 12 and sleeve 14 is determined by the rig installation capacity. The internal riser joint 16 is readily installed in the sleeve 14 at the offshore location of the structure 11 due to the threaded connection on flange 22 . The API 6A flange 23 and tapered riser 12 may be machined from one forged piece. However, welding a standard API 6A flange to the tapered riser joint 12 is more economically efficient. The tapered riser joint 12 and the lower part of the sleeve 14 may be pre-assembled to the flange 22 in the shop while the rest of the parts are installed at the offshore site using a drilling rig.
FIG. 3 illustrates an alternate embodiment of the connecting flange 18 arrangement. In this embodiment, the threaded end 24 of the internal riser joint 16 is replaced with an API 6A flange 34 which has the same dimension and profile as the flange 23 on the tapered riser joint 12 . This allows easy matching and bolting of both flanges 23 and 34 to threaded flange 22 . Each flange 23 , 34 is provided with a gasket 32 as described above. Threaded flange 22 provides the same function as an attachment point for the tapered riser joint 12 , internal riser joint 16 , and sleeve 14 . In this embodiment the internal riser joint 16 is pre-assembled in the shop rather than installed offshore. This embodiment has the same function and mechanical behaviors as the embodiment of FIG. 2 .
FIG. 4 and 5 illustrate an alternate embodiment of the invention that uses a compliant ball mechanism 36 between the riser joints and the sleeve 14 . A thick wall dual tapered riser section 38 with a keel ball 40 attached is received in ball socket 42 . The compliant ball mechanism is preferably moved up from the lower end of the sleeve 14 . The ball socket 42 is formed by clamping together the two halves using pre-tension bolts and then rigidly attaching the mechanism to the sleeve 14 by any suitable method such as welding. The smooth contact between keel ball 40 and ball socket 42 allows for the desired relative rotation between the riser 38 and the sleeve 14 . The internal riser and sleeve below the compliant ball mechanism are pre-assembled in the shop before transfer to the offshore installation. This embodiment provides more flexibility than the embodiment of FIG. 1 and 2 .
The bottom of the sleeve 14 is preferably positioned approximately twenty feet below the bottom of the keel of the offshore structure 11 . As seen from the description and drawings, the connection between the sleeve and riser causes them to act as one unit moving up and down in the keel of the offshore structure as the riser moves up and down relative to the structure in response to the environmental motions of the structure. The invention provides a flexible mechanical assembly with adequate strength and friendly fatigue resistant details for high stroke demand top-tensioned riser arrangements.
The invention provides numerous advantages over the known art.
The arrangement of the invention provides a flexible mechanical assembly with adequate strength and friendly fatigue resistant details for a high stroke demand top-tensioned riser arrangement.
A problem solved by the invention is to provide a compliant assembly to accommodate the relative pitch and stroke between the riser system and hull structure. This is accomplished by adding a tapered riser joint to the lower part of a long piece of outer sleeve bushing in the hull keel structure. It should be understood that the position of the bottom end sleeve below the hull keel structure is important for this invention and this is controlled by the length of the sleeve that is used. The result is an extension of the fatigue life of the system by providing sufficient flexibility in the keel joint assembly in a manner that is lower in cost than the prior art.
Another problem solved by the invention is to provide three types of mechanical interfaces as an attachment point for the lower tapered riser joint and upper riser joint inside the sleeve to the stem sleeve. The interface can be either rigid moment connection or ball type pin connection. This configuration has a wide application from relatively shallow water to ultra-deep water.
The invention provides a significant reduction in the time, cost, and risk offshore to install the can and keel joint system. By adding a sliding keel sleeve to the riser system at the keel region instead of the conventional way of adding a long stem hanging from the buoyancy can, the suspended load on the buoyancy can is lessened and the can does not have to be attached to the sleeve in the field.
Another advantage is that the sliding keel sleeve can be run using a drilling rig in the normal course of running the risers. The overall length of the keel joint assembly of the invention is approximately ninety feet. However, the pre-assembled length of each joint is not more than sixty feet, which is less than the general installation joint length limits of the drilling rig. A mechanical connector is used to make up the two lengths of sleeve that constitute the full joint. Therefore, no special installation equipment is required to install the keel joint assembly of the invention.
Another advantage is that a large stroke is allowed in this invention. The total stroke can reach to a large magnitude up to sixty feet. This amount of stroke covers a wide stroke range of the Spar top-tensioned riser from 2,000 to 10,000 foot water depth.
Another advantage is that the preferred embodiment of the invention has only a single tapered riser joint. Compared to the conventional design of a dual tapered riser joint, it cuts the length and volume of the forged, machined, tapered pieces by half. Significant material and machining work is reduced.
Another advantage is that the invention maximizes the utilization of the standard API 6A connectors and profiles. This off-the-shelf flange technology minimizes the application risk while simplifying the design and testing procedures required.
As in all keel joints, the maximum bending moment occurs when the offshore structure is in its maximum laterally offset position because this is also the time when the points of load transfer between the riser and the keel joint are at the maximum distance below the keel guide, thus creating the largest distance between the lateral force and the guides resisting the lateral force (the largest bending moment in the keel joint). In this invention, when the riser is in this maximum downward position, the keel joint sleeve is at its most flexible and thus best able to draw bending moment away from the riser pipe itself. When the keel is minimally offset, the keel joint sleeve is at its stiffest position but the bending moments on the riser are the smallest so this stiffness is acceptable.
The invention introduces:
elimination of the need for a stem section from the keel to the buoyancy can. Normally, this means two hundred fifty to three hundred feet of stem is eliminated on each riser.
elimination of the weight of these long stem sections on the buoyancy cans.
two levels of guides to provide moment resistance for the sleeve section.
joint construction almost entirely from off-the-shelf items.
a simple bolted connection using standard flanges that can be readily made up in the field.
elimination of the special tapered, heavy wall section of riser above the riser-sleeve connection (the section of riser inside the sleeve).
Because many varying and differing embodiments may be made within the scope of the inventive concept herein taught and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
|
A riser joint keel assembly. A tapered riser joint is connected to a larger diameter outer sleeve through a connection that allows the tapered section and outer sleeve to function as one unit. In the combined design, the outer sleeve provides the required sliding interface between the riser and the guide at the keel of the hull while also providing some of the bending compliance needed to transition from the riser supported in the hull to the riser unsupported below the hull. The tapered section also provides the remaining bending compliance needed for the transition. The connection between the tapered and sleeve sections is a forged, machined ring plate welded to the bottom end of the sleeve, which provides a base for either bolted or threaded type attachment points for the tapered riser joint below the ring plate and the internal riser joint that continues to the surface.
| 4
|
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention pertains to methods and apparatus for underwater communication and, more particularly, to the transmission of acoustic vibrations to the cochlea through a tooth of a diver.
2. Discussion of the Prior Art
Communication among divers and between divers and surface support personnel is essential to the efficiency and safety of virtually all undersea operations. Elaborate systems of hand signals have been used where light and distance permits but the range of utility is small. Coded pulses offer more range but are inadequately slow and distracting. One approach to voice communication has been developed that transmits mechanically generated acoustic sound energy directly through the water to intended receivers. A second approach has been to use electronics to transfer signals, by direct wire through ultrasonics or electromagnetic radiation.
Mechanical systems of underwater voice communication must provide an impedance match between the acoustic energy of the speaker's voice and the acoustic energy generated in the water for sound transmission, as described for example, by U.S. Pat. No. 4,071,110 (Payne). The unamplified range of such devices is limited and both the comfort of the diver and the intelligibility of the communication are compromised by the requirement that a bit or rigid mouthpiece, for instance a metal rod, be gripped or clenched tightly by the teeth of the diver in order to properly transmit and receive audio signals.
Existing electronic underwater communications systems require that both the ears and mouth are surrounded by air. The bulkiness of the air-conduction earphones and the distortion resulting from the interaction of underwater pressure on the air column in the outer human ear have hindered the usefulness and acceptance of these devices.
An alternative approach, imparting vibrations to the skull for osseus transmission through the skull bones to the cochlea, and hence as signals via the auditory nerve to the brain, is exemplified by U.S. Pat. No. 5,033,999 (Mersky). That bone conduction device uses the teeth as the input site into the skull. Such tooth related devices have not been intended or adapted for use with an underwater breathing apparatus, however, instead having focused on the advantage of repeatable skull coupling to achieve better speech intelligibility, comfort and improved cosmetics. The issues inherent to maintaining an efficient and effective vibration-transmitting engagement between the tooth and the vibration input device without placing unacceptably distracting demands on the diver while simultaneously permitting intelligible articulation despite the intrusion of breathing support apparatus has not been addressed.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and apparatus that overcomes the above mentioned shortcomings and disadvantages of the prior art by providing for underwater communication reception transmitted through tooth and bone structure.
It is another object of the present invention to provide a method and apparatus for efficiently transmitting sound-associated vibrations to the ear of a diver via bone structure without interfering with the ability to clearly and intelligibly articulate words.
A further object of the present invention is to provide a method and apparatus for providing a comfortable yet efficient selectively adjustable vibration-transmitting engagement between a tooth of a diver and a vibration-imparting transducer.
It is also an object of the present invention to provide an electrical connector plug for interchangeably interfacing externally-mounted underwater sound receiver-transmitter and signal processing components with microphone and vibration-imparting transducer components housed within the mouthpiece of a diver.
Some of the advantages of the present invention over the prior art are that an underwater diver can enjoy hands free selectively controllable voice communication, clearly and intelligibly perceived without significant interference with the ability to enunciate and without the inconvenience and discomfort of earplugs or earphones. The device and method of the present invention are well suited to compact configuration, modular interchangeability and inexpensive manufacture.
In accordance with one aspect of the present invention, a transducer for imparting low amplitude vibrations in the audible frequency range is mounted in the mouthpiece of the breathing apparatus of an underwater diver. The transducer is held in adjustable vibration-transmitting engagement with a maxillary tooth by the muscle control of the lips, tongue and bite of the diver. These vibrations are transfered from the teeth via bone structures to the ear of the diver to be perceived as intelligible sound. A microphone mounted externally of the mouth but within the air chamber of the mouthpiece converts spoken communication of the diver into electrical signals transmitted through the connector plug to external processor and transmission means.
In an alternative embodiment of the invention, the vibration-transmitting transducer is embedded in a bite plane of the mouthpiece and the engagement force between the teeth and the transducer is selectively controlled by the bite pressure exerted by the diver.
These and other objects, features and many of the attendant advantages of the present invention will be appreciated more readily as they become better understood from the reading of the following description considered in connection with the accompanying drawings wherein like parts in each of the several figures are identified by the same reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a diver wearing goggles and an underwater breathing device incorporating a mouthpiece constructed according to the present invention.
FIG. 2 is a top view in plan and partial section of the mouthpiece of the present invention.
FIG. 3 is a side elevation view in section of the mouthpiece of the present invention shown in the mouth of a diver.
FIG. 4 is an electrical schematic diagram of the communication system of the present invention.
FIG. 5 is an exploded side view of the connector arrangement of the present invention.
FIG. 6 is a view in elevation and partial section of a magnetostrictive transducer that can be employed in the present invention.
FIG. 7 is a side elevation view in section of a transducer of the present invention embedded in a mouthpiece bite plate shown in the mouth of a diver.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A scuba diver 10 is shown in FIG. 1 wearing a facemask assembly 12 comprising goggles 14 held against the face of the diver by elastic straps 15. A mouthpiece 16 is adapted to supply the diver with oxygen and remove carbon dioxide through hoses 18 communicating with pressure tanks 19 and one or more regulator valves, not shown. The mouthpiece 16 is described herein with terms such as "vertical" and "horizontal" with reference to the mouthpiece oriented in the mouth of a diver whose head is in an upright position. The mouthpiece includes an outer, labial flange 24 aligned generally vertically and extending arcuately on each side of the mouth to reside in the labial space between the teeth and lips or cheek of the diver, as shown in FIG. 2. Projecting inwardly from the inner side of labial flange 24 toward the tongue or lingual side of the mouth along the occlusal plane are left and right horizontal bite plates 20 and 21, respectively, arranged to be engaged between the diver's upper, or maxillary, and lower, or mandibular, teeth. The inner edges of bite plates 20 and 21 terminate in vertical lips 22 and 23, respectively, positioned to reside adjacent the interior surfaces of the engaging teeth. Centrally located between bite plates 20 and 21, the forward portion of labial flange 24 has an air passageway, or through hole 26, defined therein. The outside surface of the forward portion of flange 24 has a forwardly-extending air tube 28 of generally oval cross-section. The lips of the diver sealingly encircle air tube 28, simultaneously exerting rearward pressure on flange 24 urging it against the teeth and gums. The interior of air tube 28 defines a forward extension of passage 26.
A transducer 30 is mounted on the inner side of flange 24 above air passageway 26 in a position adjacent the buccolabial or outward non-bearing surface of at least one of the diver's maxillary incisors 29 as shown in FIG. 3. Acoustic communication signals transmitted through the water, as represented schematically in FIG. 4, are collected by a receiver or receiver-transmitter 31, for example, a hydrophone, converted into audio driver signals by amplifier-processor 32, energized by power source 33 and conducted to transducer 30 via leads 34, connector plug 36 and conductors 38.
Connector plug 36, shown in detail in FIG. 5, comprises an internally threaded cylinder 40 water-tightly cemented into a circular hole 41 defined transversely through one side of air tube 28. An externally threaded female connector 42 is received and engaged within the cylinder, and a male connector 44 is received and engagable in a friction fit within female connector 42. Male connector 44 is attached to leads 34 from the signal processor, and female connector 42 is attached to transducer 30 by conductors 38. An 0-ring 45 encircles male connector 44 and forms a watertight seal between the mated male connector 44 and female connector 42. The male and female connectors 44 and 42, respectively, are of conventional design. The connector configuration of connector plug 36 provides a convenient and effective interface for selectively attaching alternative or modular components to the communication system of the present invention.
The audio driver signals generated by amplifier-processor 32 are converted by transducer 30 into sound-associated vibrations imparted to the tooth and transmitted via bone structure to the cochlea for conversion to electrical signals carried by the auditory nerve to the brain of the swimmer and perceived as sound. Transducer 30 is urged into vibration-transmitting engagement with the adjacent incisor by the diver's oro-facial muscles acting against the outer surface of mouthpiece flange 24 and by the compressive force of the diver's bite against bite plates 20 and 21 flexing and drawing flange 24 inward.
In the preferred embodiment, transducer 30 transmits low amplitude vibrations through the changes in length of a highly magnetostrictive rod. These dimensional changes are induced by cyclical magnetic field fluctuations applied in response to variable amplitude input driver signals. Described in detail in U.S. patent application Ser. No. 08/111,527 (Mersky et al), incorporated herein by reference, a magnetostrictive transducer 35 compatible with the present invention is shown in FIG. 6. Transducer 35 includes a magnetically permeable open cylindrical housing 80 externally threaded on one end to engage internally threaded end cap 82, cup-like in configuration and having a central aperture 84. A flanged, circular vibration coupler, or activator 86, extends through aperture 84 and is supported at top and bottom by disc-shaped permanent magnets 88 and 90, respectively. The magnets transmit vibrations resulting from the change in length of an axially disposed rod 92 of magnetostrictive material, for example Terfenol-D, surrounded within housing 80 by a tightly wound coil 94 of insulated conductor. Rod 92 changes length in response to varying magnetic field strengths generated by coil 94 and driven at sound-related frequencies by an external signal driver via conductors 38.
The axis of vibration for each of these transducer embodiments is generally normal to the long axis of the tooth. The transducer is held in contact with the tooth by the urging of the lips, tongue and bite of the diver against the mouthpiece 16.
A conventional non-floodable microphone transducer 108 may be mounted in the air passageway 26 of the mouthpiece 16 external to the lips and mouth of the diver as shown in FIGS. 2 and 3. Transducer 108 is connected through female connector 42 and connector plug 36 to external amplifier power, signal processing and transmission means, as shown in FIG. 4, and allows the present invention to be used for two-way communication. The non-bearing surface placement of transducer 30 permits relatively unimpeded lip, tongue and tooth movement to support clear and intelligible articulation for spoken communication.
In an alternative embodiment transducer 30 is embedded in an occlusal bite plate 20 or 21, of the mouthpiece 116, shown in FIG. 7. Vibration-transmitting engagement is made between the transducer 30 and the bearing or occlusal surface 112 of canine or premolar teeth 114 by the voluntary and selectively controllable force exerted by the diver in clenching the bite plate between the teeth of the opposing upper and lower arches. Although some loss of word-forming flexibility attends the requirement of bearingly gripping the bite plate with the wearer's teeth, the selectable force exerted allows the diver to control the level of vibration transmission and hence the quality and amplitude of received communication. Moreover, the grip on the bite plate ideally held in generally rigid engagement by the bite of the diver during reception to assure distinct vibration-transmitting engagement with the receptor tooth, can be relaxed during transmission, at the expense of reception, of course, to facilitate word-forming.
In use the diver selects a mouthpiece according to the present invention having the type and location of vibration-imparting, transducer of choice, and attaches a selected suite of external components, (i.e., transmitter-receiver, an antenna, a signal processor and a power source) through the connector plug interface. The diver can selectively adjust the force applied between the transducer and receptor tooth to accommodate changes in diving conditions. Moreover the muscle urging of the mouthpiece against the tooth can be relaxed periodically, especially during periods of minimum communication demands, to avoid muscle fatigue. Signals transmitted through the water are received and transformed into electrical driver signals by conventional means, then transferred to the vibration-imparting transducer and converted into low amplitude vibrations that transmit through the tooth, jaw and skull bones to the cochlea. The cochlea transforms incident vibrations into electrical signals carried by the auditory nerve to the brain for perception as sound and speech. As necessary the diver can speak into a microphone mounted in the air tube forward of and outside the teeth. The microphone transducer transforms input vibrations transmitted as sound through the air in the mouthpiece or, alternatively, as vibrations through the mouthpiece structure, into electrical signals which can be amplified and transferred to conventional broadcast means to complete the interactive cycle of communication.
At any time the diver can relax the force exerted between the transducer and the tooth to vary the efficiency of the vibration-transmitting engagement and correspondingly change the perceived sound level. Similarly, relaxation of the mouthpiece may reduce the pressure-sensitivity of the microphone.
The present invention presents several advantages over prior art underwater communication devices. Osseus transmission of sound avoids the frequently encountered auditory problems associated with diving pressures. The awkward and uncomfortable aspects of either earphones or earplugs are avoided and a significant amount of hands-free control is provided in the volume of sound received, allowing the diver to detach himself from interference, static or unwanted communication by reducing the voluntary force applied between the transducer and the tooth. Moreover, the unique connector plug supports a quickly reconfigurable modular communication system, and the inexpensive manufacture of the mouthpiece permits affordable customization of the fit and location of the transducer to optimize "sound" perception. The collocation of both vocalization and auditory perception permits the development of consolidated compact communication apparatus.
Having described preferred embodiments of a new and improved method and apparatus for transmitting clearly intelligible underwater voice communication through one or more teeth of a diver in accordance with the present invention, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings sets forth herein and that all such variations, modifications and changes fall within the scope of the present invention. It is therefore to be understood that the subject matter discussed above and illustrated in the accompanying drawings are illustrative and not limiting.
|
Waterborne acoustic signals are received and processed into electrical driver signals to energize a transducer held in selectively controllable vibration-transmitting engagement with a tooth of an underwater diver. The transducer converts the electrical signals into low amplitude sound-associated vibrations imparted to the tooth, through the jawbone and scull to the cochlea for processing into electrical signals carried to the brain and perceived as intelligible sound. The addition of conventional broadcast means permits two-way underwater communication. The transducer can be labially or occlusively mounted, preferably against an upper or maxillary tooth and the force of engagement between the transducer and the tooth is at least partially controlled by the diver to optimize communication characteristics.
| 7
|
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention relates to single-crystal diamond substrates having a large area, and methods for producing such substrates.
[0003] (2) Description of the Related Art
[0004] Diamond, which exhibits outstanding properties as a semiconductor, is a promising material for use in semiconductor devices, such as high-output power devices, high-frequency devices, light-receiving devices, etc. In particular, in order to realize the practical use of diamond as a semiconductor material, wafers of single-crystal diamond having a large area and uniform quality are required.
[0005] Typical methods for growing single-crystal diamond heretofore used include a high-pressure synthesis method and a vapor-phase synthesis method. Of these methods, the high-pressure synthesis method can produce substrates with an area of only up to about 1×1 cm, and cannot be expected to produce single-crystal substrates with a larger area. Furthermore, single-crystal diamond substrates with an area of about 5×5 mm or more are not readily available, nor is it easy to increase the substrate area of these substrates.
[0006] For this reason, a method for producing a so-called mosaic diamond has been developed to prepare a single-crystal diamond with a large area. This method involves growing diamond crystals by a vapor-phase method on a plurality of diamond crystals aligned on a support surface, and bonding the aligned diamond crystals, thereby producing a large diamond crystal (see Meguro, Nishibayashi, and Imai, SEI Technical Review 163, 53 (2003)).
[0007] In the known production method of a mosaic diamond, only single-crystal diamond substrates are used, or single-crystal diamond substrates are used together with polycrystal diamonds or other material(s), as the substrates to be bonded. In either case, these diamond substrates are bonded by growing a diamond thereon by a vapor-phase method.
[0008] Among these methods, as one example of a method for producing a large single-crystal diamond by using only single-crystal diamond substrates, and bonding these substrates, a method for producing a large diamond crystal has been reported, in which the spacing and differences in height among the single-crystal diamond substrates to be bonded are adjusted to be within predetermined ranges, and a diamond crystal layer is grown on these substrates by a vapor-phase method, thereby suppressing the growth of non-epitaxial crystallites along the boundary between substrates (see Japanese Unexamined Patent Publication No. 7-48198).
[0009] Another method has been proposed in which diamond substrates having suitable off-angles and off-directions are selected and aligned; subsequently, diamond crystals are grown by a vapor-phase synthesis method preferentially in the direction of adjacent single crystals to promote bonding (see Japanese Unexamined Patent Publication No. 2006-306701).
[0010] Also known are a method in which cleaved faces are used as the side faces to be bonded, and a method in which the side faces to be bonded are angled (see Japanese Examined Patent Publication No. 6-53638 and EP 0687747 A1).
[0011] It is noted that methods for growing single-crystal diamond on diamond substrates by homoepitaxial growth using a vapor-phase synthesis method are applied to, for example, the synthesis of semiconductor-grade, high-quality diamond. However, during epitaxial growth of diamond by a vapor-phase synthesis method, many defects such as non-epitaxial crystallites and hillocks tend to occur, making the synthesis of a large single-crystal diamond difficult.
[0012] The formation of these defects strongly depends on the off-angle and off-direction of the substrate surface on which a diamond is grown. It has been reported that even a change of 1° in the off-angle and off-direction of this substrate surface will alter the properties of the growth layer (see, e.g., H. Okushi, Diamond and Related Materials 10 (2001), 281-288; and O. Maida, H. Miyatake, T. Teraji, and T. Ito, Diamond and Related Materials 17 (2008), 435-439.). The off-angle and off-direction dependencies also vary according to the synthesis conditions. Thus, the properties of the growth layers do not become uniform, unless the synthesis conditions are adjusted according to the off-angle and off-direction of each substrate during the growth of single-crystal diamond on substrates having different off-angles and off-directions.
[0013] Defects on the substrate surface are also continued in the growth layer, and the positions of these defects cannot be controlled for each substrate. Therefore, the presence of these defects is one hindrance to achieving uniform growth layer properties. Furthermore, it is known that the properties of a growth layer are also affected by strains present in the substrate prior to growth (see P. S. Weiser and S. Prawer, K. W. Nugent, A. A. Bettiol, L. I. Kostidis, D. N. Jamieson, Diamond and Related Materials 5 (1996), 272-275.).
[0014] Generally, in methods for preparing mosaic diamonds by growing diamond crystals on a plurality of diamond crystals by a vapor-phase method, the threshold at which the off-angles of diamond substrates to be bonded are considered to be identical is 1° or more at a minimum. However, even a difference of 1° in off-angle will result in variations in the qualities of growth layers under identical conditions. On the mosaic substrate bonded by this method, a single-crystal layer having a different quality according to each crystal region of the bonded single crystals will grow. Similar problems also arise in the method described above, wherein substrates with different off-angles and off-directions are positively used and bonded with one another to produce a mosaic substrate (see Japanese Unexamined Patent Publication No. 2006-306701).
[0015] As stated previously, in homoepitaxial growth on diamond substrates using a vapor-phase synthesis method, the growth layer is affected not only by the off-angle, but also by the off-direction and substrate properties such as strains and defects in the substrate. Nevertheless, none of the previously known methods for producing mosaic substrates have proposed an effective solution to make the properties of substrates to be bonded uniform.
[0016] Furthermore, when diamond is used as a material for semiconductor devices, impurities are intentionally doped into the growth diamond on substrates (diamond wafers). It is known that the amount of the impurities doped into the growth layer, as well as the resulting change in crystallinity, will depend on the substrate properties (see K. Arima, H. Miyatake, T. Teraji, and T. Ito, Journal of Crystal Growth 309 (2007), 145-152.). Therefore, if large diamond wafers obtained using any of the above-mentioned methods do not have a uniform off-angle, off-direction, strain distribution, defect distribution, etc., it is expected that the devices prepared thereon will also exhibit non-uniform properties. Therefore, the use of these mosaic wafers with non-uniform properties will obviously result in an extremely low yield of devices that can withstand practical use. Further, because mosaic diamond substrates must be strong enough to withstand processing for device preparation, it is sometimes necessary to additionally grow a single-crystal diamond onto the bonded substrates. If the single-crystal diamonds used as the substrates to be bonded have different properties, it will be difficult to uniformly grow the single-crystal diamond on the bonded substrates.
[0017] Furthermore, as mentioned above, it is difficult to obtain a desired number of crystals whose substrate properties are uniform. For example, the preparation of diamond substrates that meet predetermined requirements by processing a single-crystal diamond requires a great deal of time, because processing of the diamond crystal is very difficult; moreover, the preparation of a precisely processed single-crystal diamond substrate is difficult. In particular, it is impossible to impart specific strain and defect distributions to a given substrate.
[0018] For reasons as stated above, despite their high demand, single-crystal diamond substrates with a large area that can withstand practical use are not available yet.
SUMMARY OF THE INVENTION
[0019] The present invention has been accomplished in view of the above-mentioned state of the prior art. A principal object of the invention is to provide methods for producing single-crystal diamond substrates with a large area by bonding a plurality of single-crystal diamond substrates having uniform properties, which enable large mosaic single-crystal diamonds of good quality to be produced relatively easily.
[0020] The inventors conducted extensive research to achieve the above-mentioned object, and consequently arrived at the following finding.
[0021] First, a single-crystal diamond is used as a parent substrate, and a non-diamond layer is formed near the surface of the diamond by ion implantation, allowing a surface portion to be easily separated from the non-diamond layer (the separated diamond layer is hereinafter sometimes referred to as the “child substrate” or “child substrate layer”). By using in this step the ion implantation and etching method described below, the off-angle and crystal direction of the parent substrate can be maintained in the child substrate. Thus, the face of the child substrate layer where it is separated from the parent substrate has a crystal off-angle and crystal direction identical to those of the parent substrate, and has strain and defect distributions identical to those of the parent substrate. By separating a plurality of diamond layers from the identical parent substrate by repeating this procedure, it is possible to easily prepare a plurality of child substrates having a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc.
[0022] When the thus-obtained single-crystal diamonds (child substrates) have a substantially identical thickness, they may be arranged in a mosaic pattern on a flat support such that their faces separated from the parent substrate face up. In this case, all of the single-crystal diamonds constituting a mosaic maintain, on the top faces thereof, the off-angle, crystal direction, strain and defect distributions, etc. of the parent substrate. Therefore, by growing a single-crystal diamond on the top faces by a vapor-phase synthesis method, the boundary between adjacent single-crystal diamonds is uniformly coated with the grown diamond, allowing a large single-crystal diamond having a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc. to be easily produced.
[0023] When the diamond substrates separated from the parent substrate do not have an identical thickness, they are aligned on a flat support such that the faces separated from the parent substrate are in contact with the surface of the support, and a diamond is subsequently grown thereon by a vapor-phase synthesis method. In this way, the single-crystal diamond substrates aligned on the support are bonded with the grown diamond layers. The bonded diamonds are subsequently inverted on the support, with the faces separated from the parent substrate facing up. Each single-crystal diamond maintains, on this face, the off-angle, crystal direction, strain and defect distributions, etc. of the parent substrate. That is, all of the single-crystal diamonds constituting a mosaic have an identical off-angle, crystal plane direction, strain distribution, defect distribution, etc. By subsequently growing a single-crystal diamond on these faces by a vapor-phase synthesis method, the boundary between adjacent single-crystal diamonds is uniformly coated with the grown diamond, allowing the formation of a large single-crystal diamond having a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc.
[0024] Furthermore, large single-crystal diamonds produced by this method can be used instead of child substrates separated from the identical parent substrate, and can be similarly bonded with one another, thereby preparing an even larger single-crystal diamond.
[0025] The above-described method can eliminate troublesome processing for making the thickness, off-angle, crystal plane direction, strain and defect distributions, etc. of the single-crystal diamonds to be bonded uniform. The faces on which a diamond is grown have a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc., thereby enabling precise growth of diamond. Furthermore, because the thus-prepared large substrate has a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc., it is not necessary to consider the distribution of these properties when making devices on this substrate, thereby allowing devices with uniform properties to be easily prepared. Additionally, because the thus-prepared large substrate contains uniform defects, any unwanted portion can be easily identified. Furthermore, because the large substrate has the uniform properties across the entire region of the substrate surface, a diamond can be further grown on the substrate easily.
[0026] The present invention has been accomplished as a result of further research based on the above-described findings.
[0027] In summary, the invention provides large single-crystal diamond substrates and methods for producing the substrates, as set forth below.
[0028] 1. A method for producing a single-crystal diamond substrate having a large area, comprising the steps of:
[0029] (1) implanting ions into a parent substrate of single-crystal diamond to form a graphitized, non-diamond layer near a surface of the parent substrate, and subsequently etching the non-diamond layer to separate therefrom a single-crystal diamond layer above the non-diamond layer;
[0030] (2) repeatedly subjecting the parent substrate used in Step (1) to the operation of Step (1), to separate from the parent substrate one or more single-crystal diamond layers having a substantially identical thickness to that of the single-crystal diamond layer separated in Step (1);
[0031] (3) placing the plurality of single-crystal diamond layers separated in Steps (1) and (2) on a flat support such that side faces of adjacent diamond layers are in contact with each other, and faces of the diamond layers where the diamond layers have been separated from the parent substrate are exposed as top faces; and
[0032] (4) growing a single-crystal diamond by a vapor-phase synthesis method on the faces of the plurality of single-crystal diamond layers placed on the support in Step (3), thereby bonding the plurality of single-crystal diamond layers.
[0033] 2. The method according to Item 1, wherein Step (1) further comprises, subsequent to forming a non-diamond layer, and prior to etching the non-diamond layer, growing a single-crystal diamond layer on the surface of the parent substrate by a vapor-phase synthesis method.
[0034] 3. A method for producing a single-crystal diamond substrate having a large area, comprising the steps of:
[0035] (1) implanting ions into a parent substrate of single-crystal diamond to form a graphitized, non-diamond layer near a surface of the parent substrate, and subsequently etching the non-diamond layer to separate therefrom a single-crystal diamond layer above the non-diamond layer;
[0036] (2) repeatedly subjecting the parent substrate used in Step (1) to the operation of Step (1), to further separate from the parent substrate one or more single-crystal diamond layers;
[0037] (3) placing the plurality of single-crystal diamond layers separated in Steps (1) and (2) on a flat support such that side faces of adjacent diamond layers are in contact with each other, and faces of the diamond layers where the diamond layers have been separated from the parent substrate are in contact with a surface of the support;
[0038] (4) growing a single-crystal diamond by a vapor-phase synthesis method on the plurality of single-crystal diamond layers placed on the support in Step (3), thereby bonding the plurality of single-crystal diamond layers; and
[0039] (5) inverting the single-crystal diamond layers bonded in Step (4) on the support, and subsequently growing a single-crystal diamond on the diamond layers by a vapor-phase synthesis method, thereby growing a single-crystal diamond on faces of the diamond layers where the diamond layers have been separated from the parent substrate.
[0040] 4. The method according to Item 3, wherein Step (1) further comprises, subsequent to forming a non-diamond layer, and prior to etching the non-diamond layer, growing a single-crystal diamond layer on the surface of the parent substrate by a vapor-phase synthesis method.
[0041] 5. The method according to Item 1, wherein the single-crystal diamond substrate having a large area obtained by the method of Item 1 is used as the parent substrate.
[0042] 6. The method according to Item 1, wherein the single-crystal diamond substrate having a large area obtained by the method of Item 3 is used as the parent substrate.
[0043] 7. The method according to Item 3, wherein the single-crystal diamond substrate having a large area obtained by the method of Item 1 is used as the parent substrate.
[0044] 8. The method according to Item 3, wherein the single-crystal diamond substrate having a large area obtained by the method of Item 3 is used as the parent substrate.
[0045] 9. A method for producing a single-crystal diamond substrate having a large area, comprising the steps of:
[0046] preparing a plurality of large single-crystal diamond substrates having a substantially identical thickness according to the method of Item 1;
[0047] placing the large substrates on a flat support such that side faces of adjacent substrates are in contact with each other, and single-crystal diamond layers grown by a vapor-phase synthesis method in Step (4) of Item 1 are exposed as top faces; and
[0048] growing a single-crystal diamond thereon by a vapor-phase synthesis method, thereby bonding the plurality of large substrates.
[0049] 10. A method for producing a single-crystal diamond substrate having a large area, comprising the steps of:
[0050] preparing a plurality of large single-crystal diamond substrates having a substantially identical thickness according to the method of Item 2;
[0051] placing the large substrates on a flat support such that side faces of adjacent substrates are in contact with each other, and single-crystal diamond layers grown by a vapor-phase synthesis method in Step (4) of Item 1 are exposed as top faces; and
growing a single-crystal diamond thereon by a vapor-phase synthesis method, thereby bonding the plurality of large substrates.
[0053] 11. A method for producing a single-crystal diamond substrate having a large area, comprising the steps of:
[0054] preparing a plurality of large single-crystal diamond substrates having a substantially identical thickness according to the method of Item 3;
placing the large substrates on a flat support such that side faces of adjacent substrates are in contact with each other, and single-crystal diamond layers grown by a vapor-phase synthesis method in Step (5) of Item 3 are exposed as top faces; and growing a single-crystal diamond thereon by a vapor-phase synthesis method, thereby bonding the plurality of large substrates.
[0057] 12. A method for producing a single-crystal diamond substrate having a large area, comprising the steps of:
[0058] preparing a plurality of large single-crystal diamond substrates having a substantially identical thickness according to the method of Item 4;
[0059] placing the large substrates on a flat support such that side faces of adjacent substrates are in contact with each other, and single-crystal diamond layers grown by a vapor-phase synthesis method in Step (5) of Item 3 are exposed as top faces; and
[0060] growing a single-crystal diamond thereon by a vapor-phase synthesis method, thereby bonding the plurality of large substrates.
[0061] 13. A single-crystal diamond substrate having a large area which is prepared by the method of Item 1.
[0062] 14. A single-crystal diamond substrate having a large area which is prepared by the method of Item 2.
[0063] 15. A single-crystal diamond substrate having a large area which is prepared by the method of Item 3.
[0064] 16. A single-crystal diamond substrate having a large area which is prepared by the method of Item 4.
[0065] 17. A single-crystal diamond substrate having a large area which is prepared by the method of Item 9.
[0066] 18. A single-crystal diamond substrate having a large area which is prepared by the method of Item 10.
[0067] 19. A single-crystal diamond substrate having a large area which is prepared by the method of Item 11.
[0068] 20. A single-crystal diamond substrate having a large area which is prepared by the method of Item 12.
[0069] The methods for producing a single-crystal diamond substrate having a large area of the invention will be described in detail below.
[0070] Parent Substrate
[0071] In the invention, a single-crystal diamond substrate is used as the parent substrate. The type of the single-crystal diamond is not limited; for example, a single-crystal diamond whose surface has a crystal face capable of epitaxial growth, or a single-crystal diamond having an angle of inclination, i.e., an off-angle, with respect to the above-mentioned crystal face, can be used. The method for producing such a single-crystal diamond is also not limited. Examples of usable single-crystal diamonds include, in addition to natural diamonds, single crystal diamonds produced by a high-pressure synthesis method, single-crystal diamonds produced by vapor-phase synthesis, etc.
[0072] Typically, a single-crystal diamond having a surface along a ( 100 ), ( 111 ), or a like plane can be used, or a single-crystal diamond having an off-angle of up to about 10° with respect to any of these crystal planes, can be used, particularly for growing a semiconductor-grade diamond.
[0073] Ion Implantation Step
[0074] In the invention, ions are first implanted from one surface of the single-crystal diamond used as the parent substrate to form an ion-implanted layer whose crystal structure is deteriorated near the surface of the diamond.
[0075] The ion implantation method is a method in which a sample is irradiated with swift ions. In general, ion implantation is performed as follows: a desired element is ionized, and a voltage is applied to the resulting ions to accelerate the ions in an electric field. The ions are subsequently mass-separated, and those with a desired level of energy are directed to the sample. Alternatively, it may be performed by plasma ion implantation, wherein the sample is immersed in plasma, and negative high-voltage pulses are applied to the sample, thereby attracting positive ions in the plasma to the sample. Examples of implanted ions include carbon, oxygen, argon, helium, protons, and the like.
[0076] The ion implantation energy may be in the range of about 10 keV to about 10 MeV, which is typically used in ion implantation. Implanted ions are distributed mainly in an average depth (projectile range), with a certain width of depth; the average depth is determined according to the type and energy of the ions, as well as the type of the ion-implanted material. Damage to the sample is the greatest in the vicinity of the projectile range where ions stop, but the surface side of the substrate above the vicinity of the projectile range is also damaged to some extent by the passage of ions. The projectile range and the extent of damage can be calculated and predicted using a Monte Carlo simulation code, such as the SRIM code.
[0077] By implanting ions into the parent substrate, once the dose has exceeded a certain level, the surface side of the substrate above the vicinity of the projectile range deteriorates, causing the diamond structure to be destroyed, resulting in the formation of a non-diamond layer.
[0078] The depth and thickness of the resulting non-diamond layer vary depending on the type of ion used, the ion implantation energy, the dose, and the like. Therefore, these conditions may be determined so that a separable non-diamond layer is formed in the vicinity of the projectile range. Typically, the atomic density of a region having the highest atomic density of implanted ions is preferably about 1×10 20 atoms/cm 3 or more. In order to ensure that a non-diamond layer is formed, the atomic density is preferably about 1×10 21 atoms/cm 3 or more, i.e., a displacement damage of 1 dpa or more.
[0079] For example, when carbon ions are implanted at an implantation energy of 3 MeV, the ion dose may be about 1×10 16 ions/cm 2 to about 1×10 17 ions/cm 2 . In this case, if the ion dose is too high, the crystallinity of the surface will degrade; whereas if the dose is too low, a non-diamond layer will not be sufficiently formed, making it difficult to separate the surface portion.
[0080] A non-diamond layer is formed near the surface of the parent substrate by conducting ion implantation according to the above-described method.
[0081] In the invention, the depth at which the non-diamond layer is formed is not limited; however, the greater the depth, the thicker the surface portion that can be subsequently separated.
[0082] After the ion implantation, a heat treatment is conducted at a temperature of 600° C. or higher in a non-oxidizing atmosphere such as vacuum, a reducing atmosphere, or an oxygen-free inert gas atmosphere, thereby allowing graphitization of the non-diamond layer to proceed. This causes etching in the subsequent step to proceed more rapidly. The upper limit for the heat-treatment temperature is the temperature at which the diamond begins to graphitize, which is typically about 1,200° C. The heat-treatment time varies depending on the treatment conditions such as the heat-treatment temperature and the like; for example, it may be about 5 minutes to about 10 hours.
[0083] Further, to provide the surface portion to be separated in the etching process described below with a desired thickness, a single-crystal diamond layer may be grown on the parent substrate after the ion implantation and prior to the step of etching the non-diamond layer. The growth method is not limited; known vapor-phase synthesis methods that are applicable include, for example, a microwave plasma CVD method, a hot filament method, a DC discharge method, etc. A high-purity diamond film can be grown by using, in particular, a microwave plasma CVD method. Specific production conditions are not limited; a single-crystal diamond may be grown according to known conditions. For example, a gas mixture of methane and hydrogen can be used as a source gas. The addition of nitrogen gas to this mixture can further enhance the growth rate.
[0084] Specifically, the conditions for diamond growth may, for example, be as follows. When a gas mixture of hydrogen, methane, and nitrogen is used as a reaction gas, methane is preferably supplied in a proportion of about 0.01 to about 0.33 mol per mol of hydrogen supplied, and nitrogen is preferably supplied in a proportion of about 0.0005 to about 0.1 mol per mol of methane supplied.
[0085] The pressure inside the plasma CVD apparatus can be typically about 13.3 to about 40 kPa. Microwaves typically used are those having a frequency of 2.45 GHz, 915 MHz, or like frequencies that are industrially or scientifically sanctioned. The microwave power is not limited, and is typically about 0.5 to about 5 kW. Within these ranges, the conditions may be adjusted so that the temperature of the single-crystal diamond substrate is about 900 to about 1,300° C., preferably about 1,000 to about 1,100° C., and more preferably about 1,040 to about 1,060° C.
[0086] Step of Etching the Non-Diamond Layer
[0087] After graphitization of the non-diamond layer by the method described above, and optional growth of a single-crystal diamond layer, the surface portion is separated from the non-diamond layer by etching the non-diamond layer. This causes the single-crystal diamond at the surface portion to be separated. The separated face maintains the crystal face of the parent substrate. Therefore, when the parent substrate has an off-angle, the separated face of the separated crystal (child substrate) has an off-angle and crystal direction identical to those of the parent substrate, and also maintains the strain and defect distributions of the parent substrate.
[0088] The method for separating the surface portion from the non-diamond layer is not limited; for example, methods such as electrochemical etching, thermal oxidation, electric discharge machining, etc. can be applied.
[0089] An example of the method for removing the non-diamond layer by electrochemical etching is as follows. Two electrodes are disposed in an electrolytic solution at a certain interval. A single-crystal diamond in which a non-diamond layer is formed is placed between the electrodes in the electrolytic solution, and a DC voltage is applied across the electrodes. Pure water is preferable as the electrolytic solution. While the electrode material may be any conductive material, chemically stable electrodes, such as platinum, graphite, or the like, are preferable. The electrode interval and the applied voltage may be adjusted so that the etching proceeds most rapidly. The electric field strength in the electrolytic solution is typically about 100 to about 300 V/cm.
[0090] Moreover, when etching is conducted by applying an AC voltage in the method for removing the non-diamond layer by electrochemical etching, even if a large single-crystal diamond substrate is used, etching proceeds extremely rapidly into the non-diamond layer of the crystal, allowing the diamond at the surface side above the non-diamond layer to be separated in a short period of time.
[0091] Also in the method wherein an AC voltage is applied, the electrode interval and the applied voltage may be adjusted so that the etching proceeds most rapidly. Typically, the electric field strength in the electrolytic solution, determined by dividing the applied voltage by the electrode interval, is preferably about 50 to about 10,000 V/cm, and more preferably about 500 to about 10,000 V/cm.
[0092] While a commercial sinusoidal alternating current with a frequency of 60 or 50 Hz is readily available as an alternating current, the waveform may be a waveform other than a sinusoidal wave, as long as the current has a similar frequency component.
[0093] Advantageously, pure water used as an electrolytic solution has a higher resistivity (i.e., a lower conductivity) to allow the application of a higher voltage. Ultrapure water produced using a general apparatus for producing ultrapure water has a sufficiently high resistivity, i.e., about 18 MΩ·cm, and is thus suitable for use as an electrolytic solution.
[0094] An example of the method for removing the non-diamond layer by thermal oxidation is as follows. The substrate is heated to a high temperature of about 500 to about 900° C. in an oxygen atmosphere, thereby etching the non-diamond layer by oxidation. In this method, as etching proceeds farther into the diamond, the passage of oxygen from the outer periphery of the crystal becomes difficult. For this reason, if oxygen ion has been selected as the ion to form a non-diamond layer, and implanted at a dose sufficiently greater than the dose necessary for etching to occur, oxygen can also be supplied from the inside of the non-diamond layer during etching, allowing the non-diamond layer to be etched more rapidly.
[0095] Because the graphitized non-diamond layer is conductive, it can also be cut (etched) by electric discharge machining.
[0096] Further, after the surface portion above the non-diamond layer has been separated by the method described above, the separated face may be optionally polished by scaife polishing or the like for final polishing, so as to remove the deteriorated layer formed by ion implantation. Since the amount of final polishing is typically about several micrometers or less, which is about equal to the thickness of the ion-implanted layer, the deteriorated layer can be removed within an extremely short period of time, with little deviation in the crystal plane.
[0097] Step of Preparing a Plurality of Child Substrates
[0098] The parent substrate from which the single-crystal diamond at the surface portion has been separated by the above-described method is again repeatedly subjected to the formation of a non-diamond layer by ion implantation and the separation of the surface portion above the non-diamond layer by etching, in the same manner as described above, thereby preparing a required number of child substrates.
[0099] All of the child substrates obtained by this method have an off-angle, crystal plane direction, strain distribution, and defect distribution identical to those of the parent substrate. Further, child substrates having a substantially identical thickness can be easily obtained by employing identical conditions for ion implantation.
[0100] FIG. 1 shows schematic cross sections of the child substrates separated according to the method of the invention. As shown in the upper diagram of FIG. 1 , the child substrate layers grown on the parent substrate maintain the strains and defects in the crystal face of the parent substrate, and hence have an off-angle, crystal plane direction, strain distribution, and defect distribution identical to those of the parent substrate. As shown in the lower diagram of FIG. 1 , when a plurality of child substrates are separated from the identical parent substrate, each child substrate has an off-angle, crystal plane direction, strain distribution, and defect distribution identical to those of the parent substrate. When these substrates are arranged in a planar array, the thus-arranged substrates have a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc.
[0101] The child substrates must be aligned such that side faces of adjacent child substrates are in contact with each other, and the directions of the crystal faces are identical. Therefore, each child substrate must have linear side faces so that it can be placed with its side face being in contact with a side face of another child substrate. When the parent substrate has a rectangular surface shape, child substrates prepared therefrom will also have a rectangular surface shape, so that one of the side faces can be utilized. In this case, when placing the child substrates, the child substrates are preferably placed in such a manner that the angle formed by the side faces of adjacent child substrates is 5° or less, and more preferably 1° or less, allowing the directions of the crystal faces of adjacent child substrates to be as identical as possible.
[0102] When the parent substrate has an indefinite surface shape, the child substrates may be processed to form linear side faces using laser cutting, polishing, or the like, and then placed in the same manner as the child substrates having a rectangular surface shape.
[0103] Step of Bonding Child Substrates
[0104] The method for producing a single-crystal diamond substrate with a large area by bonding the plurality of child substrates obtained according to the above-described method will be described below for a case where the child substrates have a substantially identical thickness, and a case where the child substrates do not have an identical thickness.
[0105] (1) Case where the Child Substrates have a Substantially Identical Thickness
[0106] When the plurality of child substrates obtained as above have a substantially identical thickness, they are placed with side faces of adjacent child substrates being in contact with each other on a flat support, and the faces separated from the parent substrate being exposed as top faces, i.e., with the separated faces facing up.
[0107] In this case, the thicknesses of all of the child substrates need not be completely the same. The expression “the child substrates have a substantially identical thickness”, as used herein, means that the difference in thickness is within the range of about 20 μm or less.
[0108] The child substrates may be aligned using any desired method, as long as they can be placed with the directions of their crystal faces being identical. For example, in the case of three child substrates, the substrates may be aligned in parallel, or may be aligned such that one contacting corner of two substrates is in contact with one side face of the other substrate. In the case of four substrates, the substrates may be aligned in parallel, or may be aligned such that they contact one another at one corner. According to the method of the invention, the boundary surface is coated with a grown diamond layer evenly and smoothly, even at the portions of contacting corners among child substrates, thereby achieving a favorable surface condition.
[0109] A single-crystal diamond is subsequently grown by a vapor-phase synthesis method on the faces of the aligned substrates separated from the parent substrate. Consequently, the plurality of child substrates placed on the support are bonded with the grown single-crystal diamond.
[0110] In this method, a single-crystal diamond is grown on a plurality of child substrates having a substantially identical thickness placed on a flat support, so that the faces of the resulting bonded child substrates separated from the parent substrate are substantially flush with one another. Furthermore, because a plurality of child substrates separated from the identical parent substrate are used, all of these child substrates have a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc.
[0111] Therefore, a single-crystal diamond having a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc. can be easily grown by growing a single-crystal diamond on these separated faces by a vapor-phase synthesis method. A uniform single-crystal diamond is grown even on the boundary portions of the child substrates, coating these boundary portions completely. This results in the formation of a single-crystal diamond substrate having a large area and having a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc.
[0112] The growth method is not limited; known vapor-phase synthesis methods that are applicable include, for example, a microwave plasma CVD method, a hot filament method, a DC discharge method, etc.
[0113] A high-purity single-crystal diamond film can be grown by using, in particular, a microwave plasma CVD method. Specific production conditions are not limited; a single-crystal diamond may be grown according to known conditions. A gas mixture of methane and hydrogen is usable as a source gas. Specifically, the conditions for diamond growth may, for example, be as follows. In the gas mixture of hydrogen and methane used as a reaction gas, methane is preferably supplied in a proportion of about 0.01 to about 0.33 mol per mol of hydrogen supplied. The pressure inside the plasma CVD apparatus can be typically about 13.3 to about 40 kPa. Microwaves typically used are those having a frequency of 2.45 GHz, 915 MHz, or like frequencies that are industrially or scientifically sanctioned. The microwave power is not limited, and is typically about 0.5 to about 5 kW. Within these ranges, the conditions may be adjusted so that the temperature of the substrates (child substrates of single-crystal diamond) is about 900 to about 1,300° C., and preferably about 900 to about 1,100° C.
[0114] The thickness of the single-crystal diamond grown is not also limited, and may be such that adjacent child substrates can be bonded sufficiently. The thickness may, for example, be about 100 to about 1,000 μm.
[0115] (2) Case where the Child Substrates do not have an Identical Thickness
[0116] When the plurality of child substrates do not have an identical thickness, a single-crystal diamond substrate having a large area and having a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc. can be obtained by performing the first bonding step and second bonding step described below. The following method can also be employed for a plurality of child substrates having a substantially identical thickness.
[0117] First Bonding Step
[0118] Child substrates obtained by the above-described etching step are first aligned on a flat support such that side faces of adjacent child substrates are in contact with each other. At this time, the child substrates are placed such that the faces separated from the parent substrate are in contact with the support.
[0119] The child substrates may be aligned in the same manner as the substrates having a substantially identical thickness.
[0120] A single-crystal diamond is subsequently grown by a vapor-phase synthesis method on the plurality of child substrates aligned. Consequently, the plurality of child substrates placed on the support are bonded with the grown single-crystal diamond.
[0121] The vapor-phase synthesis method is not limited; known methods that are applicable include, for example, a microwave plasma CVD method, a hot filament method, a DC discharge method, etc., as in the case where the child substrates have a substantially identical thickness. A high-purity single-crystal diamond film can be grown by using, in particular, a microwave plasma CVD method. Specific production conditions are not limited; a single-crystal diamond can be grown according to the method described above.
[0122] The thickness of the single-crystal diamond grown is not also limited, and may be such that adjacent child substrates can be bonded sufficiently. The thickness may, for example, be about 100 to about 1,000 μm.
[0123] FIG. 2 is a schematic diagram showing child substrates bonded with a grown single-crystal diamond layer in the first bonding step. As shown in FIG. 2 , the top faces of single-crystal diamonds, which have been placed with the separated faces formed in the etching step being in contact with the support surface, are typically coarse, as compared with the separated faces. When the thicknesses of the child substrates are not strictly identical, a gap is formed between adjacent child substrates. Therefore, if diamond is grown on these faces by a vapor-phase synthesis method, the resulting diamond layers will be non-uniform, and each boundary portion between adjacent child substrates will not be coated uniformly with the diamond.
[0124] Second Bonding Step
[0125] In the next step, the child substrates bonded with the diamond layers are inverted, so that the diamond faces grown in the first bonding step come into contact with the support surface. Consequently, the faces separated from the parent substrate are exposed as top faces.
[0126] A single-crystal diamond is subsequently grown on these faces by a vapor-phase synthesis method. The conditions for the vapor-phase synthesis method may be the same as those in the first bonding step.
[0127] FIG. 3 is a schematic diagram showing a single-crystal diamond layer grown in the second bonding step. In the first bonding step, single-crystal diamond has been grown on the child substrates placed with their faces separated from the parent substrate being in contact with the flat support. Therefore, the faces of the bonded child substrates where they are separated from the parent substrate are substantially flush with one another. Furthermore, because a plurality of child substrates separated from the identical parent substrate are used, these child substrates all have a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc. Thus, a single-crystal diamond having a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc. can be easily grown by growing a single-crystal diamond on these separated faces by a vapor-phase synthesis method in this step. A uniform single-crystal diamond is grown evenly on the boundary portions of the child substrates, so that these boundary portions are completely coated with the diamond. This results in the formation of a single-crystal diamond having a large area, as well as a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc.
[0128] Furthermore, an even larger single-crystal diamond can be easily formed by using, as child substrates, a plurality of large single-crystal diamond substrates obtained by bonding a plurality of child substrates according to any of the above-described methods, and by bonding these large substrates according to the same method as that employed in the case where the child substrates have a substantially identical thickness.
[0129] Furthermore, an even larger single-crystal diamond can be easily formed by using, as a parent substrate, a large single-crystal diamond substrate obtained by bonding a plurality of child substrates according to any of the above-described methods, and by repeating the ion-implantation step, the step of etching a non-diamond layer, and the bonding step described above.
EFFECTS OF THE INVENTION
[0130] According to the method for producing a single-crystal diamond substrate having a large area of the invention, mechanical processing for making the thickness of each child substrate uniform is not necessary when a large single-crystal diamond is produced by bonding a plurality of single-crystal diamonds. Furthermore, because the child substrates constituting a mosaic diamond have a uniform off-angle, crystal plane direction, strain distribution, and defect distribution, uniform diamond layers can be obtained according to set conditions, without the need to vary the diamond growth conditions for each child substrate.
[0131] Thus, precise growth of single-crystal diamond on the child substrates can be easily accomplished by a vapor-phase synthesis method, allowing the above-mentioned properties of a single-crystal diamond substrate having a large area prepared by bonding the child substrate to be uniform.
[0132] Furthermore, according to the methods of the invention, a large single-crystal diamond having a uniform off-angle, crystal plane direction, strain distribution, defect distribution, etc. can be produced relatively easily. The large diamond substrate obtained has uniform properties, which facilitates the treatment or processing on the large substrate. Therefore, devices of uniform quality can be evenly prepared on the thus-prepared large substrate of single-crystal diamond. Furthermore, even if the parent substrate contains defects, the large single-crystal diamond obtained contains identical defects for each of the bonded single-crystal diamond substrates, allowing unwanted portions to be easily identified during the preparation of devices or the like. Furthermore, it is possible to easily grow additional single-crystal diamond on the thus-prepared large single-crystal diamond substrate, in order to impart to the substrates strength sufficient to withstand various processes during the preparation of devices.
[0133] Therefore, according to the methods of the invention, it is possible to easily prepare a large mosaic substrate of single-crystal diamond that is particularly suitable for realizing the practical use of single-crystal diamond as a semiconductor material.
[0134] Effects similar to those of the invention can also be attained when a plurality of child substrates are prepared by using, instead of the ion implantation method used in the invention, other methods whereby a plurality of child substrates whose above-mentioned properties are uniform can be prepared. Furthermore, by replacing single-crystal diamond with single crystals of other wide bandgap semiconductors, such as SiC, GaN, AlN, and ZnO, similar effects can also be attained for these wide bandgap semiconductor single crystals.
BRIEF DESCRIPTION OF DRAWINGS
[0135] FIG. 1 shows schematic cross sections of the child substrates separated according to the method of the invention;
[0136] FIG. 2 is a schematic diagram showing child substrates bonded with a grown single-crystal diamond layer in the first bonding step;
[0137] FIG. 3 is a schematic diagram showing a single-crystal diamond layer grown on the faces separated from the parent substrate in the second bonding step;
[0138] FIG. 4 shows a micrograph (upper section) of the surface of a bonded region after the first bonding step in Example 1; and an image (lower section) of a cross section around a bonded region, taken by a laser microscope;
[0139] FIG. 5 shows a micrograph (upper section) of the surface of a bonded region after the second bonding step in Example 1; and an image (lower section) of a cross section around a bonded region, taken by a laser microscope; and
[0140] FIG. 6 is a schematic plan view of the arrangement of child substrates employed in Test Example 1 and Comparative Test Example 1.
DESCRIPTION OF EMBODIMENTS
[0141] The invention is described in greater detail below, referring to the following Examples.
Example 1
[0142] A single-crystal diamond ( 100 ) substrate having dimensions of 3×3×0.5 mm 3 was used as a parent substrate, and a large single-crystal diamond substrate was prepared according to the following method.
[0143] Carbon ions were first implanted into the single-crystal diamond substrate at an implantation energy of 3 MeV and a dose of 2×10 16 ions/cm 2 , using a 1.5 MV tandem accelerator. The calculated value of the ion implantation depth was about 1.6 μm. After the radiation, the diamond substrate changed from transparent to black, which confirmed that a non-diamond layer was formed.
[0144] The single-crystal diamond substrate was subsequently heat-treated using a commercially available microwave plasma CVD apparatus, thereby causing the graphitization of the non-diamond layer to proceed. The conditions for heat treatment were as follows: a substrate temperature of 1,060° C.; a pressure of 16 kPa; a hydrogen gas flow rate of 500 sccm; and a treatment time of 5 minutes. Subsequent to the heat treatment, methane gas was passed at 25 sccm, and the growth of a single-crystal diamond film was conducted for 7 hours.
[0145] Two separate platinum electrodes were disposed at an interval of about 1 cm in a beaker containing pure water, and the single-crystal diamond substrate having the single-crystal diamond film grown by the above-described method was placed between the electrodes. An AC voltage with an effective value of 5.6 kV and a frequency of 60 Hz was applied across the electrodes, and the substrate was allowed to stand for 15 hours. As a result, the black, graphitized non-diamond layer was not visually observed. Because of the possibility that the non-diamond layer that could not be visually observed still remained, the application of an AC current was continued for another 24 hours under the same conditions. Consequently, the CVD-deposited single-crystal diamond film was removed from the single-crystal diamond substrate. The thickness of the CVD-deposited single-crystal diamond film was 65 μm, as measured using a micrometer.
[0146] The single-crystal diamond substrate from which the surface layer was removed by the above-described method was again subjected to the implantation of carbon ions and heat treatment, the growth of a single-crystal diamond film, and the removal of a surface layer by electrochemical etching, in the same manner as described above. The thickness of the CVD-deposited single-crystal diamond film was 103 μm, as measured using a micrometer.
[0147] The thus-obtained two single-crystal diamond substrates were subsequently aligned on a substrate support, with their separated faces facing down, so that the side faces of these substrates were placed in contact with each other in parallel when visually observed. Using a commercially available microwave plasma CVD apparatus, the growth of a single-crystal diamond film was subsequently conducted for 7 hours, at a substrate temperature of 1,000° C., a pressure of 16 kPa, a hydrogen gas flow rate of 500 sccm, and a methane gas flow rate of 25 sccm. As a result, the substrates were integrated.
[0148] FIG. 4 shows a micrograph (upper section) of the surface of a bonded region after diamond growth; and an image (lower section) of a cross section around a bonded region, taken by a laser microscope. As is clear from the image showing a cross section, there was a difference in thickness of about 50 μm between the substrates; thus, the surface was not uniformly coated with the grown diamond, resulting in a gap being formed between the substrates.
[0149] The integrated substrate was subsequently turned upside down, and a single-crystal diamond film was grown on the faces separated from the parent substrate under the same conditions as above. FIG. 5 shows a micrograph (upper image) of the surface of a bonded region after diamond growth; and an image (lower image) of a cross section around a bonded region, taken by a laser microscope. The boundary surface was confirmed to be coated with a diamond layer evenly and smoothly, thereby achieving a favorable surface condition.
Example 2
[0150] A single-crystal diamond ( 100 ) substrate having a diameter of 9 mm and a thickness of 1 mm, and provided with a linear notch was used as a parent substrate, and a large single-crystal diamond substrate was prepared according to the following method.
[0151] The single-crystal diamond substrate was first implanted with ions by the same method as in Example 1. The single-crystal diamond substrate was subsequently heat-treated by the same method as in Example 1, using a commercially available microwave plasma CVD apparatus, thereby causing the graphitization of the non-diamond layer to proceed. The growth of a single-crystal diamond film was subsequently conducted for 3 hours, at a substrate temperature of 1,100° C., a pressure of 15 kPa, a hydrogen gas flow rate of 500 sccm, a methane gas flow rate of 25 sccm, and a nitrogen gas flow rate of 2 sccm.
[0152] The CVD-deposited single-crystal diamond film was then removed from the single-crystal diamond substrate according to the same method as in Example 1, by electrochemical etching. The thickness of the CVD-deposited single-crystal diamond film was 127 μm, as measured using a micrometer. The diamond film was subsequently laser cut, so as to form a linear side face in parallel with the notch.
[0153] The single-crystal diamond substrate from which the surface layer was removed by the above-described method was again subjected to the implantation of carbon ions and heat treatment, the growth of a single-crystal diamond film, and the removal of a surface layer by electrochemical etching, in the same manner as described above. The thickness of the CVD-deposited single-crystal diamond film was 139 μm, as measured using a micrometer. The diamond film was then laser cut, so as to form a linear side face in parallel with the notch.
[0154] The thus-obtained two single-crystal diamond substrates were subsequently aligned on a substrate support, with their separated faces facing down, so that the side faces of these substrates were placed in contact with each other in parallel when visually observed. Using a commercially available microwave plasma CVD apparatus, the growth of a single-crystal diamond film was subsequently conducted for 8 hours, at a substrate temperature of 930° C., a pressure of 15 kPa, a hydrogen gas flow rate of 500 sccm, and a methane gas flow rate of 25 sccm. As a result, the substrates were integrated. The integrated substrate was subsequently turned upside down, and the growth of a single-crystal diamond film on the faces separated from the parent substrate was conducted for 13 hours, under the same conditions as above. An observation of the surface condition of the bonded region after diamond growth using a laser microscope confirmed that the boundary surface was coated with the grown diamond evenly and smoothly, thereby achieving a favorable surface condition.
Comparative Example 1
[0155] A single-crystal diamond ( 100 ) substrate having dimensions of 4.5×4.5×0.5 mm 3 and an off-angle of 1.6°, and a single-crystal diamond ( 100 ) substrate having dimensions of 4.5×4.5×0.5 mm 3 and an off-angle of 0.6° were each used as parent substrates, and two single-crystal diamond layers were prepared according to the following method. The former single-crystal diamond substrate is hereinafter referred to as “the parent substrate 1 ”, and the latter is referred to as “the parent substrate 2 ”. The difference in off-direction between these parent substrates was 54°.
[0156] Carbon ions were first implanted into the parent substrate 1 at an implantation energy of 3 MeV and a dose of 2×10 16 ions/cm 2 , using a 1.5 MV tandem accelerator. The calculated value of the ion implantation depth was about 1.6 μm. After the radiation, the parent substrate 1 changed from transparent to black, which confirmed that a non-diamond layer was formed.
[0157] The parent substrate 1 was subsequently heat-treated using a commercially available microwave plasma CVD apparatus, thereby causing the graphitization of the non-diamond layer to proceed. The conditions for heat treatment were as follows: a substrate temperature of 1,060° C.; a pressure of 15 kPa; a hydrogen gas flow rate of 890 sccm; and a treatment time of 3 minutes. Subsequent to the heat treatment, methane gas and nitrogen were passed at 66 sccm and 1.5 sccm, respectively, and the growth of a single-crystal diamond film was conducted for 6 hours.
[0158] Two separate platinum electrodes were disposed at an interval of about 1 cm in a beaker containing pure water, and the parent substrate 1 having the single-crystal diamond film grown by the above-described method was placed between the electrodes. An AC voltage with an effective value of 5.6 kV and a frequency of 60 Hz was applied across the electrodes, and the substrate was allowed to stand for 15 hours. As a result, the black, graphitized non-diamond layer was not visually observed. Because of the possibility that the non-diamond layer that could not be visually observed still remained, the application of an AC current was continued for another 24 hours under the same conditions. Consequently, the CVD-deposited single-crystal diamond film was removed from the parent substrate 1 . The thickness of the CVD-deposited single-crystal diamond film was 235 μm, as measured using a micrometer.
[0159] Next, the parent substrate 2 was subjected to the implantation of carbon ions and heat treatment, the growth of a single-crystal diamond film, and the removal of a surface layer by electrochemical etching, in the same manner as described above. The thickness of the single-crystal diamond film removed from the parent substrate 2 was 246 μm, as measured using a micrometer.
[0160] The thus-obtained two single-crystal diamond substrates were subsequently aligned on a substrate support, with their separated faces facing down, so that the side faces of these substrates were placed in contact with each other in parallel when visually observed. Using a commercially available microwave plasma CVD apparatus, the growth of a single-crystal diamond film was subsequently conducted for 14 hours, at a substrate temperature of 1,000° C., a pressure of 15 kPa, a hydrogen gas flow rate of 500 sccm, and a methane gas flow rate of 25 sccm. As a result, the substrates were integrated.
[0161] The integrated substrate was subsequently turned upside down, and a single-crystal diamond film was grown on the faces separated from the parent substrate under the same conditions as above. Although the growth was conducted for 18 hours, the boundary surface was not smoothly coated.
Test Example 1
[0162] An experiment was conducted according to the following method, in order to confirm whether a diamond coating with a favorable surface condition can be formed even at overlapping corners of child substrates when three child substrates are bonded.
[0163] A single-crystal diamond layer was prepared using as a parent substrate a single-crystal diamond ( 100 ) substrate having dimensions of 4.5×4.5×0.5 mm 3 , according to the following method.
[0164] The diamond substrate was first implanted with ions according to the same method as in Example 1. The single-crystal diamond substrate was subsequently heat-treated according to the same manner as in Example 1, using a commercially available microwave plasma CVD apparatus, thereby causing the graphitization of the non-diamond layer to proceed. The growth of a single-crystal diamond film was conducted for 6 hours, at a substrate temperature of 1,140° C., a pressure of 15 kPa, a hydrogen gas flow rate of 890 sccm, a methane gas flow rate of 66 sccm, and a nitrogen gas flow rate of 1.5 sccm.
[0165] The CVD-deposited single crystal diamond film was then removed from the single-crystal diamond substrate according to the same method as in Example 1, by electrochemical etching. The thickness of the CVD-deposited single-crystal diamond film was 221 μm, as measured using a micrometer.
[0166] The single-crystal diamond substrate from which the surface layer was removed by the above-described method was again subjected to the implantation of carbon ions and heat treatment, the growth of a single-crystal diamond film, and the removal of a surface layer by electrochemical etching, in the same manner as described above. The thickness of the CVD-deposited single-crystal diamond film was 216 μm, as measured using a micrometer. The CVD-deposited single-crystal diamond film was subsequently cut in parallel with one side of the outer periphery of the growth face.
[0167] The thus-obtained three single-crystal diamond substrates were subsequently aligned on a substrate support, with their separated faces facing down, so that the side faces of these substrates were placed in contact with each other in parallel when visually observed, as shown in FIG. 6 . Using a commercially available microwave plasma CVD apparatus, the growth of a single-crystal diamond film was subsequently conducted for 13 hours, at a substrate temperature of 1,100° C., a pressure of 15 kPa, a hydrogen gas flow rate of 500 sccm, and a methane gas flow rate of 25 sccm. As a result, the substrates were integrated.
[0168] The integrated substrate was subsequently turned upside down, and a single-crystal diamond film was grown on the faces separated from the parent substrate under the same conditions as above. An observation of the surface conditions of bonded regions after diamond growth using a laser microscope confirmed that the boundary surface was coated evenly and smoothly with the grown diamond not only along the boundaries but also at the intersecting corners, thereby achieving a favorable surface condition.
Comparative Test Example 1
[0169] Single-crystal diamond layers were formed according to the following method on the surfaces of three commercially available single-crystal diamond ( 100 ) substrates having dimensions of 4.5×4.5×0.538±0.004 mm 3 , and these diamond layers were integrated. The maximum difference in off-angle among the substrates was 1.4°, and the minimum difference was 0.1° or less. The maximum difference in off-direction among the substrates was 75°, and the minimum difference was 25°.
[0170] The three single-crystal diamond substrates were first aligned on a substrate support so that the side surfaces of these substrates were placed in contact with each other in parallel when visually observed, as shown in FIG. 6 . Using a commercially available microwave plasma CVD apparatus, the growth of a single-crystal diamond film was subsequently conducted for 24 hours, at a substrate temperature of 1,100° C., a pressure of 16 kPa, a hydrogen gas flow rate of 500 sccm, and a methane gas flow rate of 25 sccm. As a result, the substrates were integrated.
[0171] The integrated substrate was subsequently turned upside down, and a single-crystal diamond film was grown on the faces of the turned substrate under the same conditions as above. An observation of the surface conditions of bonded regions after diamond growth with a laser microscope revealed that the boundary surface was not smoothly coated along the boundaries and at the intersecting corners.
|
The present invention provides a method for producing a large substrate of single-crystal diamond, including the steps of preparing a plurality of single-crystal diamond layers separated form an identical parent substrate, placing the single-crystal diamond layers in a mosaic pattern on a flat support, and growing a single-crystal diamond by a vapor-phase synthesis method on faces of the single-crystal diamond layers where they have been separated from the parent substrate.
According to the method of the invention, a mosaic single-crystal diamond having a large area and good quality can be produced relatively easily.
| 2
|
BACKGROUND OF THE INVENTION
The invention relates to an engine in which instead of effecting the direct combustion of fuel in air in one stage of combustion, the fuel is reacted in a plurality of successive stages of which a first stage is an endothermic chemical reaction and a subsequent stage is an exothermic chemical reaction. Examples of gas turbine plant providing successive endothermic and exothermic chemical reactions are disclosed in British Pat. Specifications Nos. 1194586 of Motoren und Turbinen Union Munchen GMBH, 1138165 of M.A.N. Turbo GMBH and 923316 Maschinenfabrick Augsburg-Nurnberg A. G.
SUMMARY OF THE INVENTION
According to the invention, an engine comprises a first reaction chamber to which at least one reactant is introduced to produce, by an endothermic chemical reaction, under substantially reversible conditions, in said first reaction chamber, a combustible product, means defining an air passage in heat exchange relationship with said first reaction chamber, means for introducing the combustible product into said air passage, a second reaction chamber to which air from said air passage together with the combustible product from said first reaction chamber are passed to effect an exothermic chemical reaction in said second reaction chamber, heat exchange means in said second reaction chamber defining with said second reaction chamber a first heat exchange path through which air is led to said air passage and a second heat exchange path, in indirect heat exchange relation to said first heat exchange path, through which air and said combustible product are passed to effect said exothermic chemical reaction and to impart heat to air passing through said first heat exchange path to said air passage, air-path defining means, including said first heat exchange path and said air passage connected in series, and power-producing means positioned in said air-path defining means and through which air flowing through said air passage is passed during operation of the engine.
The combustible product from the first reaction chamber in which the endothermic chemical reaction occurs is herein called "reformed fuel" and is produced by reacting a fuel with itself, water or a restricted supply of air substantially reversibly at a lower temperature than that at which normal combustion occurs, whereby the reformed fuel has a lower equilibrium reaction temperature with air and can be burnt with lower losses at practicably acceptable temperatures.
Conveniently, the second reaction chamber and the heat exchange means together comprise a fluidised bed heat exchanger having a bed through which the reformed fuel from the first reaction chamber is passed together with air or other reactant, the air or other reactant having been preheated by being passed through a heat exchanger path heated by the fluidised bed.
The second reaction chamber and the heat exchange means may alternatively together comprise a plurality of fluidised beds arranged in series or cascade, through the first of which with respect to the direction of flow of the reformed fuel from the first reaction chamber, the reformed fuel is passed together with air or other reactant, the air or other reactant having been preheated by being passed through a heat exchange path heated by the fluidised beds, the products from the exothermic reaction in the first fluidised bed being passed through the downstream fluidised bed, or fluidised beds in succession, the temperature of each fluidised bed being lower than the immediately preceding fluidised bed in the direction of flow of reformed fuel or said products.
The power-producing means may comprise at least one turbine through which a stream of compressed air or other reactant heated by the exothermic chemical reaction in the fluidised bed heat exchanger is passed before its introduction to the fluidised bed or beds together with the reformed fueld from the first reaction chamber.
By effecting the reaction of fuel in a first stage to produce the reformed fuel by an endothermic reaction followed by an exothermic reaction of the reformed fuel in one, or in a plurality of reaction chambers in succession and at a decreasing temperature, a significant reduction in fuel consumption occurs.
BRIEF DISCRIPTION OF THE DRAWINGS
By way of example, an engine incorporating the aforesaid endothermic and exothermic reaction stages is now described with reference to the accompanying drawings, in which:
FIG. 1 is an axial section through the engine;
FIG. 2 is a transverse section through the engine on the line II--II in FIG. 1;
FIG. 3 is a transverse section through the engine on the line III--III in FIG. 1;
FIG. 4 is a transverse section through the engine on the line IV--IV in FIG. 1;
FIG. 5 shows a modification to the part of the engine shown in FIG. 1 for producing the aforesaid reformed fuel, and
FIG. 6 shows a modification to the part of the engine shown in FIG. 1, including the original exhaust gas stage of the engine, the modification comprising a further exhaust gas stage in series with the original exhaust gas stage.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 to 4, the engine comprises a shaft 1 carrying an air compressor rotor 2. This draws in air from the atmosphere and discharges compressed air to a heat exchanger 3 heated by exhaust gases, as hereinafter explained. Heated air from the heat exchanger 3 passes through heating passages 16, 17 (e.g., tubes) in two fluidised bed heat exchangers 4 and 5 respectively, where the air is successively further heated and expanded through turbine rotors 13, 14 and 15. The air then passes to an annular duct 6 adjacent an annular mixing chamber 7 from which reformed fuel, as hereinbefore defined, is discharged through a plurality of (e.g., six) nozzles 11 spaced apart in a circle in the lower wall, as viewed in FIG. 1, of the annular duct 6. The formation of the reformed fuel in the mixing chamber is referred to hereinafter. The reformed fuel from the nozzles 11 mixes with the heated air passing through the annular duct 6 and the resulting mixture is then passed through the fluidised bed 19 of the fluidised bed heat exchanger 5 and a first exothermic reaction of the reformed fuel with air occurs. Then the products of the first exothermic reaction are passed through the fluidised bed 18 of the fluidised bed heat exchanger 4 where a second exothermic reaction occurs. Heat from each of the exothermic reactions in the fluidised beds 19, 18 is imparted to the air flowing from the heat exchanger 3 to the annular duct 6. Finally hot exhaust gases from the fluidised bed 18 of the fluidised bed heat exchanger 4 pass through the heat exchanger 3 before being exhausted to atmosphere and thus initially heat the compressed air discharged from the compressor 2 before the air enters the heating passages of the fluidised bed heat exchanger 4 and 5. The exothermic reaction occurring in the fluidised bed heat exchanger 5 is hotter than that in the fluidised bed heat exchanger 4 and so there is increasing temperature in both air and reformed fuel streams in the direction of arrow X. The temperature of each exothermic reaction is preferably maintained at or near to the equilibrium temperature by the design of the fluidised beds. The shaft 1 carries the aforesaid turbine rotors 13, 14 and 15 positioned in the air stream from the compressor 2 to the annular duct 6 and located respectively upstream of the fluidised bed heat exchanger 4, between the fluidised bed heat exchangers 4 and 5 and downstream of the fluidised bed heat exchanger 5 with respect to the direction of flow of the air stream. Air is expanded through the turbine rotors 13, 14 and 15 and thus energy is extracted from the air to drive the compressor rotor 2. Excess energy is available as shaft power at the shaft 1. The heat exchanger 3 may be of any suitable kind, e.g., a counterflow recuperative heat exchanger, as shown.
The reformed fuel is produced in the annular mixing chamber 7 from a mixture of vaporised liquid fuel and water by an endothermic reaction. The fuel and water required for this are discharged from fuel and water pumps 8 and 9 driven by a gear drive 10 from the shaft 1. The fuel pump 8 delivers fuel through a delivery pipe 20 in the shape of a closed ring to a plurality of spaced (e.g., three) ports 21 and the water pump delivers water through a delivery pipe 22 in the shape of a closed ring to a plurality of (e.g., three) spaced ports 23, alternately arranged with the ports 21 in the bottom wall as in FIG. 1 of the mixing chamber 7. The heat required for the endothermic reaction is obtained by heat transfer through the wall between the duct 6 and the chamber 7.
If necessary, additional heat for effecting the endothermic reaction may be produced by providing annular heating chambers around the mixing chamber 7, the annular heating chambers receiving hot air introduced from the duct 6. This modification is shown in FIG. 5 in which the annular heating chambers are shown at 24 and 25 one at each side of the chamber 7, and holes by which hot air from the duct 6 can enter the annular heating chambers 24, 25 are indicated at 26.
Although a single endothermic reaction stage and two series or cascaded exothermic reaction stages are illustrated, any other number of successive endothermic reaction stages and any number of successive exothermic reaction stages may be employed. For example, by employing two or more endothermic reaction stages the maximum temperature of the engine cycle would be reduced.
Although the exhaust gases from the heat exchanger 3 are discharged directly to atmosphere, they can be expanded to a sub-atmospheric pressure through a turbine, cooled and then re-compressed for discharge to atmosphere, thereby further reducing exhaust gas losses. A modification of the engine shown in FIG. 1 having this further exhaust stage is shown in FIG. 6. Air is introduced through radial pipes 29 to an annular inlet 30 to the compressor 2, which is otherwise as shown in FIG. 1. An annular exhaust gas outlet 31 leads from the heat exchanger 3, which is otherwise the same as in FIG. 1. The exhaust gas outlet 31 leads to a turbine 32 which expands the exhaust gases to a sub-atmospheric pressure. The exhaust gases are then passed through a heat exchanger 33, in which they are cooled by ambient air drawn through the heat exchanger 33 by a fan 34. After being discharged from the heat exchanger 33, the cooled exhaust gases at subatmospheric pressure are recompressed to atmospheric pressure by a compressor 35. The exhaust gases are then discharged to atmosphere through exhaust duct 36. The turbine rotor 32 and the compressor rotor 35 are mounted on the shaft 1, which is longer than the corresponding shaft 1 shown in FIG. 1. The fan 34 may be driven by the shaft 1. The remainder of the engine is the same as in FIGS. 1-4. The heat exchanger 33 may be of any suitable air/gas type. For example, it may be of the same recuperative type as the heat exchanger 3.
Although turbine rotors 13, 14 and 15 are described as the means of extracting energy from the heated air, alternatively the exhausted gases from each endothermic or exothermic reaction stage may be used to effect reciprocation of pistons, the latter being employed to effect compression of the air and to provide shaft output power.
The successive endothermic and exothermic reaction stages of the engine according to this invention enable a reversible or substantially reversible combustion condition to be achieved, thereby producing a higher thermal efficiency and a lower specific fuel consumption than can occur in orthodox engines.
|
An engine having a first reaction chamber to which fuel is to be supplied, either alone or with another reactant, and to which heat is applied to effect an endothermic chemical reaction to produce, under substantially reversible conditions, a reformed fuel, a second reaction chamber to which the reformed fuel discharged from the first reaction chamber is passed together with air or other reactant to effect an exothermic chemical reaction in the second reaction chamber, and a heat exchanger (conveniently of the fluidized bed type) to transfer heat produced by the exothermic reaction in the second reaction chamber to the first reaction chamber to effect the endothermic reaction.
| 5
|
[0001] This invention relates to fluid filled units and more particularly to a novel and improved plastic web of interconnected pouches for use in a machine for, and with a process of, converting the pouches to fluid filled units.
BACKGROUND OF THE INVENTION
[0002] U.S. Pat. No. Re 36,501 reissued Jan. 18, 2000 and RE 36,759 reissued Jul. 4, 2000 10 respectively entitled “Method for Producing Inflated Dunnage” and “Inflated Dunnage and Method for its Production” and based on original patents respectively issued Sep. 3, 1996 and Dec. 2, 1997 to Gregory A. Hoover et al. (the Hoover Patents) disclose a method for producing dunnage utilizing preopened bags on a roll. The preopened bags utilized in the Hoover patents are of a type disclose in U.S. Pat. No. 3,254,828 issued Jun. 2, 1966 to Hershey Lemer and entitled “Flexible Container Strips” (the Autobag Patent). The preferred bags of the Hoover patents are unique in that the so called tack of outer bag surfaces is greater than the tack of the inner surfaces to facilitate bag opening while producing dunnage units which stick to one another when in use.
[0003] U.S. Pat. No. 6,199,349 issued Mar. 13, 2001 under the title Dunnage Material and Process (the Lerner Patent) discloses a chain of interconnected plastic pouches which are fed along a path of travel to a fill and seal station. As each pouch is positioned at the fill station the pouches are sequentially opened by directing a flow of air through a pouch fill opening to open and then fill the pouch. Each filled pouch is then sealed to create an hermetically closed, inflated dunnage unit. Improvements on the pouches of the Lerner Patent are disclose in copending applications Ser. No. 09/735,345 filed Dec. 12, 2000 and Ser. No. 09/979,256 filed Nov. 21, 2001 and respectively is entitled Dunnage Inflation (the Lerner Applications). The system of the Lerner Patent and Applications is not suitable for packaging liquids. Moreover, since the production of dunnage units by the process described is relatively slow, an accumulator is desirable. An improved accumulator and dispenser for receiving dunnage units manufactured by a dunnage unit formation machine is disclose in U.S. application Ser. No. 09/735,111 filed Dec. 12, 2000 by Rick S. Wehrmann under the title Apparatus and Process for Dispensing Dunnage.
[0004] Accordingly, it would be desirable to provide an improved system for filling pouches with fluid to produce dunnage or liquid filled units at high rates of speed.
SUMMARY OF THE INVENTION
[0005] The present invention is embodied in a plastic web which enhances the production of fluid filled units which may be dunnage units similar to those produced by the systems of the Lerner Patent and Applications but at greatly improved production rates. Specifically, a novel and improved unit formation web is disclose for use with a novel machine and process. The machine and process are claimed in a concurrently filed application by Hershey Lemer et al, attorney docket no. 16-008.
[0006] The machine includes a rotatable drum having a spaced pair of cylindrically contoured surfaces. An elongated nozzle extends generally tangentially between and from the cylindrical surfaces. In use, the nozzle is inserted into the novel web at a transversely centered position as the web is fed upwardly and around the drum. The web has hermetically closed side edges and longitudinally space pairs of transverse seals. The seals of each pair are spaced a distance equal to slightly more than one half the circumference of the nozzle with which it is intended to be used.
[0007] Each transverse seal extends from an associated side seal toward the center of the web such that successive side seals and the associate side edge together define three sides of a pouch to be fluid filled. When the units being formed are dunnage, as the web passes over the nozzle, web pouches are inflated and the web is separated into two chains of inflated pouches as the nozzle assembly separates the web along longitudinal lines of weakness.
[0008] The chains are fed by the drum and metal transport belts successively under a plurality of heating and cooling shoes. Each shoe has a spaced pair of arcuate web transport belts engaging surfaces which are complemental with the cylindrical drum surfaces. The shoes are effective to clamp the transport belt and the web against the rotating drum as spaced sets of seals are formed to seal the air inflated pouches and convert the inflated pouches into dunnage units. The dunnage units are separated following their exit from the last of the cooling shoes.
[0009] Tests have shown that with pouches having four inch square external dimensions, dunnage units are produced at the rate of eight cubic feet per minute. This contrasts sharply with the machine of the Lemer Patents which produces dunnage units at the rate of three cubic feet per minute.
[0010] Accordingly the objects of the invention are to provide a novel and improved web for dunnage formation and a process of dunnage formation.
IN THE DRAWINGS
[0011] FIG. 1 is an elevational view of the unit formation machine of the present invention;
[0012] FIG. 2 is a plan view of the machine of FIG. 1 as seen from the plane indicated by the line 2 - 2 of FIG. 1 showing a web being fed into the machine;
[0013] FIG. 3 is an enlarged sectional view of a heat shoe and a portion of the drum as seen from the plane indicated by the line 3 - 3 of FIG. 1 ;
[0014] FIG. 3 a is a further enlarged view of the shoe and the drum as seen from the same plane as FIG. 3 ;
[0015] FIG. 4 is a view showing a dunnage embodiment of the machine with components which delineate a air flow path from a supply to and through the cooling shoes and then the inflation nozzle;
[0016] FIG. 5 is a perspective view of a section of the novel and improved web;
[0017] FIG. 6 is a perspective view showing a section of a web as the web pouches are inflated and the web is separated into parallel rows of inflated pouches;
[0018] FIG. 7 is an enlarged plan view of a portion of the web including a transverse pair of heat seals;
[0019] FIG. 8 is a further enlarged fragmentary view of a central part of the web as located by the circle in FIG. 7 ;
[0020] FIG. 9 is a perspective view showing a pair of completed fluid filled units following separation and as they exit the machine; and,
[0021] FIG. 10 is an enlarged view of a preferred support embodiment and a shoe which arrangement is for supporting the shoes in their use positions and for moving them to out of the way positions for machine set up and service.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] While the following description describes a dunnage formation system, it should be recognized the preferred embodiment of the machine is sterilzable so that beverages such as water and fruit juice may be packaged using the novel web, machine and process.
[0023] Referring now to the drawings and FIGS. 1 and 2 in particular, a dunnage formation machine is shown generally at 10 . The machine includes a rotatable drum 12 which is driven by a motor 14 via a gear box 15 and a belt and pulley arrangement 16 , FIG. 2 . In the preferred and disclose arrangement, the drum is comprised of spaced annular disks 18 .
[0024] When the machine is in use a web 20 is fed from a supply, not shown. As is best seen in FIG. 1 , the web 20 passes over a guide roll 22 and thence under a guide roll 24 to an inflation station 25 . The web 20 is fed around the disks 18 to pass under, in the disclose embodiment, three heat shoes 26 which shoes heat metal transport belts 27 to seal layers of the web. The heat softened web portions and the transport belts then pass under cooling shoes 28 which freeze the seals being formed. As the now inflated and sealed web passes from the cooling shoes individual dunnage units 30 are dispensed.
[0025] In practice the machine 10 will be housed within a cabinet which is not shown for clarity of illustration. The cabinet includes access doors with an electrical interlock. When the doors are open the machine may be jogged for set up, but the machine will not operate to produce dunnage units unless the doors are closed and latched.
[0000] The Web
[0026] Referring now to FIGS. 5-9 , the novel and improved web for forming dunnage units is disclose. The web is formed of a heat sealable plastic such as polyethylene. The web includes superposed top and bottom layers connected together at spaced side edges 32 . Each of the side edges is a selected one of a fold or a seal such that the superposed layers are hermetically connected along the side edges 32 .
[0027] A plurality of transverse seal pairs 34 are provided. As best seen in FIGS. 5-7 , each transverse seal extends from an associated side edge 32 toward a longitudinally extending pair of lines of weakness 35 . The longitudinal lines of weakness 35 are superposed one over the other in the top and bottom layers of the web and are located midway between the side edges. Each transverse seal 34 terminates in spaced relationship with the longitudinal lines of weakness which preferably are in the form of uniform, small perforations. The transverse seal pairs 34 together with the side edges 32 delineate two chains of centrally open side connected, inflatable pouches 37 .
[0028] As is best seen in FIGS. 7 and 8 , transverse lines of weakness 36 are provided. The pouches are separable along the transverse lines 36 . Like the longitudinal lines of weakness 35 the transverse lines are preferably perforations but in contrast to the to the longitudinal line perforations each has substantial length. The perforations of the transverse lines 36 , in a further contrast with the perforations of the longitudinal lines 35 , are not of uniform dimension longitudinally of the lines. Rather, as is best seen in FIG. 8 , a pair of small or short perforations 38 is provided in each line. The small perforations 38 of each pair are disposed on opposite sides of and closely spaced from the longitudinal lines 34 . Each transverse line of weakness also includes a pair of intermediate length perforations 40 which are spaced and positioned on opposite sides of the small perforations 38 . The intermediate perforations extend from unsealed portions of the superposed layers into the respective seals of the associated transverse seal pair. The remaining perforations of each line are longer than the intermediate perforations 40 .
[0000] The Machine
[0029] In the embodiment of FIG. 1 , the disks 18 are mounted on a tubular shaft 42 . The shaft 42 is journaled at 44 for rotation driven by the belt and pulley arrangement 16 . The shaft 42 carries a stationary, tubular, nozzle support 45 which extends from around the shaft 42 radially outwardly. A nozzle assembly 46 is carried by a support arm 45 A, FIG. 6 . The nozzle assembly 46 includes an inflation nozzle 48 . As is best seen in FIG. 6 , the nozzle 48 is an elongated tube with a closed, generally conical, lead end portion 49 . The nozzle 48 when in use extends into the web at a central location transversely speaking. The web transverse lines of weakness are spaced slightly more than a one half the circumference of the nozzle so that the web layers fit closely around the nozzle to minimize leakage of air exiting side passages 51 of the nozzle to inflate the pouches 37 .
[0030] The nozzle assembly 46 includes a web retainer 50 which guides the web against the nozzle 48 . The retainer also functions to cause the web to be longitudinally split along the longitudinal lines of weakness 35 into two strips of inflated pouches.
[0031] As is best seen in FIGS. 3 and 3 A, each of the heat shoes 26 has a mirror image pair of heat conductive bodies 52 . The bodies 52 together define a cylindrical aperture 54 , which houses a heating element, not shown. Each heat body 52 includes a seal leg 55 having an arcuate surface substantially complemental with a cylindrical surface of an associated one of the disks 18 . In the disclose embodiment the disk surfaces are defined by thermally conductive silicone rubber inserts 18 s , FIG. 3A . In the embodiment of FIGS. 3 and 3 A, springs 56 bias the legs 55 against the transport belts 27 as the web passes under the heat shoes due to rotation of the drum 12 and its disks 18 . The cooling shoes 38 are mounted identically to the heat shoes.
[0032] Each cooling shoe 28 includes an expansion chamber 58 , FIG. 4 . An air supply, not shown, is connected to a chamber inlet 60 . Air under pressure is fed through the inlet 60 into the chamber 58 where the air expands absorbing heat and thus cooling the shoe. Exhaust air from the chamber passes through an exit 62 . Cooling shoe legs 63 are biased against the web to freeze the heat softened plastic and complete seals.
[0033] In the embodiment of FIGS. 1-4 cooling shoe exhaust air then passes through a conduit 64 to the tubular shaft 42 . Air from the cooling shoes is fed via the conduit 64 and the shaft 42 to a passage 65 in the nozzle support 45 . The passage 65 is connected to the nozzle 48 . Thus air from the cooling shoes is directed to and through the nozzle 48 and the exit passages 51 into the pouches.
[0034] With the now preferred and sterilzable embodiment, cooling shoes 28 ′ as shown in FIG. 10 are employed has a jacket 67 which surrounds a body having cooling fins shown in dotted lines in FIG. 10 . An inlet 60 ′ is provided at the top of the jacket. Air flowing from the inlet passes over the fins cooling them and the exits from the bottom of the jacket. Each of the shoes 28 ′ is vented to atmosphere through an outlet 67 . The nozzle 48 is directly connected to a supply of fluid under pressure and the shaft 42 may be made of solid material.
[0035] A pair of hold down belts 66 are mounted on a set of pulleys 68 . The belts 66 are reeved around a major portion of the disks 18 . As is best seen in FIGS. 3 and 3 A, the belts 66 function to clamp portions of the web 20 against the disks on opposite sides of the shoe legs 55 . While test have shown that the machine is fully operable without the belts 66 , they are optionally provided to isolate pressurized air in the inflated pouches 37 from the heating and cooling shoes.
[0036] A fixed separator 69 is provided. As the inflated pouches approach the exit from the downstream cooling shoe the fixed separator functions to cam them radially outwardly sequentially to separate each dunnage unit from the next trailing unit along the connecting transverse line of weakness except for a small portion under the transport belts 27 .
[0037] A separator wheel 74 is provided, FIG. 1 . The wheel 74 is rotated clockwise as seen in FIG. 1 such that arms 76 are effective to engage completed dunnage units 30 sequentially to complete the separation of each dunnage unit from the web along its trailing transverse line of weakness 36 . Thus, the separator wheel is effective to tear the last small connection of each pouch which was under an associated one of the transport belts as the pouch was substantially separated by the fixed separator 69 .
[0038] In the embodiment of FIG. 1 , each of the shoes 26 , 28 is mounted on an associated radially disposed shaft 71 . Clamping arrangements shown generally at 72 are provided to fix each of the shafts 71 in an adjusted position radially of and relative to the drum 12 . As is best seen in FIG. 3 , each shaft 71 carries a yoke 73 . The springs 56 span between yoke pins 75 and shoe pins 75 to bias the shoes against a web 20 . A cylinder 70 is provided for elevating a connected yoke and shoe for machine set up and service.
[0039] In the now preferred embodiment of FIG. 10 , each shoe is pivotally mounted on an arm 78 . The arm is also pivotally mounted at 80 on a frame 82 . A cylinder 70 ′ spans between the arm and the frame for elevating the connected shoe for set up and service and for urging the shoes 28 into their operating positions. The heat shoes 26 are, in the now preferred arrangement, identically mounted.
[0000] Operation
[0040] In operation, the shoes are elevated by energizing the cylinders 70 of FIGS. 1 and 4 or 70 ′ of FIG. 10 . A web 20 is fed along a path of travel over the guide roll 22 and under the guide roll 24 and thence threaded over the inflation nozzle 48 . The web is then fed under the transport belts and the retainer 50 . As the machine is jogged to feed the web around the discs 18 and the heating and cooling shoes 26 , 28 the web is split by the nozzle support 55 . The split of the web is along the longitudinal line of weakness but the transverse lines of weakness remain intact at this time. Thus, the web portions at opposite ends of the small perforations 38 are of sufficient size and strength to avoid a longitudinal split of the web as the web is fed over the nozzle. Since the transverse seals of each pair are spaced only very slightly more than one half the circumference of the nozzle the web closely surrounds the nozzle to minimize air leakage when the pouches are inflated.
[0041] Next the heating and cooling shoes are elevated by actuating either the cylinders 70 or 70 ′. The web is then fed sequentially, and one at a time, under the heating shoes 26 and the cooling shoes 28 . Since the web has been split by the nozzle support 55 , there are in fact two parallel paths of travel each with an associated transport belt 27 and chain of side connected and inflated pouches.
[0042] Once the web has been fed around the drum to an exit location near the separator wheel 74 and the machine has been jogged until the operator is satisfied the feed is complete and the machine is ready the heat shoe elements will be energized. Air will be supplied to the cooling shoes 28 and the nozzle 48 . Next the motor 14 will be energized to commence machine operation.
[0043] As we have suggested, one of the outstanding features of the invention is that the web closely surrounds and slides along the nozzle. The close surrounding is assured by the transverse seals being spaced a distance substantially equal to one half the circumference of the nozzle 48 . Thus, the two web layers together delineate a nozzle receiving space which will closely surround an inserted nozzle. As the web advances the pouches 37 on opposed sides of the nozzle will be filled efficiently by fluid under pressure exiting the nozzle passages 51 in opposed streams. Where dunnage units are being formed the fluid will be air. The web is then split by the nozzle support into two chains of side connected and fluid filled pouches respectively traveling along associated ones of the two paths of travel.
[0044] Each of the chains is fed under spaced legs 55 of the heating shoes 26 to effect heat seals. As the web passes under cooling shoe legs 63 the seals are frozen and the pouches are separated along most of the length of transverse lines of weakness by the separator. Facile separation is assured by the long perforations because the remaining connections of the web across the transverse seals are short in transverse dimension and few in number.
[0045] When the pouches exit the last of the cooling shoes, they have been formed into finished dunnage units 30 . The finished units 30 are sequentially completely separated from the web by the arms 76 of the separation wheel 74 .
[0046] While the system as disclosed and described in the detailed description is directed to dunnage, again, as previously indicated, units filled with fluids other than air such as water and fruit juices can be produced with the same machine, process and web.
[0047] Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction, operation and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed.
|
A web for the manufacture of fluid filled units with a novel machine and process is disclosed. The web includes an elongate heat sealable, flattened plastic tube comprised of face and back imperforate layers. The layers are imperforately joined together along spaced side edges. The layers include superposed longitudinal lines of weakness disposed generally transversely midway between the side edges. The web has longitudinally spaced, pairs of transverse seals. Each transverse seal extends from a respective side edge to an end near but spaced from the longitudinal lines of weakness. The transverse seal pairs include transverse lines of weakness extending from one side edge to the other generally centrally of each seal in a longitudinal direction. The side edges, transverse seals and lines of weakness together delineating two oppositely oriented strings of pouches with each pouch having three imperforate sides and a centrally located fill opening at its fourth side. The transverse lines of weakness are spaced slightly more than one half the circumference of a cylindrical fluid fill nozzle used to fill the pouches such that the web closely surrounds the nozzle during pouch fluid filling.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 102015004416.8, filed Apr. 2, 2015, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present disclosure pertains to a front section for a motor vehicle which is optimized with respect to different types of collision accidents.
BACKGROUND
DE 10 2009 017 350 A1 discloses a motor vehicle front section with a bumper cladding and a bumper stiffening which extends in the vehicle longitudinal direction between the bumper cladding and cross beam running transversely. Predetermined breaking connections are provided as threaded connections between the cross beam and the bumper stiffening. In the case of a relatively low-energy collision with a pedestrian, the threaded connections should remain intact, in the event of a more energetic collision, possibly with a wall, the shear loading should be sufficient to tear off or tear out the fastener and/or fastener holes.
The tearing out of the fastener holes necessarily includes damage to the cross beam which involves a costly repair. However, the alternative of tearing off of the fasteners is problematical. The force required for tearing off a fastener generally fluctuates unpredictably from case to case. If it is too low, the stiffening effect of the bumper stiffening in the case of a collision is unsatisfactory; if it is too high, collision forces can be transmitted to the cross beam and damage this, which in this case also significantly increases the costs of a subsequent repair.
SUMMARY
The present disclosure provides a front section for a motor vehicle in which even at higher collision energies than those typical of a pedestrian accident, the repair expenditure can be kept low. The front section for a motor vehicle is typically provided with a bumper cladding and a bumper stiffening which extends in the vehicle longitudinal direction between the bumper cladding and a supporting body part. In a configuration of the present disclosure, a connecting unit which fixes a rear edge region of the bumper stiffening on an underside of the body part is inserted from below into an opening of the body part and has flexible legs which are reversibly splayed apart above the opening. These legs can be compressed again under the action of a sufficient tensile force on the connecting unit so that the connecting unit can pass through the opening again and can release bumper stiffening and body part from one another. Since no material must tear or rupture for compressing the legs, but a continuous bending deformation is sufficient, the force required for withdrawing the connecting unit can be reliably determined by simulation and then set reproducibly.
The connecting unit includes a blind nut and a threaded fastener. The legs which are part of the blind nut are splayed apart by screwing the fastener into a thread of the blind nut. In order to enable such a splaying, parts of the legs in the unsplayed state can cross the axis of the thread so that the fastener during screwing into the thread must impact against these sections and must push them aside. The thread can be formed in a base plate of the blind nut and the legs extend out from the edges thereof. Such a blind nut can be manufactured cheaply in one piece from flat material such as a steel sheet, in particular by stamping and bending steps. The legs can each include a distal section and a proximal section connecting the distal section to the base plate where the two proximal sections diverge from the base plate. The distal sections can form the aforementioned sections crossing the axis of the thread in the unsplayed state.
The bumper stiffening and the body part can include sliding surfaces which contact one another at least when the bumper stiffening is pressed back against the body part by a collision. At least one of the sliding surfaces should be inclined towards the vehicle interior in order to convert a collision force directed horizontally towards the vehicle interior into a downward-directed tensile force which acts on the connecting unit. If the bumper stiffening includes a base plate and stiffening ribs projecting upwards from the base plate, one of the sliding surfaces can be formed by an edge of one of these ribs. This can include an upper edge of the relevant rib; As a result of a preferred embodiment, a recess is formed on a rear end of the rib facing the body part and the sliding surface is a part of the edge which delimits this recess.
Alternatively or additionally, the collision force can be converted into a downward-directed tensile force whereby the bumper stiffening includes a projection in a flank opposite a front side of the body part, which contacts the front side at least when the bumper stiffening is pressed back against the body part by a collision and has a recess underneath the projection. Thus, in the case of a collision, a contact point between the projection and the front side of the body part can form an instantaneous axis of rotation about which the rear edge region can rotate where the connection is released by the rotation.
If the bumper stiffening includes a base plate and stiffening ribs projecting upwards from the base plate, the flank can be formed by rear edges of the ribs.
In both the aforementioned embodiments, the ribs can be stiffened by wings projecting in the vehicle transverse direction. Preferably the wings each have a front edge at which they are connected in one piece to the base plate. The wings can extend as far as the rear end of the rib in order to stiffen these directly up to a contact point with the body part.
The bumper stiffening can be curved in longitudinal section with an upwardly facing concavity so that under suitable collision conditions, the bumper stiffening deviates downwards in the region of the concavity and thereby absorbs collision energy and components arranged above the concavity are safe from any damage as a result of their deviation. The bumper stiffening can cross under at least a front part of an engine compartment and specifically in particular a radiator accommodated there.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements.
FIG. 1 shows a schematic longitudinal section through a front section of a motor vehicle according to the present disclosure;
FIG. 2 shows an enlarged detail from FIG. 1 in longitudinal section;
FIG. 3 shows the detail of FIG. 2 in perspective view;
FIG. 4 shows a perspective view of a fastener blind nut used for fastening a bumper stiffening to a body part of the motor vehicle; and
FIG. 5 shows a section through the mounted fastener blind nut in the vehicle transverse direction.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description.
FIG. 1 shows a front section of a motor vehicle in a schematic longitudinal section. Located in the engine compartment in the usual manner are an engine 1 and a radiator 2 . The engine compartment is flanked on both sides by longitudinal members 3 which are connected to one another to form a rigid frame. An auxiliary frame 4 carrying the engine 1 is fastened movably in a damped manner to this frame.
The longitudinal members 3 are provided with flanges 5 at the front ends thereof, to which an upper bumper cross beam 7 is fastened via crash boxes 6 . An intermediate space between the front side of the bumper cross beam 7 and a bumper cladding 8 is filled by a buffer body 9 made of foam.
A lower bumper cross beam 10 is fastened to the flanges 5 below the upper bumper cross beam 7 . In a central region extending in front of the radiator 2 , the lower bumper cross beam 10 is supported by a bumper stiffening 11 against a collision force acting from the front. A front edge of the bumper stiffening 11 is connected in an arbitrary manner, preferably in a torque-proof manner to the bumper cross beam 10 , here it is inserted in a groove 12 on the rear side of the bumper cross beam 10 .
A rear edge region 13 of the bumper stiffening 11 is fastened to a front cross beam 14 of the auxiliary frame 4 by fasteners 15 in a manner which will be explained in further detail by reference to FIGS. 2-4 . The bumper stiffening 11 formed in one piece from plastic has a base plate 16 which extends continuously from the front edge engaging in the groove 12 into the rear edge region 13 . Underneath the radiator 2 the base plate 16 is deflected downwards in the form of a trough extending in the vehicle transverse direction. Stiffening ribs 17 oriented in the vehicle longitudinal direction project from the upper side of the base plate 16 .
FIGS. 2 and 3 show the rear edge region 13 of the bumper stiffening 11 and the cross beam 14 , once in section in the vehicle longitudinal direction and once in a cutaway perspective view. The ribs 17 which extend over a large part of the length of the base plate 16 with uniform height increase in height towards the rear end 18 thereof as far as an apex point 19 which is located approximately at the same height as an upper side 20 of the cross beam 14 formed here as a rectangular hollow profile. The rear end 18 of the ribs 17 here includes a steeply dropping or vertical edge section 21 as well as, underneath this edge section 21 , a recess 22 which is delimited downwards by an edge 23 which slopes down towards the auxiliary frame 4 . The ribs 17 are stiffened in the region of the rear end 18 by wings 24 projecting in the vehicle transverse direction. The wings 24 are, as is clear from FIG. 3 , trapezoidal in plan view, where a wide front edge of the trapezium goes over in one piece into the base plate 16 and a rear edge lies opposite a front wall 25 of the cross beam 14 .
The base plate 16 extends beyond the rear end 18 of the ribs to under the cross beam 14 and is fastened to this by a plurality of fasteners 15 and blind nut 26 which are here each inserted from below into openings 27 in a lower wall 28 of the cross beam 14 . FIG. 4 shows such a blind nut 26 in perspective view. The blind nut 26 is formed in one piece from a sheet metal blank. It includes an approximately rectangular base plate 29 on which a cylinder shaft 30 is formed around a central opening and provided with an internal thread. At the longitudinal edges of the base plate 29 , legs 31 are angled on both sides, each including a proximal section 32 orthogonal to the base plate 29 (in the unloaded state shown in FIG. 4 ) and a distal section 33 angled by 90° with respect to the proximal section, which is bent back over the base plate 29 . A U-shaped gap 34 divides the proximal section 32 into two lateral webs 35 and a central finger 36 which is directly connected to the distal section 33 but not to the base plate 29 and projects slightly sideways beyond the webs 35 . The distal sections 33 overlap one another in the extension of the cylinder shaft 30 .
The openings 27 in the lower wall 28 of the cross beam 14 are rectangular and dimensioned to allow insertion of a blind nut 26 in an orientation in which the longitudinal direction of the base plate 29 coincides with the longitudinal direction of the vehicle. The base plate 29 is longer than the openings 27 so that a stop position of the blind nut 26 is formed by a contact of ends of the base plate 29 with the underside of the lower wall 28 . The length of the fingers 36 is matched to the thickness of the wall 28 so that in the stop position the fingers 36 have completely passed through the opening 27 and their tips lie opposite an upper side of the lower wall 28 . Thus, the blind nut 26 cannot be withdrawn from the opening 27 again without bending at least the fingers 36 .
In order to fasten the bumper stiffening 11 on the cross beam 14 , the fasteners 15 are passed through holes 37 in the rear edge region 13 of the bumper stiffening 11 as shown in FIG. 5 and screwed into the thread of the cylinder shaft 30 . The length of the fasteners 15 is determined so that their tips each impact against the distal sections 33 of the blind nut 26 before the head of the fastener 15 presses the bumper stiffening 11 against the base plate 29 of the blind nut 26 . In order to fasten the bumper stiffening 11 , the fasteners 15 are thus screwed so far into the blind nut 26 that they splay the legs 31 apart on the other side. In this way each blind nut 26 is anchored positively on the cross beam 14 but this tight fit can be cancelled if a downwardly directed tensile force acts on the blind nut 26 via the fastener 15 , which is sufficiently strong to bend the upwardly diverging proximal sections 32 towards one another in a parallel orientation. How large this tensile force is can be predefined exactly and reproducibly by selecting the wall thickness of the blind nut 26 and the shape of the legs 31 .
In the case of a collision in a medium velocity range, preferably between 15 and 40 km/h, the bumper cladding 8 and the bumper stiffening 11 are pushed back towards the vehicle interior and the rear end 18 of each rib 17 comes in contact with the front wall 25 of the cross beam 14 . If the edge section 21 is sufficiently stiff above the recess 22 , a point of the edge section 21 which contacts the front wall 25 can form the axis of a pivoting movement as a result of which, in the view in FIG. 2 in the anticlockwise direction, the bumper stiffening 11 attempts to escape from the collision force. If instead the rib 17 is resilient above the recess 22 and is compressed, the edge 23 slides obliquely downwards along a rounded corner 38 of the cross beam 14 .
In both cases, the fasteners 15 and blind nut 26 are subject to a strong, downwardly directed tensile force through which, if this is sufficiently strong, in order to deform the blind nut 26 , this is withdrawn from the openings 27 of the cross beam 14 . The blind nut 26 is thereby deformed in small space so that despite small size they can absorb an appreciable quantity of collision energy. If the blind nut 26 is torn out from the cross beam 14 , the connection between auxiliary frame 4 and bumper stiffening 11 is cancelled. The auxiliary frame 4 is thereby protected from any deformation by forces transmitted by the bumper stiffening 11 and can in any case be deformed if the collision is sufficiently strong in order to compress the entire front section so severely that the longitudinal members 3 are also deformed. Expensive repairs to the auxiliary frame 4 after a collision at moderate speed can therefore be avoided with a high probability which enables a favorable insurance category for the vehicle according to the present disclosure and reduces the operating costs for the holder.
While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, 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 of the invention as set forth in the appended claims and their legal equivalents.
|
A front section for a motor vehicle includes a bumper cladding and a bumper stiffening which extends in the vehicle longitudinal direction between the bumper cladding and a supporting body part. A connecting unit including a blind nut and a threaded fastener is inserted from below into an opening of the body part to fix a rear edge region of the bumper stiffening on an underside of the body part. The blind nut has flexible legs which are reversibly splayed apart above the opening.
| 1
|
This application is a continuation of application Ser. No. 08/460,911, filed on Jun. 5, 1995, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a superstructure of a folding apparatus.
BACKGROUND OF THE INVENTION
Folding apparatuses are used in conjunction with rotary printing presses in order to fold webs (or ribbons) of printed material. Generally, a full width web of material is cut longitudinally into a number of ribbons by a slitter mechanism prior to folding in the folder apparatus. However, for purposes of this application, the term web encompasses the term ribbon as well.
A folding apparatus is generally coupled to one or more rotary printing presses. Each folding apparatus generally includes a superstructure through which two or more webs of flat printed material are passed before they reach a cylinder unit of the folding apparatus. The superstructure includes a take-off roller corresponding to each web for driving the webs into the cylinders of the folding apparatus. A problem which frequently arises is that the circumferential velocities at which the various take-off rollers must be driven are often different from one another.
Varying circumferential velocities are necessary in order to achieve an identical transport speed of the various webs. For example, it may be necessary to ensure that a predetermined position on the imprint of one web arrives at a cutting device at the same time that the imprint of another web arrives at that cutting device. The necessity for different circumferential velocities of the take-off rollers results, for example, from the different web lengths within a turning rod section of the folder or between a turning rod and a related take-off roller, and from the different tension conditions of the various webs which result from this.
The necessity for different circumferential velocities also results from the so-called radius effect, which occurs if several webs are passed over a single roller, i.e. one above the other. In this case, the webs which are passed over the outside of the roller (e.g. the outermost web) are pulled off more rapidly than the ones which pass over the inside of the roller (i.e. the web which directly contacts the roller), because of their greater distance from the center of the roller. If the webs which are passed further to the outside are now passed to the inside on a subsequent roller, in other words at a slower web velocity in comparison with the preceding roller, wrinkles and other undesirable irregularities of the web product can occur. In order to compensate for such radius effects, the circumferential speed of the subsequent roller is increased by utilizing complicated control mechanisms.
In addition to the technical effort of providing a separate control for each drive roller of a large drive roller assembly, adjustment and monitoring of the circumferential velocity of a large number of rollers can easily overburden the operating personnel. While it is possible to use step-down gears, or separate drives which allow precise velocity adjustment, these devices are cost-intensive and require careful installation. Such devices can also reduce the operational reliability of the system because they have a tendency to break-down.
SUMMARY OF THE INVENTION
In accordance with the present invention, a mantling is provided which can be removably mounted around a take-off roller(s) to adjust the diameter, and therefore the circumferential velocity, of the take-off roller(s). The mantling is fixedly mounted on the take-off roller so that it rotates with it. By mounting mantlings with different wall thickness around the outside surface of the take-off roller, the diameter of the take-off roller and thus the circumferential or take-off velocity of the take-off roller can be adjusted. This makes it possible to take different tension conditions of the various webs into consideration and thus to achieve a predetermined take-off or transport velocity for all of the webs.
In accordance with a first embodiment of the present invention, the mantling is formed in the shape of a sleeve which can be mounted axially on the take-off rollers by pushing the sleeve over the take-off rollers. Such a mantling provides a predetermined take-off velocity which corresponds to the wall thickness of the sleeve. Moreover, a mantling formed as a sleeve can be easily mounted on the take-off roller in a very short period of time, without requiring complicated adjustment or assembly steps.
Since the take-off speed of the web is extremely sensitive to changes in the circumference of the take-off rollers, the wall thicknesses of the mantlings are preferably small. As a result, for a take-off roller having a radius between 3 inches and 8 inches, the wall thickness of the mantlings preferably lies between 20 μm and 150 μm.
The change in velocity (.sup.Δ V s ) of the surface of the take-off roller, as a function of the wall thickness (t) of the sleeve, is governed by the following equation:
.sup.Δ V.sub.s =V.sub.i t/R.sub.i ( 1)
Where .sup.Δ V s is the change in surface velocity due to the addition of the sleeve, V i is the surface velocity without the sleeve, t is the thickness of the sleeve, and R i is the radius of the take-off roller without the sleeve.
In accordance with a second embodiment of the present invention, the mantling is formed as a plate which is attached to the outside surface of the roller in the same manner that a printing plate is mounted to a plate cylinder; i.e. by using clamps to hold each end of the plate onto the roller. The relationship between the thickness of the plate and the change in take-off velocity can be obtained as described above with regard to the first embodiment.
In accordance with a third embodiment of the present invention, mantlings of varying wall thicknesses are provided to adjust the diameters of various rollers. In this manner, the circumferential velocities of the take-off rollers can be adjusted to one of a variety of velocities within a very short period of time. This is particularly advantageous in view of the need to keep the down-time of the rotary printing press and folding apparatus low.
In a accordance with a still further embodiment of the present invention, the sleeve is pushed onto a roller utilizing compressed air. By applying compressed air through apertures in the surface of the take-off roller, the sleeve is expanded slightly and can be pushed onto the take-roller without resistance. Once the sleeve has been brought into the desired position, the compressed air is shut off, the sleeve compresses and is fixed around the outside surface of the take-off roller. In this manner, installation of the mantling onto the take-off roller is accomplished easily and without the need for clamps.
In accordance with a still further embodiment of the present invention, in order to prevent damage to the web as it passes over the sleeve, and particularly to prevent ink from being removed from a printed surface of the web, the mantling may include a carrier which can be applied to the outside surface of the roller, with a resilient coating applied to the outside surface of the carrier. The carrier preferably consists of metal or plastic. The coating is preferably a rubber elastic material. The carrier is applied as a layer to the outside of the sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a superstructure of a folding apparatus according to an embodiment of the present invention.
FIG. 2 shows a more detailed view of a take-off roller carrier and take-off roller assemblies of the superstructure shown in FIG. 1.
FIG. 3 shows an illustrative drive assembly for the take-off roller carrier and take-off roller assemblies of FIG. 2.
FIG. 4 shows a cross-section through a take-off roller of the take-off roller assembly shown in FIG. 2.
FIG. 5 shows a take-off roller and sleeve shaped mantling the take-off roller having a compressed air port.
FIG. 5a shows the take-off roller of FIG. 5, but with a sleeve-shaped mantling of a different thickness.
FIG. 6 shows a mantling according to FIG. 4 having a carrier and resilient coating applied thereto.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a superstructure 2 of a folding apparatus which is coupled to a rotary printing press (not shown). Referring to FIG. 1, the rotary printing press is located behind the superstructure 2, and is aligned along the press centerline 101 such that the web is traveling towards the reader as it exits the rotary printing press. The superstructure 2 includes an intake area 4, also called an angle bar section, and a drive area 6. As webs 10 exit the rotary printing press, they are received at the superstructure 2 and are introduced into the intake area 4 via turning bars 8. From the intake area 4, the webs 10 are guided to the drive area 6, where they first pass onto take-off roller assemblies 14 which are mounted in a take-off roller carrier 12. The take-off roller assemblies 14 are driven by a drive assembly (not shown). In the transport direction 100, webs 10.1, 10.2, 10.3, and 10.4, pass through take-off roller assemblies 14.1, 14.2, 14.3, 14.4 arranged in the upper part of the take-off roller carrier 12. Webs 10.1-10.4 are then guided, as a first layered web, over a first collection roll 16 and a first funnel intake roller 18, into a first folding funnel 20 (following transport direction 110), where the first layered web, which includes webs 10.1-10.4, receives a first lengthwise fold. The other webs 10 which are passed over four take-off roller assemblies 14 arranged in the lower part of the take-off roller carrier 12 are similarly guided as a second layered web over a second collection roll 22 and then over a second funnel intake roller 24, into a second folding funnel 26 following transport direction 110. Below the two folding funnels 20, 26 is a cylinder unit of the folding apparatus, of which only a cutting cylinder 28 is shown. The cutting cylinder 28 cuts the layered webs which have previously been provided with a first lengthwise fold in the first and second folding funnels 20, 26, in a direction perpendicular to the transport direction 120.
FIG. 2 shows the take-off roller carrier 12 and the take-off roller assemblies 14 of FIG. 1 in more detail. The take-off roller carrier 12 includes a carrier strut 32 and the take-off roller assemblies 14 include take-off rollers 34 which are mounted so they can be driven by a drive assembly (not shown). The take-off rollers 14 may further include mantlings 35 which are provided in the form of sleeves 36 with different wall thicknesses. The sleeves 36 can be pushed onto the take-off rollers 34 in order to adjust the diameter of the take-off rollers 14. Sprockets 44 are mounted to each take-off roller 34. For purposes of illustration, only two representative sprockets 44 are shown.
FIG. 3 shows an illustrative drive assembly for the take-off rollers 34. A common belt 220 (or chain) is engaged with each sprocket 44 and wrapped around a drive gear 200. Rollers 210 are used to keep the belt 220 in engagement. A motor (not shown) drives the drive gear 200.
In this manner, take-off rollers 34 which are driven by a common belt drive with an identical angular velocity can nevertheless exhibit different circumferential speeds by providing different take-off rollers 34 with push-on sleeves 36 with different wall thicknesses.
As set forth above, the change in velocity (.sup.Δ V s ) of the surface of the take-off roller 34, as a function of the wall thickness (t) of the sleeve 36, is .sup.Δ V s =V i t/R i , where V i is the surface velocity without the sleeve and R i is the radius of the take-off roller without the sleeve. By choosing sleeves 36 with appropriate wall thicknesses, different take-off rollers 34 can exhibit different circumferential speeds while being driven at the same velocity by a common belt drive. As a result, radius effects, or other tension conditions existing on the material webs 10 which pass over the take-off rollers 34, can be compensated for.
Moreover, since the sleeves 36 can be easily removed and replaced, the circumferential speed of any take-off roller can be quickly and easily adjusted at any time. Since the path of the webs 10 through the folding apparatus superstructure will generally vary according to the requirements of the print job being run at any given time (e.g. number of pages, size of pages, size of signatures), quick adjustment of the circumferential speeds of the take-off rollers is extremely beneficial.
FIG. 4 shows a cross-section through a take-off roller 34 of FIG. 2 mounted on the carrier strut 32. The take-off roller 34 rotates within a bearing housing 40, the bearing housing 40 having two deep groove ball bearings 42 mounted therein. The bearing housing 40 is mounted within an opening 38 of the carrier strut 32, and is fastened to the carrier strut 32 via screws 52. The take-off roller 34 extends through the carrier strut 32, i.e. through the bearing housing 40, and has sprocket 44 (which may be formed as a toothed pulley) on its drive side end 46. The belt 45 (not shown) is engaged with the pulley 44 and drive gear 200 (not shown) to drive the take-off roller 34.
A mantling 48, shown in the form of the partially interrupted line, is applied to the outside surface 50 of the take-off roller 34.
If the mantling 48 is formed as a sleeve 36, it is mounted axially over the surface 50 of the take-off roller 34 from the right side 54 of the take-off roller 34. Referring to FIG. 5, compressed air is applied to an opening 300 in the take-off roller 34. The compressed air travels though a passage 310 in the interior of the take-off roller 34, and escapes though apertures 320 on the surface 50 of the take-off roller 34. Plugs 330 are provided for ease of manufacture. As the sleeve 36 is mounted axially from the right side 54 of the take-off roller, the sleeve 36 is expanded by air pressure, and the sleeve 36 is easily slid over the length of the take-off roller. Once the sleeve is in place, the compressed air is removed, the sleeve contracts, and a friction fit between the take-off roller 34 and the sleeve 36 is formed. FIG. 5a shows a sleeve 36a of a different thickness than the sleeve 36 in FIG. 5.
If the mantling 48 is formed as a plate, it is wrapped around the surface 50 of the take-off roller 34 and clamped. Such clamping can be accomplished in any conventional manner. For, example, clamping mechanisms 100 (shown schematically in FIG. 4) such as those used for printing plates can be used, including the mechanism disclosed in U.S. Pat. No. 5,284,093 to Guaraldi et al, the specification of which is hereby incorporated by reference. As with the sleeve shaped mantlings, plate shaped mantlings may be provided in a variety of thicknesses, and be installed and removed as appropriate in order to adjust the circumferential speed of the take-off rollers 34. The change in velocity (.sup.Δ V s ) of the surface of the take-off roller 34, as a function of the thickness (t) of the plate shaped mantling, is .sup.Δ V s =V i t/R i , where V i is the surface velocity without the mantling and R i is the radius of the take-off roller without the mantling.
Referring to FIG. 6, in accordance with a further embodiment of the present invention, a carrier 400 is applied to the surface 50 of the mantling 48, and a resilient coating 410 is applied to an outside surface 420 of the carrier 400. The carrier 400 is preferably made of metal or plastic. The resilient coating 410 is preferably an elastomeric material such as rubber. The addition of the carrier 400 and coating 410 prevents the ribbon 10 from being damaged as it passes over the mantling, and, in addition, prevents ink from being removed from the surface of the ribbon 10 as it passes over the mantling 48. While the carrier 400 and coating 410 have been shown as applied to a sleeve shaped mantling, it should be understood that the carrier 400 and coating 410 can be applied to a mantling 48 formed as a plate as well.
|
A superstructure of a folding apparatus for feeding at least two webs of flat material to a cylinder unit of the folding apparatus. The superstructure including at least two take-off roller assemblies, each take-off roller assembly including a corresponding take-off roller rotatably mounted on the superstructure. At least one mantling is provided for mounting on an outer surface of each take-off roller in order to adjust a diameter of the corresponding take-off roller assembly. A drive assembly is provided for driving the at least two take-off roller assemblies, each of the at least two take-off roller assemblies having a respective circumferential velocity which is a function of the adjusted diameter of the take-off roller assembly.
| 1
|
CROSS REFERENCE TO CO-PENDING APPLICATION
This application claims priority benefit of the filing date of U.S. provisional Patent Application Ser. No. 60/494,626, filed Aug. 12, 2003, now abandoned, the entire contents of which are incorporated herein by reference.
BACKGROUND
The present invention relates to a restraining harnesses for animals. Harnesses have been used as a functional device for animals since the time that animals have been domesticated and integrated into the human culture. With increased domestication and integration into the family life the desire to utilize humane control devices for pets has also increased. Restraining pets in a manner which minimizes and/or eliminates undesirable behaviors such as tugging and pulling while walking on a leash is especially desirable.
Prior art harnesses that discourage the tugging/pulling behavior include devices, such as choke collars and prong collars, that create a tightening effect when the animal pulls against the leash.
Prior art harnesses with restraining properties include designs that place pressure underneath the front legs of the animal. These devices may be effective in reducing tugging and pulling, however, the pressure placed on the soft tissue between the legs and chest cavity is often painful for the animal. Although some slight discomfort can be expected in controlling devices, these devices exhibit a high amount of pain and in some cases damage to muscle/tissue.
Prior art designs due to the complex, design and attachment schemes make the harness difficult to place and adjust on the animal. The complex nature of these designs make them difficult to quickly place on an animal. Due to the highly active nature of animals, particularly canine puppies and young adults, the complex installation of such devices becomes even more trying.
The prior art also discloses a restraining harness that tightens around the girth of the animal. The complex nature of this design exhibits properties that make the harness complex to manufacture and assemble.
Thus, it would be desirable to improve upon prior art harnesses by providing a harness which discourages tugging/pulling in a manner than is more comfortable for the animal; that is easily placed on, removed, and secured to the animal, and is easily manufactured and assembled.
SUMMARY
The present invention is an animal restraining harness which minimizes undesirable tugging and pulling of an animal in a manner in which creates only a slight discomfort to the animal.
In one aspect, the inventive harness includes a first front chest portion having first and second ends. A second rear chest portion has first and second ends. The first ends of the first front chest portion and the first end of the rear chest portion are connected to a first connector, and the second end of the front chest portion and the second end of the rear chest portion are connected to a second connector.
A connecting chest portion has first and second ends coupled to the first and second front chest portions and rear chest portions, respectively. A restraining means is flexibly coupled to the first and second connectors for pulling the first and second connectors together to reduce the diameter or girth of the first and second rear chest portion about an animal upon a pulling force exerted by the animal on a leash attached to the restraining means by leash attachment means coupled to the restraining means.
The first and second front and rear chest portions are formed of flexible straps. Length adjustment means may be provided in one or both of the first and second straps. At least one or two openable buckles are formed on the second strap for separating the second strap into separable portions for placement and removal of the harness on and from the animal.
The second strap has at least one cushioned exterior surface facing the animal when the second strap is mounted about the girth of the animal.
The animal restraining harness of the present invention effectively minimizes undesirable tugging and pulling of an animal wearing the harness by creating a slight discomfort to the animal rather than pain or potential to damage to internal organs, muscle, or tissue. The harness is easily applied to and removed from an animal.
BRIEF DESCRIPTION OF THE DRAWING
The various features, advantages, and other uses of the present invention will become more apparent by referring to the following detailed description in which:
FIG. 1 is a perspective view showing the animal restraining harness of the present invention mounted on an animal;
FIG. 2 is a perspective view of the inventive animal restraining harness;
FIG. 3 is a partial, top perspective front view of the restraining means of the inventive harness depicted in a normal, non-force applied position on an animal; and
FIG. 4 is a perspective view of the restraining means shown in FIG. 3 , but depicted in a girth reducing, restraining force applied position.
DETAILED DESCRIPTION
Referring now to FIGS. 1–4 , an animal restraining harness 10 constructed in accordance of the teachings of the present invention is depicted. Although the animal restraining harness 10 , hereafter referred to simply as the “harness 10 ”, is depicted in FIG. 1 as being mounted over the front body portion of a canine, it will be apparent that the harness 10 can be easily used on all kinds of domesticated and undomesticated animals. Thus, the following description of one use of the inventive harness 10 on a canine or dog would be understood to be by example only.
As shown in FIG. 1 , the harness 10 is designed for use in conjunction with a handling device, such a leash 12 having a snap-like connector 14 mounted on one end of a lead 16 .
As shown in FIGS. 1–4 , the harness 10 includes a first, front chest portion 20 , a second, rear chest portion 22 , a connecting chest strap portion 24 , connector means 26 and 28 , and a restraining means 30 .
The first front chest 20 is in the form of a first strap 34 having a first end 36 and a second end 38 . The first strap 34 is formed of a suitable flexible strap material, such as nylon webbing, although leather or other materials can also be used.
The first and second ends 36 and 38 of the first strap 34 are looped over themselves and joined in an overlapping manner to the strap 34 by stitching 40 , heat or sonic welding, etc. This forms a loop at the first and second ends 36 and 38 which can be inserted through and around an opening in the connector means 26 and 28 , respectively, as described in greater detail hereafter.
The first strap 34 may also include an optical length adjusting means 42 in the form of a slide three bar having two open loops formed by a spaced center leg and two outer legs. The loop at the second end 38 of the strap 34 is mounted around the center leg of the slide 42 . The remaining portion of the second end 38 of the strap 34 is looped through the connector 28 , and back through the slide 42 before continuing on to the first end 36 .
Alternately, the first strap 34 may be provided in a fixed length for certain sized animals and different lengths for other sized animals, such as small, medium, large, dogs, etc.
The second rear chest portion 22 is also formed of a flexible, second strap 44 , made of a suitable material, such as nylon webbing, leather, etc. The strap 44 has a first end portion 46 and a second end portion 48 .
The second strap 44 may be provided with an optional length adjustment means 50 in the form of a three bar slide element which receives looped over portions 52 at an end of the second strap 46 , in the same manner as the slide 42 and the second end 38 of the first strap 34 . The optional length adjustment means allows the length of the second strap 44 to be easily adjusted to accommodate different size dogs.
Alternately, the second strap 44 can be provided in different sizes, in conjunction with different sizes of the first strap 34 to accommodate different size ranges as animals, such as small, medium, and large dogs.
To simplify attachment of the harness 10 on an animal, such as a canine, one or two releasable buckles 54 and 56 are employed. The buckles 54 and 56 may be a conventional tongue and socket type buckle, such as one sold under the trade name Wienerlock by National Moulding. One portion, such as the spring finger, tongue portion of the buckle 54 receives a looped end portion 60 of the second strap 44 . The similar spring arm tongue portion of the buckle 56 receives the looped end portion 52 at the other end of the second strap 44 .
A short length connector strap 62 has looped ends, joined by stitching, heat welding, etc., between one leg of the connector 26 and a socket portion of the buckle 46 . Similarly, another connector strap 64 is looped between the one leg of the second connector 28 and the socket portion of the buckle 56 .
The use of two buckles 54 and 56 ensures that the lower chest connector portion strap between the first front chest portion of strap 34 and the connector strap 24 remains centered on the animal. In addition, one or both of the buckles 54 or 56 can be opened to enable the second strap 44 and the first strap 34 to be urged over the head of the animal with the first front chest portion 20 , which includes the strap 34 , extending in front of the animal's legs. The open buckle 54 or 56 is then snapped together to securely mount the rear chest portion 22 , formed of the strap 34 , about the chest or girth of the animal, behind the front legs of the animal as shown in FIG. 1 .
The connecting chest strap 24 is also formed of a strap 70 constructed of a suitable strap material, such as nylon webbing, leather, etc. The strap 70 has a first end 72 and an opposed second end 74 . Although the strap 70 could be securely and immovably fixed to the straps 34 and 44 at the ends 72 and 74 , respectively, in one aspect of the present invention, the entire strap 70 is slidably mounted on the straps 34 and 44 . This is achieved by forming the first and second end 72 and 74 of the strap 70 with loops in which the free ends of the strap 70 are looped over the strap 70 and fixedly secured to the strap 70 by stitching 76 , heat welding, etc.
The connectors 26 and 28 may be any suitable plastic or metal connector having multiple strap connector portions. Thus, the connectors 26 and 28 could be in the form of a circular ring which is capable of receiving the looped end of the various straps 34 and 44 and the restraining means 30 , as described hereafter. By way of example only, the connectors 26 and 28 are illustrated as being in the form Halter Square connectors. Such a connector 26 and 28 has a circular portion surrounding a circular aperture 80 and two generally polygonal legs 82 and 84 , each of which has a slot-shaped aperture 86 and 88 formed therein. The slots 86 and 88 provide an opening for receiving a portion of the looped ends 36 and 38 of the first chest portion 20 , and the connector straps 62 and 64 of the second, rear chest portion 22 . A larger circular aperture 80 in each of the connectors 26 and 28 receives a looped end of the restraining means 30 .
The restraining means 30 of the present invention is formed of a strap 90 constructed of a suitable material, such as nylon webbing, leather, etc. The strap 90 is formed in a loop wherein opposing ends of the strap 90 , after insertion through the apertures 80 in the connectors 26 and 28 are overlapped and fixedly joined together in at least one or more locations by fixing means, such as stitching 92 , shown by example in FIG. 2 , or by heat welding, etc. The fixing means or stitching 92 forms a transverse bore which receives a leash attachment means or connector 94 , such as a D-ring. The ring 94 provides an attachment for the snap connector 14 on one end of a leash 12 , as shown in FIG. 1 .
Referring now to FIGS. 3 and 4 , the restraining means 30 is depicted in the form of the strap 90 looped between the connectors 26 and 28 .
In FIG. 3 , the restraining means 30 is depicted in a normal mounting position on an animal. The second strap 44 is adjusted in length so as to snugly, but not compressively, fit around the girth or chest of the animal such that the connectors 26 and 28 are spaced apart a suitable distance so that the strap 90 of the restraining means 30 lies in a substantially fully extended, flat position above or on the withers of the animal.
However, when the animal exerts a force against the harness 10 and the attached leash 12 such as by trying to pull away from the person holding the leash 12 , a reactive force will be exerted on the restraining means 30 which will cause upper portion of the strap 90 of the restraining means 30 to extend at the connection point to the ring 94 in the direction of the arrow 96 in FIG. 4 away from the animal. Due to the flexible nature of the strap 90 , this extension of the upper portion of the strap 90 pulls the connectors 26 and 28 together in the direction of arrows 98 reducing the diameter of the second strap 24 and exerting a compressive force on the rib cage of the animal. This tightening pressure causes the animal to immediately reduce the pulling force on the leash 12 . Since the restraining force is applied across the entire chest or rib cage of the animal, the potential for damage to muscles, tissues or organs is minimized.
As soon as the animal reduces the pulling force, the diameter of the second strap 44 will return to its original mounting diameter which will flatten out or return the strap 90 to its maximum loop length as shown in FIG. 3 .
In addition to reducing pulling, the harness 10 also minimizes the possibility of escape of the animal from the harness 10 . The same tightening of the rear chest portion or strap 44 about the rib cage of the animal behind the front legs of the animal will prevent the animal from retracting its from legs through the rear chest strap 44 to escape from the harness 10 .
The inventive harness 10 effectively minimizes undesirable tugging or pulling of an animal in a manner that creates only a slight discomfort rather than pain or potential damage to internal organs, muscle, or tissue. The tightening of the harness applies an even pressure across the rib cage of the animal. The contraction of the rib cage creates a reaction which is less than comfortable to the animal. Thus, the animal stops pulling to relieve the unwanted pressure. Additionally, the harness 10 is easily applied to and removed from an animal.
|
An animal restraining harness includes first and second straps connected at opposed ends to connectors. A center chest strap extends between the first and second straps. A flexible restraining strap is looped between the connectors and is attachable to a leash. The restraining strap enables the first and second connectors to be pulled together reducing the diameter of the second strap as a result of a pulling movement of an animal wearing the harness which applies pressure on the rib cage of the animal.
| 0
|
This application is a continuation of Ser. No. 554,287, filed Feb. 28, 1975, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to combination electrodes of the type which include both the measuring and reference electrodes of a potentiometric electrode system. The electrode combination may be a pH electrode, other specific ion electrodes or a redox electrode.
More particularly the invention relates to a structure for a combination electrode which minimizes the effects of harsh environments such as voltage gradients within a process sample.
In the past there has been considerable difficulty in getting a consistent pH measurement, for example, in plating baths and chlorine production cells because of the large voltage gradients which exists in such process samples. For example, in a chlorine production cell the bath may carry 80,000 amperes of d.c. current and it may be at 250 volt d.c. above ground. In such applications pH electrodes of all available types have been considered and many complicated arrangements have been attempted to avoid the effects on the pH measurement of the high voltage gradients occurring in the bath. Until the invention of the present combination electrode previous attempts to obtain consistent, dependable pH measurements in such baths have not been successful.
As is well known in electrochemical measurements, and specifically the potentiometric type measurements, there is usually utilized a measuring half cell and a reference half cell. The measuring half cell may be a high impedance device such as a glass electrode, for the determination of pH, that generates a potential with respect to the liquid sample medium such that that potential is a function of the hydrogen ion concentration of the sample. The reference electrode provides a potential that is substantially independent of the variable composition of the sample. The reference half cell comprises generally a piece of metal in contact with a mass of sparingly soluble salts of that metal, the assembly being placed in a salt bridge solution. The salt bridge solution has a nonmetallic ion in common with the sparingly soluble metal salt. In order to establish contact between the metal and the sample solution there is generally provided a reference junction that allows a constant diffusion of the salt bridge solution from the reference electrode when the electrode is wetted by the sample. Well known examples of reference half cells, commonly referred to as reference electrodes, are the silver-silver chloride electrodes and the calomel electrode. The electrolyte or salt bridge solution for both types is usually potassium chloride.
Many different structures have been utilized to provide the reference junction of the reference electrode. Such reference junction structures have included the use of thin ceramic coatings on the inner portion of the body of the reference electrode which provides a very limited leakage path between the reference electrode electrolyte and the sample. Such arrangements have been suggested where the centrally oriented glass electrode for pH measurement is surrounded by the body portion of the reference electrode whose end is lined with a ceramic coating with the space between that ceramic coating and body reference electrode being sealed by an elastomeric element.
Others have utilized elastomeric elements sealing the cavity between a central pH electrode and a surrounding electrode body where the body of the glass electrode has been roughened to provide for a small amount of leakage of the reference electrode electrolytes. In both of the above mentioned arrangements the leakage of the electrolyte takes place over a complete 360° arcuate span and all of these prior devices have utilized liquid electrolytes which require, under normal conditions, frequent replenishment. These prior art devices all have the disadvantage of providing a reference junction whose resistivity is not uniform throughout the 360° span over which it is effective and hence electrodes using such arrangements are subject to erroneous measurements when the electrodes are used in samples subject to high voltage gradients.
The arrangements of the prior art described above also generally have the disadvantage of being subject to clogging, particularly where the sample is likely to coat or foul the leaking region.
It is an object of the present invention to provide a combination measuring reference electrode which would be substantially free from the disadvantages of the prior art when utilized in samples subject to voltage gradients.
SUMMARY OF THE INVENTION
The combination electrode of the present invention provides a measuring electrode with a reference electrode having a body portion surrounding the body portion of the measuring electrode. The reference electrode utilizes an annular element of porous material positioned to close the cavity between the body portions of the measuring and reference electrodes and provide a large annular area exposed to the sample in close proximity to the measuring electrode and concentric therewith so that in conjunction with the electrolyte of the reference electrode there is formed a reference junction having a uniform resistance over all radial segments. The electrolyte of the reference electrode is contained in the cavity between the body portions of the reference and measuring electrode and is a saturated gel.
BRIEF DESCRIPTION OF THE DRAWING
The DRAWING shows a sectional view of part of a combination measuring and reference electrode of the type used for measuring pH.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown the lower portion of a combination pH electrode which includes a centrally located glass electrode having a cylindrical body portion 10 closed at its lower end by a pH sensing glass membrane 12. The glass electrode contains an internal pH buffer solution including potassium chloride. There is immersed in that buffer solution a chloridized silver wire 16.
The centrally oriented glass electrode is surrounded by the cylindrical body portion of the reference electrode, namely, body portion 18. An annular element 20 of porous material is provided to close off the cavity between the body portion of the measuring and reference electrodes. The element 20 is sealed to the glass electrode by means of the 0 ring 22 so as to form a liquid-tight seal therebetween. The element 20 as shown in the drawing consists of a thick porous cylinder which may desirably have a density that is uniform so that the reference junction for the electrode combination it provides has approximately the same specific resistance for any equal segment of the porous element when the reference electrode is filled with electrolyte. The porous material at which the reference junction is formed may, for example, be cordierite. It is desirable that the electrolytic resistance of the reference junction should be low, that is in the order of 1,000 ohms, and have relatively large area in the order of 50 square millimeters.
The electrolyte contained in the cavity 24 between the body portion of the reference and measuring electrodes preferably consists of a gel such as xantham, which is a complex polysaccharide having the characteristic that it has nearly constant viscosity over the temperature range of zero to 130° Centigrade. Other materials such as methylcellulose, which thickens at higher temperatures, can be used as the gel where desirable. Included in the gel are sufficient quantities of potassium chloride crystals and silver chloride crystals to maintain complete saturation over an operating temperature, for example, of a range of -5 to +110° Centigrade. Thus, the electrolyte of the reference electrode is a non-flowing electrolyte which depends on diffusion through a relatively open and large area reference junction of the type provided by the element 20.
The electrolyte of the reference junction is contacted by a silver wire 30 which forms the silver-silver chloride element for the reference electrode.
When utilizing the electrode structure of the figure in a process having currents passing through them which cause voltage differentials between any two points not at 90° to the current flow it has been found that consistant and dependable measurements can be obtained. The same results can be obtained when using the electrode in samples having a low specific conductance wherein there can be generated potentials due to electron shearing. Thus, the electrode structure of the figure is useful in plating baths, chlorine production cells, and in measurements in flowing low conductivity water where streaming current potentials can exist.
The combination electrode of the figure with its centrally located measuring electrode and continuous annular element forming the reference junction for the reference electrode obtains a measurement unaffected by the voltage gradients regardless of the positioning of the combination electrode. This results because the orientation of the measuring electrode and the reference junction of the reference electrode results in voltages due to the voltage gradient in the sample which occurs between the measuring electrode and the reference junction are always equal and opposite. Thus, the final result is that the net effective external voltage due to the voltage gradient in the sample is zero regardless of the direction of orientation of the voltage field with regard to the electrode. Consequently, any changes in the process that change the direction of the voltage field, such as placing material to be plated within a plating bath, will not affect readings obtained with the electrode of this invention. The conventional structures of the measuring and reference electrodes, whether they be separate probes or of a single-probe variety such as the prior art arrangements for combination electrodes, effectively bridge across a potential in the field in the sample so as to add to the potential detected by the electrode system, and hence that measured by any associated measuring instrument. The potential measured with prior art systems will be the voltage between the measuring and reference electrodes due to the pH of the sample plus the potential due to the voltage gradient in the sample.
Using the gel electrolyte saturated with potassium chloride and containing an excess of potassium chloride crystals, the reference electrode functions by the diffusion of potassium chloride from the reference electrode reservoir in the cavity between the measuring and reference electrode bodies when the porous reference is wetted by the sample. The gel, of course, controls the rate of diffusion and serves to provide a combination electrode wherein the electrolyte of the reference electrode does not require large storage volume and maintains a useful electrode system for a long period of time without replenishment of the electrolyte. By virtue of the lack of need for an external reservoir for the reference electrode electrolyte there results a reduction in the danger from electrical shock when the electrode system is used in samples that are operated off ground potential.
|
A combination measuring and reference electrode which has a large annular reference junction around the centrally located measuring electrode filled with a gel electrolyte so as to provide an equal resistivity at the junction in all radial sectors to prevent a net voltage difference between the measuring and reference electrodes due to voltage gradients in the sample.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under 35 U.S.C. §119(e) of the filing date of U.S. Provisional Patent Application No. 61/800,542, filed on Mar. 15, 2013, entitled “Enhanced Disk Actuator Modeling,” the entirety of which is herein incorporated by reference.
BACKGROUND
This specification relates to computer-implemented modeling of gas and liquid flows in turbines.
Computer simulation of gas and liquid flows in axial-flow turbo machines is a sophisticated class of applied computational fluid dynamics problems due to combination of geometrical complexity of the computational domain and the large impact of additional physical effects, such as flow turbulence and separation, blade tip vertices, and wake instability. High fidelity discrete models based on 3D unsteady Navier-Stokes equations result in computationally demanding and expensive simulations.
Simpler models for such turbine systems can be constructed by a disk actuator model using 2D Navier-Stokes equations in which all blade wheels are modeled in an unducted turbine of zero thickness in an incompressible fluid of constant density.
SUMMARY
An Energy Extractor Disk Actuator model for simulating axial-flow propellers, fans, turbine and turbo compressor impellers and blade wheels is suggested along with qualitative evaluation of its fidelity. The model is intended for preliminary cost-effective engineering analysis of turbo machines based on 2D (axially symmetric) Euler or Navier-Stokes equations. It uses the same approximate representation of a blade wheel as an “equivalent” axially symmetric disk actuator as classical Betz' model [1] and Glauert's Blade Element Momentum Theory [2]. However, the suggested model is capable of supporting a significantly wider range of practical applications, since a) it does not use initial assumptions regarding magnitude of radial flow speed, b) it takes into account finite thickness of a blade wheel, and c) it is equally applicable to compressible flows, in contrast to the Betz' and Glauert's approaches.
In general, one innovative aspect of the subject matter described in this specification can be embodied in methods that include the actions of computing a total torque of a turbine from lift and drag coefficients of the turbine, including obtaining, along multiple points of a blade of a turbine from a minimum radius rmin of the blade to a maximum radius rmax of the blade, lift coefficients C yi and drag coefficients C xi ; obtaining, at the multiple points of the blade from rmin to rmax, corresponding components of an upstream fluid flow velocity vector u h,Ri and u φ,Ri and components of a downstream fluid flow velocity u h,Li and u φ,Li ; computing averaged directions β i , of the upstream and downstream fluid flow velocity vectors using the components of the upstream fluid flow velocity vector u h,Ri and u φ,Ri and the components of the downstream fluid flow velocity u h,Li and u φ,Li ; and computing the total torque M of the turbine including summing, from rmin to rmax, (C xi sin β i +C yi cos β i ). Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods. A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions.
The foregoing and other embodiments can each optionally include one or more of the following features, alone or in combination. The actions include obtaining, from rmin to rmax, averaged dynamic pressures q i ; using corresponding components of the upstream fluid flow velocity vector u h,Ri and u φ,Ri and corresponding components of the downstream fluid flow velocity u h,Li and u φ,Li , wherein the total torque M of the turbine is further based on the averaged dynamic pressures q i . computing the total torque M of the turbine comprises summing, from rmin to rmax, q i (C xi sin β i +C yi cos β i ). The actions include obtaining a number of blades N of the turbine; obtaining, from rmin to rmax, chord lengths L i of the blade; and computing, from rmin to rmax, solidity factors σ i according to L i ×N/2π·r, wherein r is the length of the radius from rmin to rmax, wherein the total torque M of the turbine is further based on the solidity factors σ i . Computing the total torque M of the turbine comprises summing, from rmin to rmax, σ i ·(C xi sin β i +C yi cos β i ). The actions include computing the output mechanical power of the turbine P by multiplying the total torque M by turbine rotational speed Ω. The actions include computing, from rmin to rmax, enthalpy jump values from an upstream enthalpy value H Ri to a downstream enthalpy value H Li ; and computing the total average power of the turbine P avg including summing, from rmin to rmax, the enthalpy jump values. P avg is given by:
P avg = 2 Π ∫ rm i n rmax r · ρ · u hi ( H R - H L ) · ⅆ r ,
where r is the radius of the turbine blade. The actions include computing the coefficient of hydrodynamic efficiency η according to:
η = M × Ω P avr ,
wherein Ω is the turbine rotational speed. The enthalpy jump values for an incompressible fluid are given by:
H Ri - H Li = p Ri - p Li ρ + u φ , Ri 2 - u φ , Li 2 2 ,
wherein, from rmin to rmax, p Ri are upstream pressure values, p Li are downstream pressure values, and p is the density of the fluid. The enthalpy jump values for a compressible fluid are given by:
H Ri - H Li = [ E int , R + p Ri ρ Ri + u h , Ri 2 + u φ , Ri 2 2 ] - [ E int , L + p Li ρ Li + u h , Li 2 + u φ , Li 2 2 ] ,
wherein E int represents the internal energy of the fluid per unit mass and depends on pressure p and temperature of the fluid T, and wherein P Ri are upstream pressure values, p Li are downstream pressure values, ρ Ri are upstream density values, ρ Li are downstream density values of the fluid.
In general, another innovative aspect of the subject matter described in this specification can be embodied in methods that include the actions of computing a total torque of a turbine from lift and drag coefficients of the turbine, including obtaining, along multiple points of a blade of a turbine from a minimum radius rmin of the blade to a maximum radius rmax of the blade, lift coefficients C yi and drag coefficients C xi ; obtaining, at the multiple points of the blade from rmin to rmax, corresponding components of an upstream fluid flow velocity vector u hi and u φI and components of a downstream fluid flow velocity u hi and u φI ; computing averaged directions β i of the upstream and downstream fluid flow velocity vectors using the components of the upstream fluid flow velocity vector u hi and u φI and the components of the downstream fluid flow velocity u hi and u φI ; and computing the total drag X of the turbine including summing, from rmin to rmax, (C yi sin β i −C xi cos β i ). Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.
The foregoing and other embodiments can each optionally include one or more of the following features, alone or in combination. The actions include obtaining, from rmin to rmax, averaged dynamic pressures q i ; using corresponding components of the upstream fluid flow velocity vector u hi and u φI and corresponding components of the downstream fluid flow velocity u hi and u φI , wherein the total torque M of the turbine is further based on the averaged dynamic pressures q i . Computing the total drag X of the turbine comprises summing, from rmin to rmax, q i ·(C yi sin β i −C xi cos β i ). The actions include obtaining a number of blades N of the turbine; obtaining, from rmin to rmax, chord lengths L i of the blade; and computing, from rmin to rmax, solidity factors σ i according to L i ×N/2π·r, wherein r is the length of the radius from rmin to rmax, wherein the total torque M of the turbine is further based on the solidity factors σ i . Computing the total drag X of the turbine comprises summing, from rmin to rmax, σ i ·(C yi sin β i −C xi cos β i ).
Particular embodiments of the subject matter described in this specification can be implemented so as to realize one or more of the following advantages. A system can compute more accurate parameters of a turbine without the computational complexity of a full 3D model. The system can use 2D equations that are more accurate than a classical disk actuator model. The system can compute turbine parameters for ducted or unducted turbines, multistage turbines, turbines with stators or rotating blades, compressible or incompressible fluids, and turbines having a finite thickness.
The details of one or more embodiments of the subject matter of this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the lateral section of a wide angle ducted turbine with slot for boundary layer control.
FIG. 2 illustrates the integration area and contour in a lateral section of a disk actuator.
FIG. 3 is a flow chart of an example process for computing torque, drag, and power using jump conditions.
FIG. 4 illustrates the cross-sectional blade element at radius r and φ=π/2.
FIG. 5 illustrates a transformed integration area and contour in a lateral section of disk actuator.
DETAILED DESCRIPTION
Computer simulation of gas and liquid flows in axial-flow turbo machines constitutes one of the most sophisticated classes of applied computational fluid dynamics (CFD) problems due to combination of geometrical complexity of computational domain, essentially unsteady flow pattern, and large impact of additional physical effects, such as flow turbulence and separation, blade tip vertices, wake instability, etc. So, high fidelity discrete models based on 3D unsteady Navier-Stokes equations result in extremely computationally demanding and expensive simulation (see, for example, [3-5]). At preliminary stages of turbine design, for geometrically optimizing blade shapes and other components of turbine assembly it is necessary to run multiple problem variants, so such precise models are unusable because of enormous amount of required computer resources. In this case, a simplified (approximate) flow model could offer an appropriate cost-effective modeling tool for preliminary design.
Approximate models for simulating turbines are usually constructed on the basis of various versions of the Energy Extractor Disk Actuator principle originally suggested by A. Betz [1], and later extended by H. Glauert [2]. The Blade Element Momentum Theory (BEM) intended for approximately representing hydrodynamic impact of an “equivalent” disk actuator on flow in a turbine in terms of hydrodynamic properties of blade sections, had been also developed by the latter researcher. Present-day numerical techniques aimed at simplified design of turbines use the classic disk actuator principle and BEM in combination with analytic or semi-analytic approximations of upstream and downstream flows (see, for example, [6]), or numerically simulating upstream and downstream flows using 2D Navier-Stokes equations (see, for example, [7]). In a number of most recent researches the disk actuator principle or its further extension for fully 3D flows, the Actuator Line Model (ALM), is used for modeling blade wheels in combination with full 3D Reynolds-averaged Navier-Stokes equations (see, for example, [5,7]). However, as long as such hybrid approaches require solving a full 3D CFD problem with turbulence and/or large eddy models, i.e. restore original computational complexity, they cannot be considered as cost-effective solutions.
A more general axially symmetric disk actuator model is suggested below. Due to taking into account extra physical effects, such as finite radial flow speed, finite thickness of disk actuator, and fluid compressibility, it provides significantly wider range of practical applications as compared with previously developed similar models.
The system of conservation laws describing fluid motion in a generalized curvilinear time-dependent coordinates (ξ, η, ζ), i.e. Navier-Stokes equations, can be written in the following divergent form:
∂
Q
∂
t
+
∂
(
E
-
E
v
)
∂
ξ
+
∂
(
G
-
G
v
)
∂
η
+
∂
(
F
-
F
v
)
∂
ϛ
=
S
-
S
v
,
(
1
)
where Q is vector of mass, momentum, and energy densities; E, G, and F are vectors of convective fluxes in respective directions ξ, η, and ζ; E v , G v , and F v are vectors of dissipative fluxes; S and S v are vectors of densities of respective convective and dissipative sources. Explicit expressions for those vectors depend on both physical properties of the fluid and selected coordinate system (ξ, η, ζ). If all dissipative fluxes and sources are zero E v =0, G v =0, F v =0, and S v =0, then Navier-Stokes equations (1) reduce to the Euler ones.
When using a differential turbulence model, system (1) should be extended with auxiliary equations describing evolution of local parameters of turbulence, such as average kinetic energy of turbulent motion k and its dissipation rate ε in the (k−ε) model. Also, when modeling a flow of non-equilibrium chemically reacting gas mixture, system (1) should be extended with extra equations describing transition and diffusion of mass concentrations of chemical components with source terms defining rates of production of the components in chemical reactions. However, in our considerations below it is supposed that turbulence and non-equilibrium chemical reactions do not create significant impact on free stream flow structure outside of boundary layers, so the mentioned additional equations are not required.
Let's now consider typical problem of approximately modeling an axial-flow turbo machine. An example of such problem, ducted hydro turbine with boundary layer control, is illustrated in FIG. 1 below. As long as simplified engineering model implies steady-state axially symmetric flow field, the latter can be compactly represented in cylindrical coordinate system (h, r, φ) whose cylindrical axis coincides with the turbine axis (see FIG. 1 ). In this case ξ=h, η=r, ζ=φ, ∂Q/∂t=0, ∂(F−Fv)/∂ζ=0, and Navier-Stokes equations (1) take the following form:
∂
(
E
-
E
v
)
∂
h
+
∂
(
G
-
G
v
)
∂
r
=
S
-
S
v
(
2
)
At high Reynolds numbers dissipative terms E v , G v , S v are negligibly small and can be omitted in free stream areas, i.e. outside of boundary layers.
When constructing energy extractor disk actuator model, all blade wheels of a turbo machine are replaced with azimuth-uniform disks of finite or zero thicknesses extracting the same average amounts of momentum and energy as real blade wheels. For example, ducted hydro turbine in FIG. 1 contains two such wheels: turbine impeller and guide vane wheel, so that two respective disk actuators should be used. For multi-staged turbines and turbo compressors each rotor and stator blade wheel should be modeled by a disk actuator, etc.
Therefore, each disk actuator approximately represents stream volume swept by respective blade wheel and works as source or sink of momentum and energy. When using disk actuators in combination with axially symmetric Navier-Stokes equations (2), it is supposed that equations (2) are responsible for description of the flow field everywhere outside of swept volumes, while disk actuators provide “jump conditions” connecting flow field parameters at upstream (“L”) and downstream (“R”) sides of respective blade wheels. Derivation of the jump conditions is presented below.
Vectors of convective fluxes E, G and sources S in axially symmetric Navier-Stokes equations (2) can be expressed in terms of flow parameters as follows:
E
=
r
ρ
u
h
r
(
ρ
u
h
2
+
p
)
r
ρ
u
h
u
r
r
2
ρ
u
h
u
φ
r
ρ
u
h
H
(*
)
,
G
=
r
ρ
u
r
r
ρ
u
h
u
r
r
(
ρ
u
r
2
+
p
)
r
2
ρ
u
r
u
φ
r
ρ
u
r
H
(*
)
,
S
=
0
rf
h
p
+
ρ
u
φ
2
+
rf
r
r
2
f
φ
re
(
3
)
where uh, ur, and uφ are components of velocity vector in respective directions h, r, and φ, ρ is fluid density, p is static pressure, H(*) is total specific enthalpy of fluid per unit mass. Source terms fh, fr, and fφ represent volume densities of components of external forces, and e is volume density of energy sources.
Although expressions (3) are valid for both compressible and incompressible fluids, standard definitions of the total specific enthalpy H(*) and physical meaning of the energy equation are different. For incompressible fluids enthalpy H* is usually introduced total mechanical energy, i.e. sum of potential and kinetic energies, per unit mass
H*=p/ρ+u 2 /2= p /ρ+( u h 2 +u r 2 +u φ 2 )/2. (4)
On the other hand, definition of enthalpy H for compressible fluids includes additional term representing internal (thermal) energy per unit mass
H=E int +p/ρ+u 2 /2= E int +p /ρ+( u h 2 +u r 2 +u φ 2 )/2, (5)
where E int (p, T) is internal energy of the fluid per unit mass, and T is fluid temperature. For example, in case of a thermally perfect gas E int =C v T/μ and (5) reduces to
H=C v T/μ+p/ρ+u 2 /2= C p T /μ+( u h 2 +u r 2 +u φ 2 )/2, (6)
where C v and C p are specific heat capacities at constant volume and pressure, respectively, and μ is molar mass of the gas. System of Navier-Stokes equations (1) for a compressible gas includes density ρ(t,ξ,η,ζ) as an additional unknown function as compared with system (1) for incompressible fluid, so equation of gas state ρ=ρ(p, T) has to be used for closing the problem.
As long as expression (4) does not include internal energy Eint, it does not represent a conservative physical value. Therefore, if energy equations for an incompressible fluid is written in terms of the function (4), it does not reflect an independent conservation law, because H* may dissipate due to the impact of viscous friction and heat transfer (Sv≠0) at finite Reynolds numbers. In fact, it can be shown that the considered equation directly follows from the mass and momentum conservation laws. On the other hand, energy equation for a compressible gas written in terms of the function (5) or (6) does represent an independent conservation law defining temperature distribution.
Vector equation (2) can be re-written in the scalar form
(∂ E k /∂h )+(∂ G k /∂r )= S k , (7)
where Ek, Gk and Sk denote k-th scalar components of the vectors (E−E v ), (G−G v ), and (S−S v ), respectively. Index k in (7) varies from 1 to 5, thus representing continuity equation (k=1), h-momentum equation (k=2), r-momentum equation (k=3), φ-momentum equation (k=4), and energy equation (k=5). Let's now select an infinitely narrow integration area A in plane (h, r), so that its lower and upper bounds cross lateral section of disk actuator and are located at radii r and r+Δr, respectively, while its left (h=h L (r)) and right (h=h R (r)) bounds are located in the areas of free stream closely adjoining left and right sides of the disk, see FIG. 2 . In our considerations below, flow parameters at the left and right bounds of the area A will be marked with the indices “L” and “R”, respectively.
Integrating scalar equations (7) over area A and applying the 1-st Green's integral formula, yields
∮
C
(
E
k
·
ⅆ
r
-
G
k
·
ⅆ
h
)
=
∫
∫
A
S
k
·
ⅆ
r
·
ⅆ
h
,
(
8
)
where C is the contour bounding area of integration A. Since height Δr of the area A is supposed to be infinitely small (Δr→0), the contour and area integrals in equation (8) can be approximated with an arbitrary precision as follows:
∮
C
E
k
·
ⅆ
r
=
Δ
r
·
{
[
E
k
(
r
)
]
R
-
[
E
k
(
r
)
]
L
}
,
∮
C
G
k
·
ⅆ
h
=
∫
h
L
(
r
)
h
R
(
r
)
[
G
k
(
h
,
r
)
-
G
k
(
h
,
r
+
Δ
r
)
]
·
ⅆ
h
=
-
Δ
r
·
∫
h
L
(
r
)
h
R
(
r
)
[
∂
G
k
(
r
)
∂
r
]
·
ⅆ
h
=
-
Δ
rD
[
∂
G
k
(
r
)
∂
r
]
avr
,
∫
∫
A
S
k
·
ⅆ
r
·
ⅆ
r
=
Δ
r
·
S
k
(
h
,
r
)
·
ⅆ
h
=
Δ
rD
[
S
k
(
r
)
]
avr
,
where D=D(r)=h R (r)−h L (r) is local thickness of disk actuator, index “avr” means respective average values on the segment h L (r)≦h≦h R (r), and indices “L” and “R” denote flow parameter at the “left” and “right” points (h, r) closely adjoining upstream and downstream sides of actuator, respectively, as indicated in FIG. 2 . After substituting approximations above in equation (8), the latter reduces to
[ E k ( r )] R −[E k ( r )] L =D[S k ( r )−∂ G k ( r )/∂ r] avr . (9)
Equation (9) can now be directly used for deriving jump conditions for flow parameters.
Since left and right bounds of A are located in free stream areas, i.e. outside of boundary layers, contribution of dissipative terms to the axial fluxes [E k (r)] R and [E k (r)] L is negligibly small at high Reynolds numbers, see note 1 above. On the other hand, impact of the dissipative effects on the average values [S k (r)] avr and [∂G k (r)/∂r] avr inside swept areas of blade wheels can be significant, but when applying disk actuator model, it is assumed that all such effects are represented by properly defined “effective” drag and lift coefficients C D and C L of blade elements defining source terms f h , f r , f φ , and e in (3), see equations 28-49 below. Therefore, explicitly including dissipative terms in expressions for E k , G k and S k is not necessary.
For evaluating accuracy of approximate formulas the standard “big O” notation will be used below. Relationship a=O(b) between two physical values a and b should be interpreted as “a has the same order of magnitude as b, or less”, so that ratio |a/b| is always finite. Also, two dimensionless parameters will be used:
ε= u r /u h , δ=D/r. (10)
which may be small or finite depending on a particular flow pattern and considered point of flow field. As long as all previous considerations were made in terms of dimensional variables, dimensional velocity scale u∞ and density scale ρ ∞ are also required for comparing orders of magnitudes of physical values. For example, when analyzing an open wind or hydro turbine, velocity and density of the far upstream flow can be accepted as such scales. Generally, it is supposed that scales u∞, ρ∞ are selected so that
u h =u ∞ ·O (1), ρ=ρ ∞ ·O (1) (11)
everywhere inside swept volume of a blade wheel. Relationship (12) results in the following initial evaluations:
u r =u ∞ ·O (ε), u φ =u ∞ ·O (1),
Δ p=ρ ∞ u ∞ 2 ·O (1), Δ H=u ∞ 2 ·O (1). (12)
In flows of an incompressible fluid static pressure p is defined with accuracy of an arbitrary spatially constant additive function p 0 (t), so that grad [p(t,x,y,z)+p 0 (t)]=grad p(t,x,y,z). In such cases only spatial variations of pressure Δp, or grad(p) make physical sense, but not its absolute values.
For k=1 scalar components of vectors (3) are
E 1 =rρu h , G 1 =rρu r , S 1 =0.
So, the 1st of averaged equations (9) reflecting mass balance across disk actuator is
r [(ρ u h ) R −(ρ u h ) L ]=−D [∂( rρu r )/∂ r] avr .
As long as ∂(rρu r )/∂r=ρ ∞ u ∞ ·O(ε), this finally results in estimation
(ρ u h ) R −(ρ u h ) L =ρ ∞ u ∞ ·O (ε·δ). (13)
In case of incompressible fluid ρ=ρ ∞ =const and estimation (13) reduces to
( u h ) R −( u h ) L =u ∞ ·O (ε·δ). (14)
For k=2 scalar components of vectors (3) are
E 2 =r (ρ u h 2 +p ), G 2 =rρu h u r , S 2 =rf h ,
where dissipative terms (E v ) 2 , (G v ) 2 , and (S v ) 2 are omitted in accordance with note 3 above. So, the 2nd of averaged equations (9) reflecting h-momentum balance across disk actuator is
r [(ρ u h 2 +p ) R −(ρ u h 2 +p ) L ]=D[rf h −∂( rρu h u r )/∂ r] avr .
As long as ∂(rρu h u r )/∂r=ρ ∞ u ∞ 2 ·O(ε), this finally results in estimation
(ρ u h 2 +p ) R −(ρ u h 2 +p ) L =D ·( f h ) avr +ρ ∞ u ∞ 2 ·O (ε·δ),
and taking into account (13),
( u h ) R −( u h ) L +( p R −p L )/(ρ u h )= D ·( f h ) avr /(ρ u h )+ u ∞ ·O (ε·δ), (15)
In case of incompressible fluid combination of estimations (14) and (15) yields
p R −p L =D ·( f h ) avr +ρ ∞ u ∞ 2 ·O (ε·δ). (16)
Note that average volume density of axial forces (f h ) avr in (15) and (16) may not be finite, since for a finite total impact of disk actuator on h-momentum balance D·(f h ) avr =O(1), hence |(f h ) avr |→∞ at D→0.
For k=3 scalar components of vectors (3) are
E 3 =rρu h u r , G 3 =r (ρ u r 2 +p ), S 3 =p+ρu φ 2 +rf r ,
where dissipative terms (E v ) 3 , (G v ) 3 , and (S v ) 3 are omitted in accordance with note 3 above. So, the 3rd of averaged equations (9) reflecting r-momentum balance across disk actuator is
r
[
(
ρ
u
h
u
r
)
R
-
(
ρ
u
h
u
r
)
L
]
=
D
{
p
+
ρ
u
φ
2
+
rf
r
-
∂
[
r
(
ρ
u
r
2
+
p
)
]
∂
r
}
avr
=
=
D
[
ρ
u
φ
2
+
rf
r
-
r
·
∂
p
∂
r
-
∂
(
r
ρ
u
r
2
)
∂
r
]
avr
,
and after dividing by r we get
(ρ u h u r ) R −(ρ u h u r ) L =δ[ρu φ 2 +rf r −r·∂p/∂r −∂( rρu r 2 )/∂ r] avr . (17)
As long average volume density of radial forces (f r ) avr is less then (f h ) avr and (fφ) avr by its order of magnitude, and an infinitely thin blade wheel should provide zero impact on r-momentum of the flow, i.e. D·(f h ) avr →0 when D→0, it would be reasonable to assume that (f r ) avr remains finite independently of D, i.e. (f r ) avr =O(1). If this assumption is valid, then the right hand side term in square brackets is finite as well:
[ρ u φ 2 +rf r −r·∂p/∂r −∂( rρu r 2 )/∂ r] avr =O (1)
everywhere in the area of integration A, and equation (17) immediately results in estimation
(ρ u h u r ) R −(ρ u h u r ) L =ρ ∞ u ∞ 2 ·O (δ). (18)
On the other hand, u r =u ∞ ·O(ε) by definition (10) of parameter ε, so that
(ρ u h u r ) R −(ρ u h u r ) L =ρ ∞ u ∞ 2 ·O (ε·δ). (19)
Combination of (18) and (19) yields
(ρ u h u r ) R −(ρ u h u r ) L =ρ ∞ u ∞ 2 ·O (ε·δ),
and taking into account jump condition (13), we finally get
( u r ) R −( u r ) L =u ∞ ·O (ε·δ), (20)
for both compressible and incompressible fluids.
For k=4 scalar components of vectors (3) are
E 4 =r 2 ρu h u φ , G 4 =r 2 ρu r u φ , S 4 =r 2 f φ ,
where dissipative terms (E v ) 4 , (G v ) 4 , and (S v ) 4 are omitted in accordance with note 3 above. So, the 4th of averaged equations (9) reflecting φ-momentum balance across disk actuator is
r 2 [(ρ u h u φ ) R −(ρ u h u φ ) L ]=D[r 2 f φ −∂( r 2 ρu r u φ )/∂ r] avr .
As long as [∂(r 2 ρu r u φ )/∂r] avr =rρ ∞ u ∞ 2 ·O(ε), this results in estimation
(ρ u h u φ ) R −(ρ u h u φ ) L =D ·( f φ ) avr +ρ ∞ u ∞ 2 ·O (ε·δ),
and taking into account jump condition (13), we finally get
( u φ ) R −( u φ ) L =D ·( f φ ) avr /(ρ u h )+ u ∞ ·O (ε·δ) (21)
for both compressible and incompressible fluids. Note that average volume density of azimuth forces (f φ ) avr in (21) may not be finite, since for a finite total impact of disk actuator on φ-momentum balance D·(f φ ) avr =O(1), hence |(f φ ) avr |→∞ at D→0.
For k=5 scalar components of vectors (3) are
E 5 =rρu h H (*) , G 5 =rρu r H (*) , S 5 =re,
where dissipative terms (E v ) 5 , (G v ) 5 , and (S v ) 5 are omitted in accordance with note 3 above. So, the 5th of averaged equations (9) reflecting energy balance across disk actuator is
r [(ρ u h H (*) ) R −(ρ u h H (*) ) L ]=D[re −∂( rρu r H (*) )/∂ r] avr .
As long as ∂(rρu r H (*) )/∂r=ρ ∞ u ∞ 3 ·O(ε), this results in estimation
(ρ u h H (*) ) R −(ρ u h H (*) ) L =D·e avr +ρ ∞ u ∞ 3 ·O (ε·δ),
and taking into account jump condition (13), we finally get
H (*) R −H (*) L =D·e avr /(ρ u h )+ u ∞ 2 ·O (ε·δ) (22)
for both compressible and incompressible fluids. Note that average volume density of energy sources e avr in (22) may not be finite, since for a finite total impact of disk actuator on energy balance D·e avr =O(1), hence |e avr |→∞ at D→0.
FIG. 3 is a flow chart of an example process for computing torque, drag, and power using jump conditions. The process will be described as being performed by an appropriately programmed system of one or more computers.
The system obtains mass, momentum, and energy jump conditions ( 310 ). After summarizing estimations (13), (15), (20), (21), and (22), we can conclude that the approximate jump conditions connecting flow parameters on the upstream and downstream sides of disk actuator
{
(
ρ
u
h
)
R
=
(
ρ
u
h
)
L
,
(
u
H
)
R
-
(
u
h
)
L
+
(
p
R
-
p
L
)
/
(
ρ
u
h
)
=
D
·
(
f
h
)
avr
/
(
ρ
u
h
)
,
(
u
r
)
R
=
(
u
r
)
L
,
(
u
φ
)
R
-
(
u
φ
)
L
=
D
·
(
f
φ
)
avr
/
(
ρ
u
h
)
,
H
R
(*
)
-
H
L
(*
)
=
D
·
e
avr
/
(
ρ
u
h
)
(
23
)
(
24
)
(
25
)
(
26
)
(
27
)
are all valid with relative accuracy O(ε·δ). Therefore, fidelity of the model is determined by the dimensionless scale factor (ε·δ), rather than scale of radial velocity ε, i.e. initial assumption furl uh, is not required. Instead, the assumption (ε·δ)<<1 should be used as a fidelity criterion, which is satisfied for virtually all practical cases.
In fact, in all axial-flow turbo machines root parts of blades (large δ=D/r) do not create significant impact on momentum and energy of the flow because of their small swept areas, tangential speed, and arm length of applied hydrodynamic loads. On the other hand, middle and tip parts of blades (small δ=D/r), producing major contribution to momentum and energy re-distribution, satisfy to the condition (ε·δ)<<1, especially as their pitch angles are typically close to 90°.
The average h- and φ-momentum sources (f h ) avr , (f φ ) avr in right hand sides of jump conditions (24), (26) can be evaluated it terms hydrodynamic properties of 2D blade sections using classical Glauert's Blade Element Momentum Model (BEM), described, for example, in dissertation [7].
For convenience of further considerations, an auxiliary Cartesian coordinate system (x, y, z) will be used below in addition to the previously introduced cylindrical coordinates (h, r, φ):
{
x
=
h
,
y
=
r
·
cos
φ
,
z
=
r
·
sin
φ
.
(
28
)
Cartesian components of flow velocity u, v, w, in respective directions x, y, z can be expressed in terms of u n , u r , u φ as
{
u
=
u
h
v
=
u
r
·
cos
φ
-
u
φ
·
sin
φ
w
=
u
r
·
sin
φ
+
u
φ
·
cos
φ
(
29
)
Let's now consider an infinitely thin blade element formed by intersection of blade with a cylinder of given radius r. Such element located in azimuth position φ=π/2 is shown in FIG. 4 , where all upstream and downstream flow parameters, as well as blade section geometry, depend on radius r. Note that u=u h , v=−u φ , and w=u r at φ=π/2.
In the coordinate system rotating with a constant speed Ω, where Ω is rotational speed of the blade wheel, Cartesian velocity components are (u, v−Ωr, w). Let's introduce additional local Cartesian coordinates (x′, y′) rotated by angle β avr with respect to initial coordinates (x, y) in tangential plane of the blade element:
x
′
=
x
cos
β
avr
+
y
sin
β
avr
,
y
′
=
-
x
sin
β
avr
+
y
cos
β
avr
,
x
=
x
′
cos
β
avr
-
y
′
sin
β
avr
,
y
=
x
′
sin
β
avr
+
y
′
cos
β
avr
,
where
(
30
)
β
avr
=
atan
[
(
v
-
Ω
r
)
avr
/
u
avr
]
=
=
-
atan
{
[
(
u
φ
)
L
+
(
u
φ
)
R
+
2
Ω
r
]
[
(
u
h
)
L
+
(
u
h
)
R
]
}
(
31
)
characterizes an averaged direction of flow velocity in rotating coordinate system. Formula (31) is specifically constructed to provide such direction of total hydrodynamic load applied to the blade element that for an ideal hydrofoil having zero drag, amount of power withdrawn by the element is exactly zero in rotating coordinate system, i.e. there is no dissipative energy losses. If the blade element produces positive output power then Ωr>|v L |, so that β avr <0.
Components of hydrodynamic load applied to the blade element in the coordinate system (x′, y′) are
Δ X ′=[(ρ U 2 ) avr /2] C D L·Δr=qC D L·Δr,
Δ Y ′=[(ρ U 2 ) avr /2] C L L·Δr=qC L L·Δr, (32)
where Δr is radial thickness of the element (Δr→0), L=L(r) is its chord, C D =C D (α, r), C L =C L (α, r) are its drag and lift coefficients, respectively, and α=θ(r)+β avr (r) is its angle of attack in the local coordinate system (x′, y′). The average dynamic pressure q=(ρU 2 ) avr /2 in (32) is defined as
q
=
(
ρ
U
2
)
avr
/
2
=
{
ρ
[
u
2
+
(
v
-
Ω
r
)
2
]
}
avr
2
=
=
{
ρ
L
[
(
u
h
)
L
2
+
(
u
φ
+
Ω
r
)
L
2
]
+
ρ
R
[
(
u
h
)
R
2
+
(
u
φ
+
Ω
r
)
R
2
+
(
u
φ
+
Ω
r
)
R
2
]
}
4
.
(
33
)
Radial velocity u r is not included in right hand side of expression (33) as its contribution to hydrodynamic loads is supposed to be negligible, see equation 17.
Components of hydrodynamic load applied to the blade element in the initial coordinate system (x, y) are
Δ X=ΔX ′ cos β avr −ΔY ′ sin β avr =q ( C D cos β avr −C L sin β avr ) L·Δr, (34)
Δ Y=ΔX ′ sin β avr +ΔY ′ cos β avr =q ( C D sin β avr +C L cos β avr ) L·Δr. (35)
Drag, torque, and mechanical power produced by the blade element are: ΔX, r·ΔY, and Ωr·ΔY, respectively, so that their total values can be computed via integration from r=r min to r=r max , and multiplication resulting integrals by number of blades.
For the considered blade element above, averaged values (f h ) avr , (f φ ) avr from (24,26) can be evaluated from the forces (34,35) as follows:
( f h ) avr =−ΔX/ΔV=−ΔX /(2π rD·Δr/N ), (36)
( f φ ) avr =ΔY/ΔV=ΔY /(2π rD·Δr/N ), (37)
where N is number of impeller blades, so that each element of each separate blade provides momentum input in the azimuth range 2π/N, so respective elementary swept volume is ΔV=2πrD·Δr/N. As long as (f h ) avr , (f φ ) avr in (24), (26) represent flow reaction to the hydrodynamic loads applied to the blade element, they should be assigned opposite signs. That is why in formula (36) sign “−” is set for ΔX (as x- and h-directions coincide, ∂x/∂h>0), while in formula (37) sign “+” is set for ΔY (as y- and φ-directions are opposite, ∂y/∂φ<0 at φ=π/2). Substitution of expressions (36), (37) in jump conditions (24), (26), respectively, and use of relationships (34), (35) for evaluating ratios ΔX/Δr, ΔY/Δr, results in representation of h- and (p-momentum jumps in terms of C D and C L :
ρ
u
h
[
(
u
h
)
R
-
(
u
h
)
L
]
+
(
p
R
-
p
L
)
=
-
(
Δ
X
/
Δ
r
)
N
/
(
2
π
r
)
=
=
-
q
(
C
D
cos
β
avr
-
C
L
sin
β
avr
)
L
N
/
(
2
π
r
)
=
q
σ
(
C
L
sin
β
avr
-
C
D
cos
β
avr
)
,
(
38
)
ρ
u
h
[
(
u
φ
)
R
-
(
u
φ
)
L
]
=
(
Δ
Y
/
Δ
r
)
N
/
(
2
π
r
)
=
=
q
(
C
D
sin
β
avr
+
C
L
cos
β
avr
)
L
N
/
(
2
π
r
)
=
q
σ
(
C
D
sin
β
avr
+
C
L
cos
β
avr
)
,
(
39
)
where σ=σ(r)=LN/(2πr) is solidity factor of blade wheel.
The system determines the upstream flow field parameters and the downstream flow field parameters that satisfy the jump conditions ( 320 ), for example, by using a computational fluid dynamics software package. The system determines momentum jump values from the upstream flow field parameters and the downstream flow field parameters ( 330 ).
The system computes the drag, torque, and power produced by the blade wheel from the momentum jumps ( 340 ). Drag ΔX, torque ΔM and mechanical power ΔW produced by N blade elements are
N·ΔX=− 2π r{ρu h [( u h ) R −( u h ) L ]+( p R −p L )}·Δ r,
N·ΔM= 2π r 2 ρu h [( u φ ) R −( u φ ) L ]·Δr,
N·ΔW=ΩN·ΔM, (40)
and total drag X, torque M, and mechanical power W from the energy and produced by the blade wheel are
X
=
-
2
π
∫
r
m
i
n
_
r
ma
x
_
r
{
ρ
u
h
[
(
u
h
)
R
-
(
u
h
)
L
]
+
(
p
R
-
p
L
)
}
·
ⅆ
r
,
M
=
2
π
∫
r
m
i
n
_
r
ma
x
_
r
2
ρ
u
h
[
(
u
φ
)
R
-
(
u
φ
)
L
]
·
ⅆ
r
,
W
=
Ω
·
M
,
(
41
)
where the integrand expressions are represented by (38) and (39).
Relationships (23), (25), (38), and (39) constitute a complete set of jump conditions for equations of continuity and momentums. Jump condition (27) for energy equation should be considered separately for the cases of incompressible and compressible fluid because of distinction of their physical meanings and different interpretations of total specific enthalpy H(*), see note 2 above.
If the energy equation, i.e. equation (7) for k=5, is written without taking into account internal (thermal) fluid energy, it describes distribution of total specific enthalpy (4) representing only potential (p/ρ) and kinetic (u 2 /2) energies per unit mass. Such form of energy equation can be derived as a combination of all remaining equations, so that density of energy sources e in (3) can be expressed in terms of momentum sources f h and f φ . In this case jump of enthalpy (4) can be expressed in terms of pressure and velocity components, without using condition (27), as follows:
H
R
*
-
H
L
*
=
[
p
/
ρ
+
(
u
h
2
+
u
r
2
+
u
φ
2
)
/
2
]
R
-
[
p
/
ρ
+
(
u
h
2
+
u
r
2
+
u
φ
2
)
/
2
]
L
=
=
(
p
R
-
p
L
)
/
ρ
+
[
(
u
φ
)
R
2
-
(
u
φ
)
L
2
]
/
2
(
42
)
using previously computed p and u φ , and taking into account that (u r ) R =(u r ) L and (u h ) R =(u h ) L at constant ρ, see (23), (25). So, mechanical power contributed to the flow by N blade elements located at radius r equals
N·ΔP*= 2π rρu h ( H* R −H* L )·Δ r, (43)
and total mechanical power P* contributed by the blade wheel is
P
*
=
2
π
∫
r
min
r
max
r
ρ
u
h
(
H
R
*
-
H
L
*
)
·
ⅆ
r
.
(
44
)
Note that generally W≠−P* (see (41)), because the latter includes part of mechanical power dissipated into heat due to viscous friction.
Let's consider an ideal blade element having zero drag (C D =0), and suppose that input flow is irrotational ((u φ ) L =0). In this case jump conditions (38), (39) reduce to
p
R
-
p
L
=
q
σ
C
L
sin
β
avr
,
(
u
φ
)
R
=
q
σ
C
L
cos
β
avr
/
(
ρ
u
h
)
,
hence
p
R
-
p
L
=
ρ
u
h
(
u
φ
)
R
tan
(
β
avr
)
=
-
ρ
(
u
φ
)
R
[
(
u
φ
)
R
+
2
Ω
r
]
/
2
==
-
ρ
r
2
ω
(
ω
/
2
+
Ω
)
,
(
45
)
where tan (β avr ) is evaluated using expression (31) at (u h ) L =(u h ) R =u h , and rotational speed ω φ =(u φ ) R /r is introduced. Note that relationship (45) exactly coincides with the classical Glauert's estimation of pressure jump across disk actuator. In the considered idealized case relationship (42) reduces to
H* R −H* L =( p R −p L )/ρ+ r 2 ω 2 /2=− r 2 ωΩ,
thus resulting in N·ΔW=Ω· 2π r 2 ρ h [( u φ ) R −( u φ ) L ]·Δr= 2π r 3 ρu h ωΩ·Δr,
and N·ΔP*=− 2π r 3 ρu h ωΩ·Δr=−N·ΔW,
see (40) and (43). Therefore, W=−P* in the absence of dissipative losses (C D =0).
When practically evaluating efficiency of open wind and water turbines, the impact of blade tip vortex structures on momentum and energy balances should also be taken into account. Contribution of the tip vortices in impeller wake to drag X and power P* of the turbine can be evaluated using one of standard tip correction techniques, which are minutely described in the publications specifically dedicated to practical implementations of disk actuator models, see for example [7].
If energy equation, i.e. equation (7) for k=5, is written with taking into account internal (thermal) fluid energy, it describes distribution of total specific enthalpy (5) or (6) representing full energy of the fluid per unit mass. In this case density of energy sources e in (3) includes both power produced by momentum sources f h , f φ , and heat fluxes arising from non-zero gradients of temperature in a thermally conductive media, so that jump condition (27) reflects full amount of power contributed to the flow. However, instead of directly evaluating energy source e and using condition (27), it is more convenient to derive an independent relationship of energy balance.
Jump of enthalpy (5) can be expressed in term of velocity components and other flow parameters, as follows:
H
R
-
H
L
=
[
E
int
+
p
/
ρ
+
(
u
h
2
+
u
r
2
+
u
φ
2
)
/
2
]
R
-
[
E
int
+
p
/
ρ
+
(
u
h
2
+
u
r
2
+
u
φ
2
)
/
2
]
L
=
[
E
int
+
p
/
ρ
+
(
u
h
2
+
u
φ
2
)
/
2
]
R
-
[
E
int
+
p
/
ρ
+
(
u
h
2
+
u
φ
2
)
/
2
]
L
.
(
46
)
taking into account that (u r ) R =(u r ) L , see (25). So, full power contributed to the flow by N blade elements located at radius r equals
N·ΔP= 2π rρu h ( H R −H L )·Δ r. (47)
Although relationship (47) has the same form as (43), it includes full power P instead mechanical power P*, and uses another definition of specific enthalpy H.
Let's suppose that rate of heat transfer between gas and turbine blades is much less than total energy flux through the blade wheel and output mechanical power (if any). If this assumption is valid, then full power withdrawn from the flow −ΔP should be spent for producing output mechanical power ΔW, i.e.
Δ P+ΔW= 0. (48)
Substitution of expressions for ΔW (40) and ΔP (47) in equation (48) finally results in the following independent relationship representing energy jump condition:
( H R −H L )+ r Ω[( u φ ) R −( u φ ) L ]=0, (49)
where the difference (H R −H L ) is defined by formula (46). Relationship (49) in combination with a given equation of state p=ρ(p, T) and expression for internal energy E int =E int (p, T) provides mathematical closure of the problem.
Numerical modeling some types of turbo machines does not allow efficiently using the cylindrical coordinate system (h, r, φ) introduced above. Let's consider, for example a wide angle ducted turbo machine schematically shown in FIG. 5 .
In such a machine flow area is bounded by two rigid surfaces, central body and external duct, so that in case of steady state and axially symmetric flow field total mass flux is the same in all cross sections h=const. Hence, an average axial flow velocity varies along the turbine depending on local area of its cross section.
In the suggested disk actuator model jump condition (23) derived in cylindrical coordinates provides conservation of mass flux if and only if radial positions of the left and right bounds of integration area A are exactly equal. Therefore, the model generally does not preserve mass conservation in case of variable cross section area because of violation of mass balance at finite thickness of disk actuator D(r). In this case the cylindrical coordinate system (h, r, φ) is not convenient for properly constructing disk actuator model, and a transformed coordinate system should be used instead.
Let's introduce an auxiliary curvilinear coordinate system (ξ, η) in a lateral section φ=const, so that the inner and outer bounds of flow field coincide with some coordinate lines η=const. If geometrical shapes of the central body and external duct are described by given functions r=r min (h) and r=r max (h), respectively, as shown in FIG. 4 , then required coordinate transformation (ξ, η)→(h, r) can be defined as
{
h
(
ξ
,
η
)
=
ξ
,
r
(
ξ
,
η
)
=
r
min
(
ξ
)
+
η
·
[
r
max
(
ξ
)
-
r
min
(
ξ
)
]
,
(
50
)
and r(ξ, 0)=r min (ξ), r(ξ, 1)=r max (ξ). Navier-Stokes equations (2) describing steady state axially symmetric flow take the following form in coordinates (ξ, η):
∂ ( E * - E v * ) ∂ ξ + ∂ ( G * - G v * ) ∂ η = S * - S v * . ( 51 )
Transformed flux and source vectors in equations (51) are expressed in terms respective vectors in equations (2) as
E* (v) =[(∂ξ/∂ h ) E (v) +(∂ξ/∂ r ) G (v) ]·det( J ),
G* (v) =[(∂η/∂ h ) E (v) +(∂η/∂ r ) G (v) ]·det( J ),
S* (v) =S (v) ·det( J ), (52)
where J is Jacobian matrix of the coordinate transformation (ξ, η)→(h, r)
J = ∂ ( r , h ) ∂ ( ξ , η ) = ∂ h / ∂ ξ ∂ h / ∂ η ∂ r / ∂ ξ ∂ r / ∂ η ,
J - 1 = ∂ ( ξ , η ) ∂ ( r , h ) = ∂ ξ / ∂ h ∂ ξ / ∂ r ∂ η . / ∂ h ∂ η / ∂ r
For transformation (50) ∂h/∂ξ=1, ∂h/∂η=0,
J
=
1
0
r
ξ
′
r
η
′
,
det
(
J
)
=
r
η
′
,
J
-
1
=
1
0
-
r
ξ
′
/
r
η
′
1
/
r
η
′
(
53
)
where brief notations for the derivatives r′ ξ =∂r/∂ξ and r′ η =∂r/∂η are introduced. After substitution of metric coefficients (53) in expressions (52) the latter reduce to
E* (v) =r′ η E (v) , G* (v) =G (v) −r′ ξ E (v) , S* (v) =r′ η S (v) , (54)
and component-wise representations of the transformed flux and source vectors are
E
*
=
rr
η
′
ρ
u
h
rr
η
′
(
ρ
u
h
2
+
p
)
rr
η
′
ρ
u
h
u
r
r
2
r
η
′
ρ
u
h
u
φ
rr
η
′
ρ
u
h
H
(
*
)
,
G
*
=
r
ρ
(
u
r
-
u
h
r
ξ
′
)
r
[
ρ
u
h
(
u
r
-
u
h
r
ξ
′
)
-
pr
ξ
′
]
r
[
ρ
u
r
(
u
r
-
u
h
r
ξ
′
)
+
p
]
r
2
ρ
u
φ
(
u
r
-
u
h
r
ξ
′
)
r
ρ
H
(
*
)
(
u
r
-
u
h
r
ξ
′
)
,
S
*
=
0
rr
η
′
f
h
r
η
′
(
p
+
ρ
u
φ
2
+
rf
r
)
r
2
r
η
′
f
φ
rr
′
e
(
55
)
Let's select an infinitely narrow integration area A in plane (ξ, η), so that its lower and upper bounds cross lateral section of disk actuator and are located on coordinate lines η and η+Δη, respectively, while its left (ξ=ξ L (η)) and right (ξ=ξ R (η)) bounds are located in the areas of free stream closely adjoining left and right sides of the disk, see FIG. 4 . Similarly to our previous considerations, flow parameters and metric coefficients at the left and right bounds of the area A will are marked with the indices “L” and “R”, respectively. As long as area A is distorted in cylindrical coordinate system (h, r), radial positions of its left and right bounds do not coincide (r L ≠r R at Δη→0) if disk actuator of a finite thickness D(η)≠0 is used for modeling.
Vector equation (51) can be re-written in the scalar form
(∂ E* k /∂ξ)+(∂ G* k /∂η)= S* k . (56)
Integration of equations (56) over area A, application of the 1-st Green's integral formula, and representation of respective integrals in terms of average values (see above), result in averaged equations
[ E* k (η)] R −[E* k (η)] L =D[S* k (η)−∂ G* k (η)/∂η] avr , (57)
which are quite similar to equations (9). Jump conditions for flow parameters can be directly derived from equations (57) can in exactly the same way as above:
{
(
rr
η
′
ρ
u
h
)
R
=
(
rr
η
′
ρ
u
h
)
L
,
(
58
)
(
u
h
)
R
-
(
u
h
)
L
+
(
p
R
-
p
L
)
(
rr
η
′
)
avr
/
(
rr
η
′
ρ
u
h
)
=
D
·
(
rr
η
′
f
h
)
avr
/
(
rr
η
′
ρ
u
h
)
,
(
59
)
(
u
r
)
R
=
(
u
r
)
L
,
(
60
)
(
ru
φ
)
R
-
(
ru
φ
)
L
=
D
·
(
r
2
r
η
′
f
φ
)
avr
/
(
rr
η
′
ρ
u
h
)
,
(
61
)
H
R
(
*
)
-
H
L
(
*
)
=
D
·
(
rr
η
′
e
)
avr
/
(
rr
η
′
ρ
u
h
)
.
(
62
)
It can be shown that approximate relationships (59) and (60) are valid with relative accuracy O(ε·δ), while (58), (61) and (62) are valid with relative accuracy O(ε*·δ), where
ε*=( u r −u h r′ ξ )/ u h . (63)
Note that magnitude of parameter ε* really should be small, as long as ε* characterizes angular difference between directions of streamlines and respective coordinate lines η=const. In particular, near flow bounds u r /u h =r′ ξ , i.e. ε*=0 at both η=0 and η=1. On the other hand, magnitude of parameters generally is not assumed to be small, since in this case ε=u r /u h =O(rr′ ξ /r′ η )=O(1). Hence ε*=O(ε), and overall relative accuracy of the model is O(ε·δ).
The Blade Element Momentum Theory can now be used for representing volume densities of forces f h and f φ in terms of drag and lift coefficients C D , C L of blade elements. Substitution of the previously derived expressions (34)-(37) into (59) and (61) results in the following representations of h- and φ-momentum jumps:
[( u h ) R −( u h ) L ]( rr′ η ρu h )/( rr′ η ) avr +( p R −p L )= q σ( C L sin β avr −C D cos β avr ), (64)
[( ru φ ) R −( ru φ ) L ]( rr′ η ρu h )/( r 2 r′ η ) avr =q σ( C D sin β avr +C L cos β avr ). (65)
Relationships (58), (60), (64), and (65) constitute a complete set of jump conditions for equations of continuity and momentums. Jump condition (62) for energy equation should be considered in accordance with the previous conclusions made in above for incompressible fluids or for compressible gases. Total drag, torque, and mechanical power produced by the blade wheel are
X
=
-
2
π
∫
0
1
{
[
(
u
h
)
R
-
(
u
h
)
L
]
(
rr
η
′
ρ
u
h
)
+
(
p
R
-
p
L
)
(
rr
η
′
)
avr
}
·
ⅆ
η
,
M
=
2
π
∫
0
1
[
(
ru
φ
)
R
-
(
ru
φ
)
L
]
(
rr
η
′
ρ
u
h
)
·
ⅆ
η
,
W
=
Ω
·
M
,
(
66
)
where the integrand expressions are represented by (64) and (65). Note that the product (rr′ η ρu h ) is specifically isolated in formulas (59), (61), (62), and (64)-(66) as rr′ η ρu h =const at η=const in accordance with (58). It can be seen that relationships (64), (65), and (66) are quite similar to the previously derived (38), (39), and (41), respectively.
Jump conditions (58)-(62) can be used instead of conditions (23)-(27) not only for keeping mass balance when modeling wide angle ducted turbo machines, but also in context of other similar problems, if for example, cylindrical coordinate system (h, r, φ) is not convenient for some problem-specific reasons, or if accuracy of (23)-(27) is not sufficient because of a strong radial flow.
Basic conditions of applicability of the suggested model can be summarized as follows. Flow field in the area of blade wheel location can be considered as steady-state and axially symmetric, i.e. impact of unsteady and azimuth variation effects on momentum and energy balances is negligible. Scale factor (ε·δ) is small in the regions of blade wheel swept area providing major contribution to mass, momentum, and energy balances. If a flow of compressible gas is considered, then rate of dissipative heat transfer between the gas and turbine blades is much less than total energy flux through the blade wheel and output mechanical power (if any).
The following references were mentioned above. 1. A. Betz. Das Maximum des theoretisch möglichen Ausnützung des Windes durch Windmotoren , Zeitschrifft für das gesamte Turbinewesen, Volume 26, p. 307, 1920. 2. H. Glauert. Windmills and Fans . In W. F. Durand (ed). Aerodynamic Theory. Dover Publications Inc., New York 1963. 3. J. Laursen, P. Enevoldsen, and S. Hjort. 3 D CFD Quantification of the Performance of a Multi - Megawatt Wind Turbine . The Science of Making Torque from Wind, Journal of Physics: Conference Series 75. IOP Publishing Ltd., 2007. 4. D. Hartwanger, A. Horvat. 3 D Modeling of Wind Turbine Using CFD . NAFEMS Conference 2008, United Kingdom, June 2008. 5. S. S. A. Ivanell. Numerical Computations of Wind Turbine Wakes . Technical Reports from Royal Institute of Technology Linnre Flow Centre, Department of Mechanics, Stockholm, Sweden, January 2009. 6. L. Battisti, G. Soraperra, R. Fedrizzi, and L. Zanne. Inverse Design - Momentum, a Method for the Preliminary Design of Horizontal Axis Wind Turbines . The Science of Making Torque from Wind, Journal of Physics: Conference Series 75. IOP Publishing Ltd., 2007. 7. R. Mikkelsen. Actuator Disk Methods Applied to Wind Turbines . Dissertation submitted to Technical University of Denmark, Fluid Mechanics, Department of Mechanical Engineering, 2003.
Embodiments of the subject matter and the functional operations described in this specification can be implemented in digital electronic circuitry, in tangibly-embodied computer software or firmware, in computer hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Embodiments of the subject matter described in this specification can be implemented as one or more computer programs, i.e., one or more modules of computer program instructions encoded on a tangible non-transitory program carrier for execution by, or to control the operation of, data processing apparatus. Alternatively or in addition, the program instructions can be encoded on an artificially-generated propagated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal, that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. The computer storage medium can be a machine-readable storage device, a machine-readable storage substrate, a random or serial access memory device, or a combination of one or more of them. The computer storage medium is not, however, a propagated signal.
The term “data processing apparatus” encompasses all kinds of apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, or multiple processors or computers. The apparatus can include special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit). The apparatus can also include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of one or more of them.
A computer program (which may also be referred to or described as a program, software, a software application, a module, a software module, a script, or code) can be written in any form of programming language, including compiled or interpreted languages, or declarative or procedural languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program may, but need not, correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data, e.g., one or more scripts stored in a markup language document, in a single file dedicated to the program in question, or in multiple coordinated files, e.g., files that store one or more modules, sub-programs, or portions of code. A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.
As used in this specification, an “engine,” or “software engine,” refers to a software implemented input/output system that provides an output that is different from the input. An engine can be an encoded block of functionality, such as a library, a platform, a software development kit (“SDK”), or an object. Each engine can be implemented on any appropriate type of computing device, e.g., servers, mobile phones, tablet computers, notebook computers, music players, e-book readers, laptop or desktop computers, PDAs, smart phones, or other stationary or portable devices, that includes one or more processors and computer readable media. Additionally, two or more of the engines may be implemented on the same computing device, or on different computing devices.
The processes and logic flows described in this specification can be performed by one or more programmable computers executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).
Computers suitable for the execution of a computer program include, by way of example, can be based on general or special purpose microprocessors or both, or any other kind of central processing unit. Generally, a central processing unit will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a central processing unit for performing or executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, e.g., a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a Global Positioning System (GPS) receiver, or a portable storage device, e.g., a universal serial bus (USB) flash drive, to name just a few.
Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
To provide for interaction with a user, embodiments of the subject matter described in this specification can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending documents to and receiving documents from a device that is used by the user; for example, by sending web pages to a web browser on a user's client device in response to requests received from the web browser.
Embodiments of the subject matter described in this specification can be implemented in a computing system that includes a back-end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front-end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described in this specification, or any combination of one or more such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), e.g., the Internet.
The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any invention or of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system modules and components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. For example, the actions recited in the claims can be performed in a different order and still achieve desirable results. As one example, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous.
|
Methods, systems, and apparatus, including computer programs encoded on computer storage media, for modeling turbine parameters. One of the methods includes obtaining, along multiple points of a blade of a turbine from a minimum radius rmin of the blade to a maximum radius rmax of the blade, lift coefficients C yi and drag coefficients C xi . At the multiple points of the blade from rmin to rmax, corresponding components of an upstream fluid flow velocity vector u h,Ri and u φ,Ri and components of a downstream fluid flow velocity u h,Li and u φ,Li are obtained. Averaged directions β i of the upstream and downstream fluid flow velocity vectors are computed using the components of the upstream fluid flow velocity vector u h,Ri and u φ,Ri and the components of the downstream fluid flow velocity u h,Li and u φ,Li . The total torque M of the turbine is computed including summing, from rmin to rmax, (C xi sin β i +C yi cos β i ).
| 5
|
FIELD OF THE INVENTION
[0001] The present invention relates to testing of complex combinatorial and sequential logic circuits embodied in large scale integration (LSI) and very large scale integration (VLSI) circuit devices and more particularly, to the diagnosing of broken or stuck-at fault scan chains.
BACKGROUND OF THE INVENTION
[0002] A fault occurring anywhere in such a LSI or VLSI circuit device can have its effect propagated through a number of feedback loops including storage or memory elements in the sequential logic before reaching a testable output of the device. Level sensitive scan design (LSSD) rules were devised to eliminate the complications in testing caused by this propagation through feedback loops. As described by E. B. Eichelberger and T. W. Williams in an article entitled “A Logic Design Structure for LSI Testablility” on pages 462-468 of the Proceedings of the 14th Design Automation conf., LSSD rules impose a clocked structure on logic circuit memory elements such as latches and registers and require these memory elements be tied together to form a shift register scan path so that they are accessible for use as test input and output points. Therefore, test input signals can be introduced or test results observed wherever one of the memory elements occurs in the logic circuit. Being able to enter the logic circuit at any memory element for introducing test signals or observing test results, allows the combinational and sequential logic to be treated as much simpler combinational logic for testing purposes thus considerably simplifying test generation and analysis. Patents describing LSSD techniques include U.S. Pat. Nos. 3,783,254; 3,784,907; 3,961,252 and 4,513,418. The subject matter of these patents and the above described Eichelberger and Williams article are hereby included by reference.
[0003] As shown in FIG. 1, in accordance with LSSD rules, shift register latches (SRL's) 100 on a semiconductor chip 102 are joined together to form a shift register LSSD scan latch chain 104 to facilitate testing of combinational logic blocks 106 , 108 and 110 interconnected by the SRLs 100 of the scan latch chain 104 . Data is inputted to the combinational logic blocks 106 , 108 and 110 and the SRLs 100 in a parallel respective primary inputs (PIs) 112 of the chip 102 . Data is outputted from the combinational logic blocks 106 , 108 and 110 and the SRLs 100 in parallel through the primary outputs (POs) vectors 114 of the chip 102 . During testing, the scan chain latch circuits 104 may also be loaded serially. Serial input (SRI) 116 provides a serial input to the scan chain latch circuits 104 . Similarly, serial output (SRO) 118 provides an output from scan chain latch circuits 104 . Scanning inputs into the serial input SR 116 and out serial output 118 enables testing the SRLs 104 independently of the combinational logic 106 , 108 and 110 . It also allows each of the individual SRLs to be used as a pseudo-primary input or a pseudo-primary output for a combinational logic block 106 , 108 or 110 . The logic circuits in each of the logic blocks to be tested separately of circuits in other of the logic blocks.
[0004] A major drawback of LSSD test methodology is encountered when the LSSD scan chain circuit 104 is not functioning properly and access to the internal logic of the circuit is greatly reduced. This is often the case early in the technology or product introduction cycle when the yields are relatively low or even zero. In these situations, the rapid determination of the fault's root cause is critical, but not easily diagnosed. For example, when there is a stuck-at 0 or 1 fault on scan chain 104 . For instance, with a stuck-at logic 0 fault, after a certain number of clock cycles, a serial output of logic 0's will come out of the scan chain 104 at the output 118 no matter what combination of 0's and 1's is scanned in the input 116 . When this occurs, it can be determined that there is a stuck-at 0 fault in the scan chain 104 , but the exact SRL 100 with the stuck-at fault condition is not isolated. While several techniques have been developed in the past to diagnose this type of failure, these techniques have produced limited success in identifying the stuck-at fault location. One series of suggestions involves modification of the structure of the latches and/or the scan chain configurations. The suggested new latch/scan chain configurations generally add hardware overhead or offer minimum or no improvement in fault coverage. In addition, scan diagnostic approaches have been proposed. Most of these test approaches are based on cause-effect algorithms. Such software solutions for diagnosing the broken scan chain generally need more storage and simulation time, and if the logic circuits between the SRLs have faults, diagnostic resolution is very poor.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In accordance with the present invention, the physical environment of latches is perturbated to change the state of latches following a stuck-at defective point. While data cannot be transmitted down a scan chain through a stuck-at fault location, data in properly operating latches downstream of the stuck-at fault location can be shifted down the chain. By varying an operating parameters, such as power supply and reference voltages, clock timing patterns, temperature and timing sequences, one or more latches down the SRL chain from the stuck-at fault location may be triggered to change state from the stuck-at fault value. The SRL chain is then operated to shift data out the output of the SRL chain. The output is monitored after a parameter is varied and any change in value of a latch from the stuck-at state is noted as identifying all good latch positions from that latch to the end of the chain. The process is repeated varying each of the selected operating parameters to locate the latch position following the stuck-at fault latch.
[0006] Therefore, it is an object of the present invention to provide improved testing methods for use in LSSD testing.
[0007] A further object of the invention is to provide improved stuck-at fault scan chain diagnosis.
[0008] Another object of the invention is to locate stuck-at fault latches in an SRL chain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other objects of the invention are best understood by reading the following description of various embodiments of the invention while making reference to the accompanying figures of which:
[0010] [0010]FIG. 1 is a schematic diagram of a VLSI semiconductor chip with SRLs arranged in an LSSD chain;
[0011] [0011]FIG. 2 is a schematic of an Logic Built-In Self Test (LBIST) arrangement with a stuck-at fault condition;
[0012] [0012]FIG. 3 is a schematic of the shift register logic (SRL) chain of the LBIST arrangement of FIG. 2;
[0013] [0013]FIG. 4 is a schematic diagram illustrating the SRL scan chain stuck-at fault problem and applicants' solution to the problem;
[0014] [0014]FIG. 5 is a schematic diagram illustrating the loading of the stuck-at fault chain in accordance with the present invention;
[0015] [0015]FIG. 6 is a flow diagram of a method of diagnosing of a scan chain of FIG. 4 with a stuck fault condition utilizing the proposed concept; and
[0016] [0016]FIG. 7 is a block diagram of a computer system for use with the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] Reference will now be made to embodiments of the invention shown in the accompanying drawings. Where possible, the same reference numerals are used throughout the drawings to refer to the same or like parts.
[0018] [0018]FIG. 2 shows a typical configuration for a LBIST circuit 200 , shown in U.S. Pat. No. 5,983,380, the contents of which patent is hereby incorporated by reference. In that LBIST circuit, SRLs in the SRL chain 202 perform both input data launching and output data capturing. The test patterns come from a scan path that is configured into a linear feedback shift register (LFSR) 204 . The test data are then outputted into the multiple input shift register (MISR) 206 for data compression. Alternate scan path shift cycles are applied to the SRLs exercising the combinational logic with the contents of the SRLs and capturing the results of the response of the combinational logic back into the SRLs where they are used as the test inputs for the next cycle. At the end of the requisite number of cycles, the contents of the scan path is read out as the signature to be compared with the desired value. As pointed out previously, a major drawback of LSSD test methodology is encountered when a LSSD scan chain circuit is not functioning properly and access to the internal logic of the circuit is greatly reduced. This is often the case early in a product's introduction cycle when the yields are relatively low or even zero. In these situations, the rapid determination of the fault's root cause is critical but not easily diagnosed. A primary cause of LSSD scan chain malfunctioning is when there is a stuck-at 0 or 1 fault stage 210 in a SRL scan chain 202 .
[0019] SRL scan chain 320 in FIG. 3 is a type of the scan chain circuits found in FIGS. 1 and 2. It comprises a plurality of shift register latches (SRLS) 300 (herein designated as SRL 1 , SRL 2 , . . . , SRL N−1 , SRL N ) in which each SRL 300 includes a master latch 308 and a slave latch 310 . For transfer of data between the latches and combinational logic, 106 , 108 and 110 such as that shown in FIG. 1, each of the SRLs 300 contains a data input terminal 302 from combinatorial logic circuits and a data output terminal 304 to combinatorial logic circuits. In addition, data can be introduced into the latches at shift register input (SRI) terminal 316 and transferred from one SRL to another to the shift register output (SRO) terminal 318 . As described below, data is clocked into each SRL 300 by applying a clock pulse to master latch 308 , and data is clocked out of each SRL 300 by applying a clock pulse to slave latch 310 . Data is outputted from slave latch 310 to a succeeding master latch 308 . For this purpose, the operation of the LSSD scan chain 320 is controlled by scan clock signals on the a-clk, b-clk and c-clk lines. Serial loading of the master latch 308 a from the SRL 316 occurs upon generation of an a-clk pulse on a-clk line. The a-clk pulse on a-clk line causes serial input applied to the SRLs 300 to be inputted to each master latch 308 . Application of a b-clk on b-clk line causes data to be output from the SRLs via slave latches 310 . The continuous, alternating application of a-clk and b-clk clock pulse signals on the a-clk and b-clk lines respectively, sequentially propagates a data signal applied to SRI terminal 316 through scan chain 320 to SRO terminal 318 . To effect a parallel load, a c 1 -clk block pulse is applied to c 1 -clk line. This causes a parallel load of data via parallel data inputs 302 and combinational logic to each master latch 308 of the SRLs 300 . Application of a b-clk or c 2 -clk pulse to the b-clk line causes a parallel output of data from each slave latch 310 of SRLs 300 to provide data on respective parallel output data lines 304 .
[0020] As shown in FIG. 4, with one of the SRLs 400 in the scan chain 320 stuck-at fault, the output 404 at the SRO of the LSSD scan chain 320 will be a string of all “0s” or “1s”. As shown, the string is all “0s” which is either after data from the latches 406 to 412 succeeding the bad latch 400 are shifted out the stuck-at fault state of the failing latch 400 or the invert of that state. Since the stuck-at fault latch 400 is intermediate, the input SRI and the output SRO of the chain 320 , it is impossible to pass data down the LSSD chain 320 to determine the exact position on the failing bit 400 in the LSSD chain 320 . In accordance with the present invention, disturb sequences are applied to the LSSD chain to cause one or more latches in the chain after the stuck-at fault latch 400 to change state from that transmitted to it by the stuck-at fault patch 400 , and then the LSSD chain is run to pass the states of the various latches to its output SRO. By counting back from the output signal 408 produced by the last bit 410 in the chain 320 to the output signal 412 furthermost from the output signal 408 to have changed state, the location of the latch 406 producing the change can be determined. The assumption is that after running all disturb sequences of the test the changed data bit 412 is from the latch 406 adjacent to the failing latch 400 and that all the latches 406 to 410 are good.
[0021] The test technique and diagnostic algorithm are depicted in FIGS. 5 and 6. As shown in FIG. 5, first the desired stuck-at fault pattern is loaded in the scan chain 500 . Then the latch disturb stimulus is applied 502 . Each different latch disturb application is followed by the scan chain unload 504 .
[0022] As shown at 600 in FIG. 6, during the expected value for all the latches in the scan chain is set to the output's stuck-at level (i.e. Exp“0” for the stuck-at-0 chain or Exp“1” for the stuck-at-1 chain). This expect value is compared at 602 with the actual output from the scan chain for failure of any bit position to be in its expected value.
[0023] If either initially or after any disturb step 500 such a failure is detected at 606 , the latch furthest from the scan chain output to fail is determined and all expects for latches following and including that farthest failing latch are masked out (Exp“x”) so that they are no longer considered.
[0024] Repeat steps 502 and 504 as discussed above for each of the disturb conditions 610 to 616 .
[0025] Each of the disturb conditions 610 to 616 is repeated a specific number of times as shown by the corresponding loop index (i,j,k,l). Each latch disturb process 502 is centered around the switching threshold 506 of the latches and can randomly or systematically vary in the vicinity of that threshold. The working threshold can be determined empirically using a similar functional scan chain or by circuit analysis and simulation.
[0026] The variables typically perturbed include the device power supply (Vdd) and Vref., clock timing edges, pattern and timing sequences, and temperature. Of these, changing temperature is the slowest process and is usually performed in multiple test passes. Other parameters can be also used to induce switching noise, but the basic diagnostic algorithm remains the same.
[0027] In the case where there are multiple faults in the same scan chain, the diagnostic process is similar, but the localization of the problem can be usually narrowed down to a range of latches rather than a single latch. Although the disclosed technique does not work 100% on all defective devices, it has been found to be highly effective and yielded good diagnosis in many instances of stuck-at scan chain problems.
[0028] The proposed solution is superior to other methods because it provides a efficient and unique solution to the stuck-at scan chain diagnostics with the following benefits:
[0029] 1. Rapid on-the-fly diagnosis.
[0030] 2. Pinpoints defective SRL with high probability.
[0031] 3. Compatible with existing test methodologies and test systems.
[0032] 4. Eliminates extensive test result data collection.
[0033] 5. Implementation is relatively simple.
[0034] 6. Easily simplified and automated for manufacturing test.
[0035] 7. Quick and direct path from test systems to PFA.
[0036] Furthermore, these new approaches are highly effective when diagnosing unmodeled faults, AC defects, and intermittent fails that do not conform to the classical or conventional stuck-at or transitional fault models. Also, many of the underlying basic concepts can be generalized and integrated into general purpose automated test generation and diagnostic products.
[0037] Although we have been discussing the use of this concept with respect to particular scan designs and test methodologies, the real benefits can be realized on LBIST designs that support on on-product clock generation and integrated latch disturb designs supported by built-in diagnostic algorithms.
[0038] As shown in FIG. 7, the testing algorithm to test a chip 700 can be provided to the testing computer 702 on magnetic or optical media 704 .
[0039] The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein. For instance, the invention has been described in terms of particular scan chain and shift register configurations. Of course, it is applicable to other such configurations. Furthermore, other means may be provided to change the state such as use of electric and magnetic fields and light emission and may be varied throughout the operating range and beyond to determine defect sensitivities and to improve or aggravate device response. Therefore, it should be understood that the present invention is not limited to those embodiments but all embodiments within the spirit and scope of the invention as defined in the following claims.
|
While data cannot be transmitted down a scan chain through a stuck-at fault location, data in properly operating latches downstream of the stuck-at fault location can be shifted down the chain. By varying an operating parameters such as power supply and reference voltages, clock timing patterns, temperature and timing sequences, one or more latches down the SRL chain from the stuck-at fault location may be triggered to change state from the stuck-at fault value. The SRL chain is then operated to shift data out the output of the SRL chain. The output is monitored and any change in value from the stuck-at state is noted as identifying all good latch positions to end of the chain. The process is repeated varying each of the selected operating parameters with the latch position following the stuck-at fault latch is identified.
| 6
|
This application is a division of application Ser. No. 626,565, filed June 29, 1984, now U.S. Pat. No. 4,548,738.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to environmentally stable electrically conducting organic polymers and, more particularly, complexes of processible poly(3,6-N-alkylcarbazolyl alkene) doped with charge transfer acceptors together with a method of making same.
2. Description of the Prior Art
High molecular weight organice polymer materials are generally non-conductive because they do not have free electrons like metals. It has been found, however, that certain high molecular weight materials having intrinsic double bond structures such as polyacetylene, polythiazine and polypyrrole may become highly conductive when doped with certain electron acceptors or donors. These compounds have proved to be of a great deal of interest inasmuch as they may combine some of the traditional properties of organic polymers such as high strength, lightweight, flexibility and low temperature processing together with selective electrical properties including high electrical conductivity. In addition, their cost is relatively low.
Such materials undoubtedly will have an important impact on many areas of technology, especially and electronics industry. For example, experimental batteries made from conducting polymers have been shown to exceed current power sources in both power and energy densities. Other areas of potential applications include chemical or gas sensors, low cost, large area optical sensors, switches, lighweight electrical connections, wire, and in their film form for many types of microelectronic circuits and large area solar cells.
Thus, organic materials that behave as metals or semiconductors will provide the advantages of these materials together with additional advantages of being soluble in organic solvents or having low melting points and glass transition temperatures which both minimize the cost of processing and permit composites to be made with thermally sensitive materials such as doped Si or GaAs, for example. The enormous molecular design flexibility of organic chemistry enables precise tailoring of properties to fill a wide range of applications as enumerated above. In addition, the high strength and conductivity-to-weight ratios lend the advantage of fabrication of many electrical devices of much lower weight than conventional materials.
In the prior art, a large number of polymeric conductors have been made. These include polyacetylene and its analogues which may be doped with I 2 , AsF 5 and BF 4 - or the like. In addition, various phenylene polymers and phthalocyanine complexes have been synthesized as conductive materials.
Highly conducting p-type materials have been obtained by doping the polymer with a charge transfer acceptor such as I 2 or AsF 5 from the gas or with ClO 4 - or BF 4 - electrochemical oxidation. An n-type material has been achieved by a doping with alkali metal. In known cases of these two types of materials, however, to date only the p-type show any environmental stability.
Theoretically, conductivity takes place both along the polymer chain and between adjacent chains. The active charge carrier, at least in the aromatic materials, is believed to be a bipolaron that is delocalized over several monomer units. The mobility of such a species along the polymer chain is reduced by conformational disorder, necessitating a rigid highly crystalline chain structure for maximum intrachain conductivity. Various mechanisms such as "hopping" and interchain exchange" are thought to be responsible for the interchain part of the conductivity. Unfortunately all of the most highly crystalline polymers of high conductivity are insoluble and infusable. Such is the case with the most common prior art conducting polymer, polyacetylene, which because of this, must be used in the same form as polymerized. In film form it becomes highly porous fibrillar networks which are tough, cheap, and can be electrochemically doped very rapidly. Polyacetylene films have been used in lightweight storage batteries and can also be used to make Shottky barriers which exhibit a photovoltaic effect.
Other slightly less conductive materials include doped poly p-phenylenes; however, poly p-phenylene can be processed only by powder metallurgical techniques, precluding thin film applications. Two solution processible polymers that are known to have been doped to high conductivities in the prior art are poly m-phenylene and poly m and p-phenylene sulfides. AsF 5 which has a very high electron affinity has been used succesfully to generate radical cations in these polymers. Unfortunately, these cations are so unstable that crosslinking and ring fusion reactions occur. This, together with high water sensitivity, greatly reduces the utility of the polymers.
Thus, in the prior art, because of the nonprocessibility of these base polymers, thin films and uniform doping have both been difficult to achieve. One attempt to remedy this difficulty consisted of co-evaporating biphenyl with AsF 5 to simultaneously polymerize the biphenyl and subsequently dope the p-phenylene polymer on the substrate. This procedure has also been used with several aromatic and heteroaromatic monomers capable of undergoing Lewis acid induced oxidative polymerization with an active radical cation chain end. Invariably black insoluble films of somewhat undetermined composition have resulted. Conductivities as high as 10 -2 /ohm-cm were reached, however. This process for generating thin films is somewhat similar to the solid state polymerization of evaporated S 2 N 2 thin films to a semiconducting (SN) X of rather low environmental stability.
Other conducting polymers which have been electrochemically synthesized and simultaneously doped are polypyrrole type films which show conductivities as high as 10 2 /ohm-cm, and are stable in air. Unfortunately, these films are also intractable and of somewhat indefinite composition.
Successful environmentally stable doped conducting polymers are described in U.S. Pat. No. 4,452,725 to S. T. Wellinghoff, S. A. Jenekhe (a co-inventor in the present application) and T. J. Kedrowski which is assigned to the same assignees as the present application. That application concerns conducting polymers of N-alkyl 3,6' carbazolyl chemically doped with charge transfer acceptor dopants such as the halogens.
SUMMARY OF THE INVENTION
The present invention provides a new class of organic polymer materials which are solution and/or melt processible to films, fibers, and other shapes, which when doped with suitable electron acceptors exhibit controllable and high p-type conductivity in the range characteristic of semiconductors. This is accomplished through condensation polymerization of 3,6-N-alkylcarbazolyl with formaldehyde or other aldehydes to high polymers. The polymers are doped with a compatible charge transfer acceptor. This endows the materials with the above polymer properties as well as enhances the conjugation of the base monomer units through chain length extension, thereby lowering the ionization potential and favoring delocalization of electrons.
The undoped materials have good ambient air stability and excellent thermal stability in air up to temperatures above 200° C. The doped polymers are capable of combining high electrical conductivity with good mechanical and thermal stability.
The compounds of the present invention have the general formula: ##STR1## where R is an alkyl group having from 1 to 3 carbon atoms, R 1 is an alkene group having from 1 to 3 carbon atoms and n is an integer greater than 1. In the preferred embodiment R is a methyl (--CH 3 ) group and R 1 is a methylene (--CH 2 --) group.
The undoped polymer is prepared by acid catalyzed polymerization of N-alkylcarbazole with an aldehyde. In the preferred embodiment the reactants are N-methylcarbazole and formaldehyde. The acid catalyst is normally sulfuric acid or acetic acid. The doped conducting polymer is obtained from the undoped polymer by a suitable doping process. This may be by exposure of the polymer to a vapor of the dopant or immersion of the polymer in a solution of the dopant.
BRIEF DESCRIPTION OF THE DRAWINGS
The lone FIGURE is a graph showing the molecular weight distribution for the four example polymerizations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Polymer Synthesis
The preparation of the polymers was achieved by acid-catalyzed condensation polymerization of N-methylcarbazole with formaldehyde. Four samples of poly(3,6-N-methylcarbazolyl methylene) were prepared as in the following Examples I-IV. The basic reaction, in the case of formaldehyde, is as follows: ##STR2##
EXAMPLE I
A solution of 1.8124 g (0.01 mole) N-methylcarbazole and 0.01 mole formaldehyde (0.811 g of 37% aqueous solution) in 15 ml dioxane containing 0.184 ml conc. H 2 SO 4 (d=1.84 g/cm 3 ) was sealed in a 1 inch dia×5 inch long pyrex glass tube. The reaction vessel was heated in an oil bath at 90° C. for 3 hours with continual shaking. Then the reaction mixture was poured into 1.0 liter of well-stirred methanol to precipitate the polymer. The precipitate was dissolved in N-methyl-2-pyrrolidone (NMP) and re-precipitated in methanol to produce a white polymer.
EXAMPLE II
The same procedure as in Example I was used except that 5.4337 g (0.03 mole) N-methylcarbazole, 2.433 g (0.03 mole) 37% formaldehyde solution, 0.55 ml conc. H 2 SO 4 , and 45 ml dioxane was used.
EXAMPLE III
18.124 g (0.10 mole) N-methylcarbazole, 8.11 g (0.10 mole) 37% formaldehyde, 1.84 ml conc. H 2 SO 4 , and 150.0 ml dioxane was prepared in a 500 ml 3-neck flask in flowing argon atmosphere (2 ml/min). After mechanically stirring at 86° C. for 3 hours, the reaction mixture was poured into 3.0 liters of rapidly stirring methanol to precipitate the polymer. The polymer was twice dissolved in 250 ml NMP and precipitated in methanol, giving a white product.
EXAMPLE IV
The same procedure as Example I was used except tht 0.3003 g (0.01 mole) of paraformaldehyde (CH 2 O)x, was used in place of the formaldehyde solution.
The polymers of Examples I-IV were dissolved in methylene chloride, nitrobenzene or N-methyl-2-pyrrolidone (NMP) solvent and thin polymer films were cast on NaCl plates for infrared spectroscopy. These films were oxidized on the substrates by exposing them either to I 2 vapor or a hexane solution of I 2 at 50° C., or a solution of NOBF 4 (Aldrich) in acetonitrile at 25° C. under nitrogen atmosphere.
POLYMER CHARACTERIZATION
Polymer molecular weight distribution was characterized using a Waters Associate Model 501 Permeation Chromatography (GPC) at room temperature (23° C.). The GPC was packed with 10 5 , 10 4 , 10 3 , and 500A microstyrogel columns in methylene chloride solvent and operated at a flow rate of 2 ml/min. The infrared spectra of the thin polymer films cast from methylene choride solutions were recorded on KCl windows or as free standing films using a Digilab model FTS-14 Fourier transform spectrometer. Electrical conductivity measurements were made on complexed films with a standard four-point probe instrument or a contactless conductivity instrument (Tencor M-gage) operating at 1 KHz.
The poly(3,6-N-methylcarbazolyl methylene) (PMCZM) samples were considerably more soluble and in more solvents than poly(3,6-N-methylcarbazolyl) (PMCZ), as expected. In addition to nitrobenzene which is a good solvent for PMCZ, the methylene linked polymer samples were also soluble in NMP, methylene chloride, THF, DMF, and similar solvents. The molecular weight distribution of the PMCZM samples obtained by GPC analysis is shown in FIG. 1. The numbers I-IV correspond to Examples I-IV. The molecular weight parameters calculated using polystyrene standards are collected together in Table 1. The narrow molecular weight distribution (Mw/Mn) of 1.17-1.51 in the four polymer samples is noteworthy. The effect of polymerization conditions on Mw/Mn is not significant; however, a significant variance between 13-25 is observed in the average DP. Differential scanning calorimetry (DSC) showed only a Tg in the range of 100°-148° C. which increased with increasing molecular weight. The absence of any endothermic peaks in the DSC thermograms up to 300° C. indicated that the polymer samples were amorphous.
TABLE I______________________________________Properties of PMCZM SamplesPMCZMSamples Mw Mn Mw/Mn DP Tg (°C.) σ(Ω.sup.-1 cm.sup.-1)______________________________________Example 2931 2497 1.17 12.9 100 10.sup.-3Example 4090 3221 1.27 16.7 111 10.sup.-3IIExample 7194 4767 1.51 24.7 148 10.sup.-2IIIExample 2943 2457 1.20 12.7 101 10.sup.-3IV______________________________________
The DC conductivity of iodine-doped PMCZM samples at 23° C. was about 10 -3 to 10 -2 ohm -1 cm -1 as shown in Table I. The effect of molecular weight or DP on conductivity is not yet fully clear, although it appears that the polymer with the longest chain length has the highest conductivity. From studies of p-phenylene oligomers and polymers, it has recently been suggested in the literature that the chain length, beyond a certain minimum may only be of minor relevance to conductivity. Evidently in these polymers, the principal charge transport mechanism is intermolecular, along stacks of face to face packed aromatic rings. Delocalization of carriers along the chain serves mainly to increase the probability of hopping between chains. Beyond a certain conjugation length, one might expect this probability to be unchanged.
The observed moderately high conductivity of oxidized PMCZM suggests the following oxidation mechanism: ##STR3## In fact, it is known that a hydrogen of the bridge methylene of 3,3'-N,N'-dimethyl-dicarbazolyl methylene bis can be abstracted as hydride ion by reagents such as triphynelmethyl tetrafluoroborate (Ph 3 C + BF 4 - ), triphenylmethyl perchlorate (Ph 3 C + ClO 4 - ), and triphenylmethyl hexachloroantimonate (Ph 3 C + SbCl 6 - ) or other suitable sources of these anions to form the salt of highly conjugated imine cations analogous to that shown above. The conductivity of iodine complexes of PMCZM is also to be compared to 1-10 ohm -1 cm -1 typically observed in iodine complexes of the parent unbridged polycarbazoles. The orders of magnitude lower conductivity is conceivably due to a significant number of methylene linkages not converted to methine linkages after complexation.
While the particular embodiment shown is poly(3,6-N-methylcarbazolyl methylene) other polymers prepared with other alkyl carbazoles and aldehydes also produce good results. These include, for example, poly(3,6-N-methylcarbazolyl ethylene), poly(3,6-N-ethylcarbazolyl ethylene) and poly(3,6-N-methylcarbazolyl methylene).
|
Environmentally stable polymer complexes of processible poly (3,6-N-alkylcarbazolyl alkenes) are disclosed together with a method of making the complexes.
| 2
|
TECHNICAL FIELD
[0001] The present invention relates to a variable capacity turbine having a function of changing a flow characteristic.
BACKGROUND ART
[0002] There are known techniques as disclosed in Patent Literatures 1 and 2, for example, as a variable capacity turbine suitable for use as a turbine of a turbocharger which mainly includes the turbine and a compressor and in which exhaust gas (fluid) from an engine (internal combustion engine) rotates the turbine to thereby rotate the compressor to send atmosphere as high-pressure air into the engine.
CITATION LIST
Patent Literature
[0000]
{PTL 1} Japanese Unexamined Patent Application, Publication No. Heil0-8977
{PTL 2} Japanese Unexamined Patent Application, Publication No. 2000-110572
SUMMARY OF INVENTION
Technical Problem
[0005] However, in the variable capacity turbines disclosed in Patent Literatures 1 and 2, a flow path sectional area at an inlet portion of an outer scroll increases on a way from an upstream side to a downstream side, which reduces a flow velocity of the exhaust gas, causes separation from an outer peripheral face of an involute dividing wall for separating the outer scroll and the inner scroll from each other, and reduces performance and a flow rate.
[0006] The present invention has been made with the above circumstances in view and it is an object of the present invention to provide a variable capacity turbine in which separation from an outer peripheral face of an involute dividing wall at an inlet portion of an outer scroll can be suppressed, performance can be enhanced, and a flow rate can be increased.
Solution to Problem
[0007] To achieve the above object, the present invention employs the following means.
[0008] A variable capacity turbine according to a first aspect of the present invention includes: a turbine housing having an involuted scroll formed therein; a turbine wheel rotatably provided on an inner periphery side of the scroll; an involute dividing wall mounted on the turbine housing to divide the scroll into an inner scroll and an outer scroll; and a flow regulating valve for opening and closing an introducing port formed at an inlet end of the outer scroll. An inlet portion of the outer scroll is formed to have a continuous and gentle throttle flow path from an upstream side to a downstream side.
[0009] According to the variable capacity turbine of the first aspect of the present invention, the flow path at the inlet portion of the outer scroll is the continuous throttle flow path from the upstream side to the downstream side. In other words, the inner peripheral face of the outer scroll at the inlet portion of the outer scroll and/or the outer peripheral face of the involute dividing wall are/is formed so that a flow path sectional area gradually reduces, which facilitates acceleration of the exhaust gas at the inlet portion of the outer scroll, suppresses separation from the outer peripheral face of the upstream tip end portion of the involute dividing wall, enhances performance, and increases a flow rate thereof.
[0010] In the variable capacity turbine according to the first aspect of the present invention, preferably, an inner peripheral surface of the flow control valve is a flat face and the flow control valve is formed so that the flat face and a central axis of an inlet flange forming an inlet portion of the turbine housing become substantially parallel with each other when the valve is fully open.
[0011] According to this variable capacity turbine, the flow control valve is formed so that an angle formed by the flat face positioned on the inner periphery side of the flow control valve and the central axis of the inlet flange is substantially parallel with each other, which reduces a turning angle of a fluid passing through the introducing port to thereby further suppress separation from the outer peripheral face of the upstream tip end portion of the involute dividing wall, further enhance performance, and further increase the flow rate.
[0012] In the variable capacity turbine according to the first aspect of the present invention, preferably, the flow regulating valve is formed to move parallel between positions at times when the flow rate is high and low so that the turning angle of the fluid passing through the introducing port is maintained constant at any of times when the flow rate is low, the flow rate is high, the flow rate shifts from a low rate to a high rate, and the flow rate shifts from the high rate to the low rate.
[0013] According to this variable capacity turbine, the turning angle of the fluid passing through the introducing port is maintained constant at any of times when the flow rate is low, the flow rate is high, the flow rate shifts from the low rate to the high rate, and the flow rate shifts from the high rate to the low rate, which further suppresses separation from the outer peripheral face of the upstream tip end portion of the involute dividing wall, further enhances performance, and further increases the flow rate.
[0014] A variable capacity turbine according to a second aspect of the present invention includes: a turbine housing having an involuted scroll formed therein; a turbine wheel rotatably provided on an inner periphery side of the scroll; an involute dividing wall mounted on the turbine housing to divide the scroll into an inner scroll and an outer scroll; and a flow regulating valve for opening and closing an introducing port formed at an inlet end of the outer scroll. An inner peripheral surface of the flow control valve is a flat face and the flow control valve is formed so that the flat face and a central axis of an inlet flange forming an inlet portion of the turbine housing become substantially parallel with each other when the valve is fully open.
[0015] According to the variable capacity turbine of the second aspect of the present invention, the flow control valve is formed so that an angle formed by the flat face positioned on the inner periphery side of the flow control valve and the central axis of the inlet flange is substantially parallel when the valve is fully open, which reduces a turning angle of a fluid passing through the introducing port to thereby further suppress separation from the outer peripheral face of the upstream tip end portion of the involute dividing wall, further enhance performance, and further increase the flow rate.
[0016] A variable capacity turbine according to a third aspect of the present invention includes: a turbine housing having an involuted scroll formed therein; a turbine wheel rotatably provided on an inner periphery side of the scroll; an involute dividing wall mounted on the turbine housing to divide the scroll into an inner scroll and an outer scroll; and a flow regulating valve for opening and closing an introducing port formed at an inlet end of the outer scroll. The flow regulating valve is formed to move parallel between positions at times when the flow rate is high and low so that a turning angle of a fluid passing through the introducing port is maintained constant at any of times when the flow rate is low, the flow rate is high, the flow rate shifts from a low rate to a high rate, and the flow rate shifts from the high rate to the low rate.
[0017] According to the variable capacity turbine of the third aspect of the present invention, the turning angle of the fluid passing through the introducing port is maintained constant at any of times when the flow rate is low, the flow rate is high, the flow rate shifts from the low rate to the high rate, and the flow rate shifts from the high rate to the low rate, which further suppresses separation from the outer peripheral face of the upstream tip end portion of the involute dividing wall, further enhances performance, and further increases the flow rate.
[0018] A turbocharger according to a fourth aspect of the present invention includes a variable capacity turbine with a reduced loss due to separation and satisfactory performance.
[0019] According to the turbocharger of the fourth aspect of the present invention, it is possible to enhance performance of the whole apparatus.
ADVANTAGEOUS EFFECTS OF INVENTION
[0020] With the variable capacity turbine according to the present invention, separation from the outer peripheral face of the involute dividing wall at the inlet portion of the outer scroll can be suppressed, performance can be enhanced, and the flow rate can be increased.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a sectional view perpendicular to an axis of a variable capacity turbine when a flow rate is low, according to a first embodiment of the present invention.
[0022] FIG. 2 is a sectional view perpendicular to the axis of the variable capacity turbine when the flow rate is high, according to the first embodiment of the present invention.
[0023] FIG. 3 is a diagram for explaining a characteristic portion of the variable capacity turbine according to the first embodiment of the present invention.
[0024] FIG. 4 is a sectional view perpendicular to an axis of a variable capacity turbine when a flow rate is high, according to a second embodiment of the present invention.
[0025] FIG. 5 is a sectional view perpendicular to an axis of a variable capacity turbine according to a third embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0026] A first embodiment of a variable capacity turbine according to the present invention will be described below with reference to FIGS. 1 to 3 .
[0027] FIG. 1 is a sectional view perpendicular to an axis of the variable capacity turbine when a flow rate is low according to the present embodiment, FIG. 2 is a sectional view perpendicular to the axis of the variable capacity turbine when a flow rate is high according to the present embodiment, and FIG. 3 is a diagram for explaining a characteristic portion of the variable capacity turbine according to the present embodiment.
[0028] As shown in FIGS. 1 and 2 , the variable capacity turbine 1 according to the present embodiment is mainly formed of a turbine housing 3 in which an involuted scroll 2 is formed, and a turbine wheel 4 rotatably provided on an inner periphery side of the scroll 2 .
[0029] The scroll 2 includes an inner scroll 5 formed inside in a radial direction (on the inner periphery side) and an outer scroll 6 formed outside in the radial direction (on an outer periphery side), i.e., formed to surround a radial outside of the inner scroll 5 . The inner scroll 5 and the outer scroll 6 are divided (separated) by an involute dividing wall 7 and the involute dividing wall 7 is formed (mounted) in the turbine housing 3 so that the outer scroll 6 has a larger capacity than the inner scroll 5 . The involute dividing wall 7 is formed of a tongue-shaped first dividing wall 8 and a plate-shaped second dividing wall 9 . In the second dividing wall 9 , there is formed a plurality of communication holes 10 which introduces from the outer scroll 6 to the inner scroll 5 exhaust gas (fluid) introduced into the outer scroll 6 when the flow rate is high.
[0030] The turbine housing 3 is adjacent to a compressor housing (not shown) and mounted on a bearing housing (not shown) which is mounted on the compressor housing, and has an exhaust gas introducing port 11 and an exhaust gas discharge port (not shown). On an upstream side (on the exhaust gas introducing port 11 side) of the first dividing wall 8 , the turbine housing 3 is provided with a flow control valve 12 . The flow control valve 12 is mainly formed of a plate-shaped member formed so that a flat face formed on an inner periphery side of a downstream tip end portion comes in contact with (overlaps) a flat face (flat slope) formed on an outer periphery side of an upstream tip end portion of the first dividing wall 8 . The flow control valve 12 is turned by turning means (not shown) about a turning shaft 13 positioned on the exhaust gas introducing port 11 side and provided (mounted) onto the turbine housing 3 to switch between a position for closing (fully closing) an introducing port 14 (see FIG. 2 ) of the outer scroll 6 shown in FIG. 1 and a position for opening (fully opening) the introducing port 14 of the outer scroll 6 shown in FIG. 2 . In FIGS. 1 and 2 , a reference numeral 15 designates a cover closing an opening portion of the turbine housing 3 , a reference numeral 16 designates a bolt for fixing the cover 15 to the turbine housing 3 , and a reference numeral 17 designates a built-up portion covering a tip end portion of the bolt 16 .
[0031] The outer scroll 6 of the variable capacity turbine 1 according to the present embodiment is formed so as to have a continuous throttle flow path from an upstream side to a downstream side at the inlet portion, i.e., so that a flow path sectional area at the inlet portion follows a track shown in a solid line in FIG. 3 , for example. In other words, the outer scroll 6 of the variable capacity turbine 1 according to the present embodiment is formed so that a sectional area (see ( 1 ) in FIG. 3 ) of a flow path surrounded with the tip end on the downstream inner periphery side of the flow control valve 12 , an outer peripheral face of the first dividing wall 8 , and an inner peripheral face of the turbine housing 3 is larger than a sectional area (see ( 2 ) in FIG. 3 ) of a flow path surrounded with an inner peripheral face of the built-up portion 17 , the outer peripheral face of the first dividing wall 8 , and the inner peripheral face of the turbine housing 3 , that the sectional area (see ( 2 ) in FIG. 3 ) of the flow path surrounded with the inner peripheral face of the built-up portion 17 , the outer peripheral face of the first dividing wall 8 , and the inner peripheral face of the turbine housing 3 is larger than a sectional area (see ( 3 ) to ( 6 ) in FIG. 3 ) of a flow path surrounded with the outer peripheral face of the first dividing wall 8 and the inner peripheral face of the turbine housing 3 , and that the sectional area of the flow path surrounded with the outer peripheral face of the first dividing wall 8 and the inner peripheral face of the turbine housing 3 gradually (gently) reduces from the upstream side to the downstream side (see ( 3 ) to ( 6 ) in FIG. 3 ).
[0032] ( 1 ) to ( 6 ) in FIG. 3 respectively correspond to six broken lines (broken lines drawn in directions orthogonal to a central axis of the outer scroll 6 ) shown in FIG. 2 , ( 1 ) in FIG. 3 corresponds to the broken line positioned most upstream in FIG. 2 , and ( 6 ) in FIG. 3 corresponds to the broken line positioned most downstream in FIG. 2 .
[0033] A 0 in FIG. 3 indicates a sectional area of a flow path along the broken line positioned most upstream in FIG. 2 and A in FIG. 3 indicates a sectional area of a flow path along each of the broken lines in FIG. 2 .
[0034] In the variable capacity turbine 1 according to the present embodiment, a flow path at the inlet portion of the outer scroll 6 is formed as the continuous throttle flow path from the upstream side to the downstream side. In other words, the inner peripheral face of the outer scroll 6 at the inlet portion of the outer scroll 6 and/or the outer peripheral face of the first dividing wall 8 are/is formed so that the flow path sectional area gradually reduces, which facilitates acceleration of the exhaust gas at the inlet portion of the outer scroll 6 , suppresses separation from the outer peripheral face of the upstream tip end portion of the first dividing wall 8 , enhances performance, and increases the flow rate.
[0035] A variable capacity turbine according to a second embodiment of the present invention will be described with reference to FIG. 4 . FIG. 4 is a sectional view perpendicular to an axis of the variable capacity turbine when a flow rate is high, according to the present embodiment.
[0036] The variable capacity turbine 21 according to the present embodiment is different from the turbine of the first embodiment in that the turbine 21 has a turbine housing 22 instead of the turbine housing 3 . Because the other components are similar to those of the first embodiment described above, description thereof will not be repeated.
[0037] As shown in FIG. 4 , the turbine housing 22 according to the present embodiment is formed so that an angle α formed by a line 40 connecting the upstream tip end and a downstream tip end of the first dividing wall 8 and a central axis 23 of an inlet flange 22 a forming an inlet portion of the turbine housing 22 is in a range of 35° to 50° when the flow rate is high (i.e., when the flow control valve 12 is in the position for opening (fully opening) the introducing port 14 of the outer scroll 6 ). In other words, the turbine housing 22 according to the present embodiment is formed so that a flat face 12 a positioned on an inner periphery side of the flow control valve 12 and the central axis 23 of the inlet flange 22 a becomes substantially parallel with each other when the flow control valve 12 is fully open.
[0038] Inside the inlet flange 22 a , the exhaust gas introducing port 11 is formed.
[0039] In the variable capacity turbine 21 according to the present embodiment, a flow path at the inlet portion of the outer scroll 6 is formed as the continuous throttle flow path from the upstream side to the downstream side. In other words, the inner peripheral face of the outer scroll 6 at the inlet portion of the outer scroll 6 and/or the outer peripheral face of the first dividing wall 8 are/is formed so that the flow path sectional area gradually reduces, which facilitates acceleration of the exhaust gas at the inlet portion of the outer scroll 6 , suppresses separation from the outer peripheral face of the upstream tip end portion of the first dividing wall 8 , enhances performance, and increases the flow rate.
[0040] Moreover, the inlet flange 22 a is disposed so that the angle α formed by the line 40 connecting the upstream tip end and the downstream tip end of the first dividing wall 8 and the central axis 23 of the inlet flange 22 a forming the inlet portion of the turbine housing 22 is smaller than that of the first embodiment described above and a turning angle of the exhaust gas passing through the introducing port 14 is smaller than that of the first embodiment described above, which further suppresses separation from the outer peripheral face of the upstream tip end portion of the first dividing wall 8 , further enhances performance, and further increases the flow rate.
[0041] A variable capacity turbine according to a third embodiment of the present invention will be described with reference to FIG. 5 . FIG. 5 is a sectional view perpendicular to an axis of the variable capacity turbine according to the present embodiment.
[0042] A variable capacity turbine 31 according to the present embodiment is different from the turbine of the first embodiment described above in that the turbine 31 has a flow control valve 32 instead of the flow control valve 12 . Because other components are similar to those of the first embodiment described above, description thereof will not be repeated.
[0043] As shown in FIG. 5 , the flow control valve 32 according to the present embodiment is formed to move parallel between a high flow rate position shown in a solid line in FIG. 5 (i.e., when the flow control valve 32 is in a position for opening (fully opening) the introducing port 14 of the outer scroll 6 ) and a low flow rate position shown in a two-dot chain line in FIG. 5 (i.e., when the flow control valve 32 is in a position for closing (fully closing) the introducing port 14 of the outer scroll 6 ). In other words, the flow control valve 32 according to the present embodiment is formed to be opened and closed with a flat face 32 a positioned on an inner periphery side of the flow control valve 32 and the central axis 23 of an inlet flange 3 a forming the inlet portion of the turbine housing 3 maintained at a certain angle with respect to each other.
[0044] Inside the inlet flange 3 a , the exhaust gas introducing port 11 is formed.
[0045] In the variable capacity turbine 31 according to the present embodiment, a flow path at the inlet portion of the outer scroll 6 is formed as the continuous throttle flow path from the upstream side to the downstream side. In other words, the inner peripheral face of the outer scroll 6 at the inlet portion of the outer scroll 6 and/or the outer peripheral face of the first dividing wall 8 are/is formed so that the flow path sectional area gradually reduces, which facilitates acceleration of the exhaust gas at the inlet portion of the outer scroll 6 , suppresses separation from the outer peripheral face of the upstream tip end portion of the first dividing wall 8 , enhances performance, and increases the flow rate.
[0046] Moreover, a turning angle of the exhaust gas passing through the introducing port 14 is constantly maintained at any of times when the flow rate is low, when the flow rate is high, when the flow rate shifts from the low rate to the high rate, and when the flow rate shifts from the high rate to the low rate, which further suppresses separation from the outer peripheral face of the upstream tip end portion of the first dividing wall 8 , further enhances performance, and further increases the flow rate.
[0047] The present invention is not limited to the embodiments described above but may be carried out while being modified or changed suitably as necessary without departing from the scope of the technical idea of the present invention.
[0048] For example, in the second embodiment shown in FIG. 4 , it is possible to employ the flow control valve 32 according to the third embodiment shown in FIG. 5 instead of the flow control valve 12 .
[0049] Moreover, although the turbine, in which a gently curved recessed portion 8 a (see FIG. 1 ) is formed in the outer peripheral face of the first dividing wall 8 in order to mitigate abrupt reduction in the flow path sectional area due to the built-up portion 17 , has been described as a concrete example in the embodiments described above, the inner peripheral face of the turbine housing 3 may be recessed instead of recessing the outer peripheral face of the first dividing wall 8 , so that the flow path at the inlet portion of the outer scroll 6 becomes a continuous and gentle throttle flow path from the upstream side to the downstream side.
REFERENCE SIGNS LIST
[0000]
1 variable capacity turbine
2 scroll
3 turbine housing
4 turbine wheel
5 inner scroll
6 outer scroll
7 involute dividing wall
12 flow control valve
12 a flat face
14 introducing port
21 variable capacity turbine
22 turbine housing
22 a inlet flange
23 central axis
31 variable capacity turbine
32 flow control valve
|
There is provided a variable capacity turbine that is capable of suppressing separation from an outer peripheral face of an involute dividing wall at an inlet portion of an outer scroll, enhancing performance, and increasing a flow rate. The variable capacity turbine includes: a turbine housing having an involuted scroll formed therein; a turbine wheel rotatably provided on an inner periphery side of the scroll; the involute dividing wall mounted on the turbine housing to divide the scroll into an inner scroll and the outer scroll; and a flow regulating valve for opening and closing an introducing port formed at an inlet end of the outer scroll. The inlet portion of the outer scroll is formed to have a continuous and gentle throttle flow path from an upstream side to a downstream side.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Japanese Patent Application No. 2015-133188 filed on Jul. 2, 2015, the entire subject matter of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates to an electronic device, a charging apparatus, a charging program, and a charging method.
BACKGROUND
[0003] In the background art, a secondary battery such as a lithium battery is used in an electronic device such as a smart phone. In such an electronic device, a technique has been known which eliminates affects of heat generation at the time of charging of the secondary battery.
SUMMARY
[0004] According to one aspect of this disclosure, an electronic device includes: a secondary battery; a terminal, which receives electric power to charge the secondary battery; a switch, which turns on and off a connection between the secondary battery and the terminal; and a controller, which controls the switch to be turned off for a predetermined period at a time of starting to charge the secondary battery.
[0005] According to another aspect of this disclosure, a charging apparatus includes: a terminal, which is used to supply electric power to a secondary battery; a detector, which detects a current flowing to the terminal; a switch, which turns on and off a connection between the secondary battery and the terminal; and a controller, which controls the switch to be turned off if the detector detects a current for a predetermined period at a time of starting to charge the secondary battery.
[0006] According to another aspect of this disclosure, a non-transitory computer-readable medium having instructions to control electronic device to perform operations includes: detecting a start of charging of a secondary battery; and controlling a switch connected to the secondary battery to be turned off for a predetermined period at a time of starting to charge the secondary battery.
[0007] According to another aspect of this disclosure, a non-transitory computer-readable medium having instructions to control electronic device to perform operations comprising: detecting a current flowing to a terminal which is used to supply charging power to a secondary battery; and turning off a switch for a predetermined period at a time of starting to charge the secondary battery if the current is detected in the detecting.
[0008] According to another aspect of this disclosure, a charging method comprising: detecting a start of charging of a secondary battery; and controlling a switch connected to the secondary battery to be turned off for a predetermined period at a time of starting to charge the secondary battery.
[0009] According to another aspect of this disclosure, a charging method includes: detecting a current flowing to a terminal which is used to supply charging power to a secondary battery; and turning off a switch for a predetermined period at a time of starting to charge the secondary battery when the current is detected in detecting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and additional features and characteristics of this disclosure will become more apparent from the following detailed descriptions considered with the reference to the accompanying drawings, wherein:
[0011] FIG. 1 is a schematic diagram of a charging system to which an electronic device of an embodiment of this disclosure is applied;
[0012] FIG. 2 is a block diagram of an internal configuration of a smart phone 105 illustrated in FIG. 1 ;
[0013] FIG. 3 is a block diagram of an internal configuration of a charger 103 illustrated in FIG. 1 ;
[0014] FIG. 4 is a schematic diagram illustrating a connection state of the charging system illustrated in FIG. 1 ;
[0015] FIG. 5 is a timing chart for operation of the charging system illustrated in FIG. 1 ;
[0016] FIG. 6 is a timing chart for operation of the charging system illustrated in FIG. 1 ;
[0017] FIG. 7 is a flowchart for operation of the charging system illustrated in FIG. 1 ; and
[0018] FIG. 8 is a schematic diagram illustrating a modified connection state of the charging system to which the electronic device according to an embodiment of this disclosure is applied.
DETAILED DESCRIPTION
[0019] In some embodiments of electronic device will be described below with reference to the accompanying drawings. FIG. 1 is a schematic diagram of a charging system to which electronic device of this embodiment is applied. The following description also explains an embodiment of a charging program and a charging method of this disclosure.
[0020] In the electronic device, it is expected to further improve safety at the time of charging of the secondary battery.
[0021] This disclosure provides an electronic device, a charging apparatus, a charging program, and a charging method that is able to realize improvement of safety.
[0022] In FIG. 1 , reference numeral 101 denotes a receptacle outlet, reference numeral 103 denotes a charger, and reference numeral 105 denotes a smart phone serving as an electronic device of an embodiment. Electric power from the receptacle outlet 101 may be supplied to the smart phone 105 through a cable 103 a of the charger 103 . The charger 103 and the smart phone 105 may be connected to each other by a microUSB terminal, etc.
[0023] An internal configuration of the smart phone 105 illustrated in FIG. 1 will be described below with reference to FIG. 2 . FIG. 2 is a block diagram of the internal configuration of the smart phone 105 illustrated in FIG. 1 .
[0024] As illustrated in FIG. 2 , the smart phone 105 may include a controller (for example, CPU) 202 that controls the entire apparatus and a storage unit 204 that stores, for example, a charging program of an embodiment and other programs or data. The smart phone 105 further may include a display unit 206 that is configured by, for example, a touch panel display for displaying images, characters, or the like, and a communication unit 208 that performs communication with an external apparatus using a short-distance wireless communications or a LAN cable, for example.
[0025] The smart phone 105 further may include an input unit 210 made up of a button for ON/OFF operation of a power supply, a button for volume adjustment, and other operation buttons. The smart phone 105 further may include an interface unit 212 configured to be connected to external device such as the charger 103 by, for example, the microUSB.
[0026] The smart phone 105 further may include a secondary battery 214 that supplies electric power to the entire apparatus. The secondary battery 214 may be detachable. The secondary battery 214 is used as a power supply of the smart phone 105 in an embodiment, but may be a battery other than a lithium battery as long as storing electricity by charging and being able to be used as a battery.
[0027] The smart phone 105 further may include a switch 216 that switches to turn ON and OFF the charging power supplied from the charger 103 .
[0028] An internal configuration of the charger 103 illustrated in FIG. 1 will be described below with reference to FIG. 3 . FIG. 3 is a block diagram of the internal configuration of the charger illustrated in FIG. 1 .
[0029] As illustrated in FIG. 3 , the charger 103 may include a rectifier 301 that may rectifie a current supplied from the receptacle outlet 101 , a switching unit 303 that may convert a DC voltage into an AC voltage having a necessary duty cycle, a transformer 305 that may convert the AC voltage, and a controller 307 that may control the switching unit 303 or the like. The charger 103 may receive the electric power from an in-side terminal and outputs the electric power from an out-side terminal.
[0030] The charger 103 further may include a current detector 309 that detects a current flowing to a charging terminal for the smart phone 105 and a switch 311 that may switch on and off the current flowing to the charging terminal for the smart phone 105 .
[0031] A connection state of the charging system illustrated in FIG. 1 will be described below with reference to FIG. 4 . FIG. 4 is a schematic diagram illustrating a connection state of the charging system illustrated in FIG. 1 . For the description of the connection relation, FIG. 4 illustrates only a part of the charging system illustrated in FIG. 1 .
[0032] In FIG. 4 , the charger 103 and the smart phone 105 may be connected to each other. In the charger 103 , the switch 311 and the current detector 309 may be connected. Terminals 407 a and 407 b may be provided to be connected to the smart phone 105 and supply the electric power to the smart phone from the charger 103 .
[0033] The smart phone 105 may be provided with a load circuit 405 including the display unit, the communication unit, and the like, in addition to the switch 216 and the secondary battery 214 . The load circuit 405 may be connected to the switch 216 and the secondary battery 214 . The smart phone 105 may include a connector 403 that may be connected to the terminals 407 a and 407 b of the charger 103 . The smart phone 105 may include terminals 409 a and 409 b connected to the terminals 407 a and 407 b of the charger 103 .
[0034] In some embodiments, it is assumed that an abnormal portion 401 has occurred between the terminals 407 a and 407 b of the charger 103 . As the abnormal portion 401 , for example, there is a short circuit between the terminals 407 a and 407 b or an electric leakage in the terminals 407 a and 407 b. Naturally, the abnormal portion 401 of an embodiment is not limited to the short circuit or the electric leakage, and may be any abnormality, for example, contamination of a foreign material such as water or dust. In some embodiments, as an example, the abnormal portion 401 due to the short circuit between the terminals 407 a and 407 b will be described below. It is assumed that the abnormal portion 401 has a function equivalent to resistance.
[0035] Information such as control signals may be exchanged between the charger 103 and the smart phone 105 through the terminals 407 a and 407 b.
[0036] Operation of the charging system illustrated in FIG. 1 will be described below with reference to FIGS. 4, 5, 6, and 7 . FIGS. 5 and 6 are timing charts for operation of the charging system illustrated in FIG. 1 . FIG. 5 illustrates a timing chart in a case where abnormality does not occur in the charging system; FIG. 6 illustrates a timing chart in a case where abnormality occurs in the charging system; and FIG. 7 is a flowchart for operation of the charging system illustrated in FIG. 1 .
[0037] The controller 202 of the smart phone 105 may control to start charging when the smart phone 105 and the charger 103 may be connected to each other (step S 701 ).
[0038] The controller 202 may control ON/OFF operations of the switch 216 (step S 703 ). The switch may be turned ON/OFF only once and may be repeatedly turned ON/OFF several times after the charger 103 is connected to the smart phone 105 . In some embodiments, the controller 202 may maintain the switch 216 in the ON state in an initial state where the charger 103 is not connected to the smart phone 105 . Naturally, the controller 202 may maintain the switch 216 in the OFF state in the initial state. The controller 202 may control to turn OFF the switch 216 for a short time.
[0039] Subsequently, the controller 307 of the charger 103 may determine whether to detect a current using the current detector 309 when the switch 216 is in the OFF state (step S 705 ).
[0040] If the current is detected (“Yes” in step S 705 ), the controller 307 may turn OFF the switch 311 and stops the charging (step S 707 ). If the current is not detected (“No” in step S 705 ), the controller 307 may continue to turn ON the switch 311 to continue the charging (step S 711 ) and ends the operation.
[0041] Next, after stopping the charging, the controller 307 may notify the smart phone 105 of the fact that the current is detected (step S 709 ) and ends the operation.
[0042] An operation of the charging system illustrated in FIG. 1 will be further described below.
[0043] 1) Operation in the Normal State
[0044] When the switch 216 is turned off, the current detected by the current detector 309 becomes zero (time T 1 or T 2 in FIG. 5 ), even under the charging. The controller 307 may determine that the operation is normal by detection of the time T 1 or T 2 during which the current becomes zero.
[0045] 2) Operation in the Abnormal State
[0046] When a current flows through a path other than an original charging path due to, for example, the presence of the abnormal portion 401 , the current continuously flows between the terminal 407 a and the terminal 407 b even when the switch 216 is turned off. In this case, the current detector 309 may detect a current even after a certain period from the start of charging, and also may detect a current while the switch 216 is being tuned OFF (time T 3 in FIG. 6 ). The controller 307 may determine that the abnormal occurs if the current is detected at a time period in which the current will not be detected if the operation is normal. The controller 307 may turn off the switch 311 and stops the charging (current supply) if it is determined that the abnormal occurs.
[0047] In this way, according to the charging system using the electronic device of an embodiment, the of presence or absence of abnormality occurrence is detected depending on whether the current is detected, and thus a temperature sensor or the like may be not necessary for detection of heat generation.
[0048] Therefore, according to the charging system using the electronic device of an embodiment, it may be not necessary to mount a plurality of sensor devices with assuming the heat generation in various places, and thus it is advantageous in cost as compared with a case where a sensor is mounted.
[0049] According to the charging system employing the electronic device of an embodiment, the charger 103 can detect an abnormal state. For this reason, the charger 103 can activate a protective circuit such as a current stopping switch.
[0050] This disclosure provides an electronic device, charging apparatus, a charging program, and a charging method that is able to realize improvement of safety.
[0051] The charging system to which the electronic device according to an embodiment of this disclosure is applied is not limited to the above configuration. An example of the charging system to which the electronic device according to an embodiment of this disclosure is applied will be described with reference to FIG. 8 . FIG. 8 is a schematic diagram illustrating a connection state of a modified charging system to which the electronic device according to an embodiment of this disclosure is applied.
[0052] In the charging system illustrated in FIG. 8 , an abnormal portion 801 occurs inside a connector 403 of a smart phone 105 . It is assumed that such an abnormal portion 801 occurs when a foreign material such as water or dust enters into the connector 403 , but the abnormal portion 801 according to the modified example will not be limited thereto. The operation of the charging system illustrated in FIG. 8 is similar to that of the charging system described with reference to FIGS. 1 to 7 .
[0053] The charging system illustrated in FIG. 8 also has the same effect as the charging system described with reference to FIGS. 1 to 7 .
[0054] This disclosure can be variously changed without being limited to an embodiment described above. For example, the controller 307 may reduce the amount of current supply in the charging when determining to be abnormal based on the detection of the current at a time period in which the current will not be detected if the operation is normal.
[0055] Although the disclosure is based on some embodiments and the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art based on this disclosure. Therefore, such changes and modifications may be understood as included within the scope of this disclosure. For example, in some functions and structural components and the like of some embodiments may be reordered in any logically consistent way. Furthermore, the functions and the structural components may be combined into some embodiments or divided from an embodiment.
|
An electronic device includes: a secondary battery; a terminal, which receives electric power to charge the secondary battery; a switch, which turns on and off a connection between the secondary battery and the terminal; and a controller, which controls the switch to be turned off for a predetermined period at a time of starting to charge the secondary battery.
| 7
|
This Application claims the benefit of the U.S. Provisional Application No. 60/130,505, filed Apr. 23, 1999.
FIELD OF THE INVENTION
The present invention relates to a security laminate that is thermally non reversible.
BACKGROUND OF THE INVENTION
Security documents that must be verifiable on their authenticity are e.g. all kinds of identification documents such as passports, visas, identity cards, driver licenses, bank cards, credit cards, security entrance cards, and further value-documents such as banknotes, shares, bonds, certificates, cheques, lottery tickets and all kinds of entrance tickets such as airplane tickets and railroad season-tickets.
Said security documents are in many cases made by the lamination of a data containing card. Said laminate can be single-sided when f.i. a card is laminated on a paper support as in a passport. It is required that said laminates are foolproof. However most laminates delaminate when heated at about 100° C. This poses a serious problem.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a laminated security document whereof the laminate is thermally non reversible.
It is a further object of the invention to provide a security document that can hardly be falsified.
SUMMARY OF THE INVENTION
According to the present invention there is provided a laminating element comprising a transparent support coated with a thermally non-reversible layer comprising an ethylene-acrylic acid copolymer , a first polyurethane polymer and a second polyurethane polymer, said layer having a pH of at least 10 and containing a metallic or an amphoteric cation.
DETAILED DESCRIPTION OF THE INVENTION
According to the invention, the laminate comprises two layers.
The first layer consist of a transparent flexible support. The transparent support is preferably a plastic such as polycarbonate, polypropylene, more preferably a polyester, most preferably polyethylene terephthalate. The thickness of said layer ranges preferably from 5 to 100 μm. Said support is coated on one side, called the inner side with a thermally non reversible layer. The inner side of the transparent support can be imprinted with various kinds of ink such as UV-inks, optical varying inks, optical varying colors, with colors such as pastel tints. Furtheron, holograms can be used. Suitable holograms are see-through holograms and high index reflective holograms. The image can be obtained by inkjet, by chromapress, by wax printers or laser printers.
The thermally non reversible layer comprises an ethylene-acrylic acid copolymer and a mixture of two polyurethanes. Said copolymer is an ionomer and is brought at a pH of at least 10, more preferably at a pH between 10.5 and 11.5 before being coated. Said pH adjustment can be done with alkali such as sodium or potassium hydroxide but preferably at least for a part with a polyvalent metal hydroxide such as magnesium hydroxide. Olefines, like ethylene or propylene can be copolymerized with polymerizable carboxylic acids, like acrylic or methacrylic acids. The acid groups are know to promote excellent adhesion to various substrates and give an outstanding toughness, which is maintained at low temperatures. Copolymers are available with (meth)acrylic acid content upto ca. 20%. These copolymers are used in various applications as described in the encyclopedia of polymer science and engineering, volume 6, John Wiley & Sons, 1986. Most frequently used are ethylene-acrylic acid copolymers. Three important changes occur when a small amount of acrylic acid is randomly copolymerized with ethylene, in comparison to a pure polyethylene: 1. The carboxylic groups are free to form bonds and to interact with any polar substrate. Increases in adhesion are essentially proportional to the comonomer content. 2. Carboxylic groups on adjacent chains can hydrogen-bond with each other. This produces thoughness far in excesss of that achieved with conventional LDPE homopolymers having equivalent molecular weight. The thoughness can further be increased when these polymers are converted into ionomers. 3. The bulky carboxyl groups inhibit the ability of the polymer to crystallize. This improves optical clarity and reduces both melting and softening points.
Copolymers which might be used are:
Ethylene-acrylic acid copolymers (EAA-copolymers)), e.g. Primacor 4990, Primacor 5980, trade names of Dow, AC 540, A-C 5120, trade names of Allied Signal Chemicals ect.
Ethylene-methacrylic acid copolymers.
Propylene-acrylic acid copolymers.
Ethylene-propylene-acrylic acid copolymers
Most frequently used are the methacrylic acid-ethylene and acrylic acid ethylene copolymers
The olefin-(meth)acrylic acid copolymers are often used as an “ionomer”. “Ionomer” is a generic term for copolymers of an olefin (ethylene, butadiene, styrene, ect.) with a carboxylic monomer (acrylic acid, methacrylic acid) which have been neutralized, the H+ions being replaced by other cations (Na+, Zn2+, etc.). Accordingly, the general understanding is that in a medium of low dielectric constant (e.g. hydrocarbon chains) the ions form aggregates. At lower ion contents, the ions aggregate to form multiplets, i.e. small aggregates (several ion pairs). At higher ion concentrations, many ions along with nonionic material give rise to sizeable clusters which not only act as crosslinks but more like microcrystallites. Well known are the ionomers as produced by DuPont under the tradename Surlyn (e.g. Surlyn ethylene-methacrylic acid copolymer Zn-salts; ethylene-methacrylic acid copolymer sodium-salt), and the AClyn products produced by Allied Signal (e.g. AClyn 295A: ethylene acrylic acid copolymer Zn-salts). The ionic cluster formation and phase segregation have a significant impact on the physical properties of the ionomers. The resulting properties of the ionomers are dependent on the molecular weight, the acrylic acid content, the type of cation, and the degree of neutralization of the base copolymer.
The thermal behaviour of the EAA copolymers and their salts can be explained by means of a three-phase model consisting of a polyethylene crystal phase, a mixed amorphous phase and a micro-phase separated ionic cluster phase as described by W. J. MacKnight (J. Polym. Sci. Symp., No. 46, 83-96 (1974)). The crystallinity of EAA copolymers and ionomers decreases with increasing acrylic acid content. Upon increasing the acrylic acid content a lower crystallinity is obtained as described by R. L. McEvoy (Polymer, vol. 39, 5223-5239 (1998) and by W. J. MacKnight (J. Polym. Sci. Symp., No. 46, 83-96 (1974)). EAA Copolymers with 20% of acrylic acid show no or a only very low crystallinity. Upon higher degree of neutralization (increased ionization) the mechanical properties improve (increase in ultimate tensile strength and melt flow viscosity) and the main Tg (glass transition temperature) often described as β-relaxation of the ethylene ionomers decreases. When aqueous dispersions of EAA copolymers or ionomers are used also a higher degree of neutralization can be obtained by addition of an aqueous alkali metal hydroxide solution (such as an aqueous NaOH solution). Upon employing a higher pH of the casting solution mechanical properties of the obtained layer are improved. Upon use of multiple charged cations, such as Zn2+, Ca2+, ect., usually higher melt viscosities are obtained.
The copolymer of ethylene-acrylic acid contains preferably between 15 and 25% acrylic acid, more preferably about 20% acrylic acid. The Tg of the ethylene-acrylic acid copolymer or of the mixture of said copolymer with the two polyurethanes lies below −17° C., more preferably below −19° C.
The first polyurethane is preferably an anionic aliphatic polyester, preferably with a viscosity between 400 and 600 mPa.s, more preferably with a viscosity between 450 and 550 mPa.s. The pH of said polyurethane is preferably around 8. The second polyurethane is preferably an aliphatic polyether, preferably with a viscosity between 250 and 450 mPa.s, more preferably with a viscosity between 300 and 400 mPa.s. The pH of said polyurethane is preferably around 8.
The copolymer ethylene-acrylic acid is preferably present in the thermally non reversible layer in an amount between 4 and 12 g/m 2 , more preferably in an amount of 7 g/m 2 . The first polyurethane is permeably present in an amount between 1.7 and 4.4 g/m 2 , more preferably in an amount of 2.6 g/m 2 . The second polyurethane is preferably present in an amount between 1.5 and 4.0 g/m 2 , more preferably in an amount of 2.4 g/m 2 . The thickness of said layer is preferably between 7.2 and 18 g/m 2 , more preferably about 12 g/m 2 .
The ratio of the copolymer ethylene-acrylic acid versus the first or second polyurethane lies preferably between 2 and 5, more preferably between 2.2 and 3.2.
Said laminate is preferably laminated over a card containing data or/and images onto a paper support. In another embodiment, said thermally non-reversible layer is imprinted with personalized data and then laminated onto a paper support. An example of such an application is a passport booklet.
EXAMPLE
On a polyethylene terephthalate support of 63 μm thickness is coated a dispersion, adjusted to a pH 11 with sodium hydroxide, with a wet coating thickness of 50 g/m 2 containing 8 g/m 2 of ethylene-acrylic acid with 20% acrylic acid, 2.4 g/m 2 of an anionic aliphatic polyester urethane with a viscosity of 500 mPa.s and 2.2 g/m 2 of an aliphatic polyether urethane with a viscosity of 350 mPa.s. After drying, the coated foil is personalized on the coated layer with a picture and personal data in mirror mode printed with a color laserprinter type Tektronix 740™. After the printing the personalized foil is placed into a passport booklet with the personalized side against the paper and laminated in said booklet with a laminator type Dorned LPB 150™. The sealing temperature in the layer is between 90 and 110° C. After testing, the foil sticks very well to the paper of the passport booklet and could not be removed without destroying the paper and the foil.
|
According to the present invention there is provided a laminating element comprising a transparent support coated with a thermally non-reversible layer comprising an ethylene-acrylic acid copolymer, a first polyurethane polymer and a second polyurethane polymer, said layer having a pH of at least 10 and containing a metallic or an amphoteric cation.
| 2
|
FIELD OF THE INVENTION
The present invention relates to the web-forming section, that is, the former section of a paper machine, board machine, tissue machine or the like. More specifically, the invention concerns a loading device for supporting and dewatering a web-forming wire of a paper machine or the like.
BACKGROUND OF THE INVENTION
Several different wire supporting and dewatering components are used in the web-forming sections of a paper machine or the like. The main purpose of these components is to generate a compression pressure and pressure pulsation in the fiber layer to be formed, to thereby promote the removal of water from the web to be formed, and at the same time contribute to the formation of the web.
With regard to know arrangements for web-forming components, general reference is made to the applicant's FI patent publication 90 673, which discloses a two-wire web-forming section of a paper machine which includes a carrying wire and a covering wire. The carrying wire and covering wire together define a two-wire forming zone. In this forming zone is fitted a forming unit including a forming table and a dewatering box which generates a vacuum for removing water from the wire. The dewatering box includes a set of spaced ribs upon which the wire travels. During operation an upper one of the wires rests against the ribs and water is removed from the web by the dewatering box through the spaces defined between the rib elements.
Reference is also made to the applicant's patent publication FI 95935 which relates to a rib construction for a draining device in a paper machine. Specifically a rib construction is disclosed in which a loading rib is used to support and/or load a wire in a paper machine to doctor water from the face of the wire or wires. The rib is loaded by means of a pressure medium. Between the rib and its frame part, a pressure space is formed and defined by a flexible belt. The pressure medium is introduced into the pressure space defined by the flexible belt thereby loading the rib against the wire.
Reference is further made to patent publication FI 100543 which relates to a ledge for resiliently supporting a drainage wire of a paper machine. The ledge disclosed includes a head ledge which is structured and arranged across the direction of travel of the wire so the wire can slide over said ledge as the wire travels. The head ledge is rigidly connected to a movable support ledge which also extends across the direction of travel of wire and is guided on a stationary support structure. Between the movable support ledge and the stationary structure there is a resilient push device which can displace the movable support ledge together with the head ledge between a position of rest away from the wire and an operating position in which the head ledge is pressed with a predetermined force against the wire. The stationary structure has several guide arms distributed over the length of the support ledge which are the exclusive means for guiding the movable support ledge. Several guide arms arranged in pairs are provided which grip around the support ledge in the manner of a clamp.
It has been a problem in known state-of-the-art loading devices that jamming of the loading member of the loading device can occur as a result of which more power is needed to make loading member move. As the loading member presses against the wire, the loading member is subjected to a torque as a result of the wire movement, which torque causes the above-mentioned jamming of the loading member. In order to overcome the jamming of the loading member a strong force must be applied to loading device. This problem is harmful to formation of the web, because the loading force placed on the wire via the loading member cannot be accurately controlled. Thus, it is a common problem that the loading member either applies too much pressure or too little pressure to the wire resulting in said web formation problems.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a loading device which overcomes the short comings of the prior art arrangements discussed above.
The present invention is based on the new and inventive idea that in order to prevent the jamming phenomenon of the loading member, a pivoting roller or rollers or balls are arranged between the loading member of the device and the base member of the device, which will prevent occurrence of said jamming problems.
According to one especially advantageous embodiment of the invention, such a roller is fitted to the top end of the base member of the loading device, the periphery said roller being arranged so that it abuts a portion of the loading member so that it can move in an up and down fashion relative to the base member.
According to another advantageous embodiment of the invention, a pin is fitted to the top end of the base member of the loading device and, correspondingly, a ball bushing is arranged within the loading member, whereby the pin will roll along the balls of the ball bushing.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention will be described in greater detail with reference to the appended drawing, to the details of which, however, the invention is not intended to be limited in any narrow sense. In the patent drawing,
FIG. 1 is a diagrammatic vertical sectional view a first embodiment of the loading device according to the present invention;
FIG. 2 is a diagrammatic vertical sectional view of a second embodiment of the loading device according to the present invention,
FIG. 3 is a diagrammatic vertical sectional view of a third embodiment of the loading device according to the present invention;
FIG. 4 is a diagrammatic elevational view of the loading device according to the present invention taken in the machine direction showing the base member, slide rail and connecting rod;
FIG. 5 is a diagrammatic elevational view of the loading device according to the present invention taken in the machine direction showing an alternate arrangement of the base member, slide rail and connecting rod.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with FIG. 1, in a first embodiment of the invention, the loading device, which extends transversely relative to the direction of movement of the wire, that is, in the cross machine (CD) direction essentially over the entire width of the web forming section. The loading device includes a loading member 41 which extends in the CD direction and a base member 43 which also extends in the CD direction. The base member 43 has an upper portion which defines a slide rail 44 . The slide 44 may be formed integrally with base member 43 or it may separately formed and attached to an upper surface of the base member 43 .
The loading member 41 includes a lengthwise longitudinal groove 54 formed in a lower face thereof, said longitudinal groove extending in the cross machine direction. The loading device according to the invention is structured and arranged so that loading member 41 is maintained in stable position in cross machine direction but is able to move towards and away from the wire while being supported on slide rail 44 to thereby enable the selective loading and unloading of the wire.
A planar and/or inclined ceramic piece 42 is coupled to the upper part of loading member 41 . The ceramic piece 42 is structured and arranged to drag against the wire surface loading the same. The ceramic piece scrapes the lower surface of the wire and in this manner serves to remove water therefrom. The water acts as a lubricated fluid between the ceramic piece 42 and the wire.
The loading device according to the present invention further includes roller means 100 which also extend substantially along the length of the device in the cross machine direction.
As shown in the figures the loading member 41 is substantially U-shaped and includes two substantially parallel arms 53 . The parallel arms define an upper internal longitudinal groove 59 and said longitudinal grove 54 . Groove 59 and 54 are separated by a shoulder portion 60 of the arms as shown. Internal longitudinal groove 59 is adapted and to receive said roller means 100 such that an internal wall of each of said parallel arms abuts said roller means 100 and acts as a contact surface between said loading element 41 and said roller means.
In the embodiment of the invention shown in FIG. 1, the loading member 41 moves in the up-and-down direction in relation to slide rail 44 . In order to maximize easy sliding, rolling is promoted with the aid of roller 100 between body part 43 , slide rail 44 and loading member 41 . According to the invention, roller 100 is coupled to slide rail 44 of the loading element with the aid of rotating shaft 110 .
In the first embodiment of the invention shown in FIG. 1, a single roller 100 arrangement is preferably employed. However, a multiple roller arrangement may also be employed.
To make sure that rolling friction is constantly maintained between roller 100 and the loading member 41 , the loading member 41 and base member 43 are structured and arranged so when they are fit together a certain degree of play exists therebetween. As a result of this arrangement when the force caused by the wire is imposed upon the loading member 41 , base member 43 does not generate friction force except on a side of roller 100 . In this manner the smooth movement of the loading member 41 is insured and the jamming problems associated with prior art arrangements is avoided.
In a second embodiment of the invention, shown in FIG. 2, the loading device extends transversely to the direction of movement of the wire, that is, in the CD direction, essentially over the entire width of the web forming section. The device includes a loading member 41 in the CD direction and a base member 43 also arranged in the CD direction. A top part of the base member forms a slide rail 44 . In accordance with the invention, loading member 41 , which lengthwise has a longitudinal groove 54 , is supported evenly in its position in the CD direction and is adapted to move towards and away from the wire supported by slide rail 44 and by roller means 100 , which are installed in the upper surface of slide rail 44 with the aid of rotating shafts 110 . The upper side of loading member 41 drags against the wire surface loading the same, whereby the loading member 41 scrapes water to be removed from the web away from the lower surface of the wire.
In the embodiment shown in FIG. 2, loading member 41 is adapted to move in an up-and-down direction in relation to slide rail 44 . In order to maximize ease of sliding, rolling is promoted with the aid of rollers 100 arranged between base member 43 , slide rail 44 and loading member 41 . In accordance with the invention, rollers 100 are coupled to body part 43 with the aid of rotating shafts 110 .
In the second embodiment of the invention, rollers 100 are mounted along either side of slide rail 44 as show in FIG. 2 . Each roller 100 and their corresponding rotating shafts 110 extend in the CD direction across the width of loading member 41 . The rotating shafts 110 are coupled to the slide rail 44 at least at their ends. It is advantageous that over the length of each roller 100 supporting bearings (not shown in FIG. 2) are arranged at selected intervals along the length of the roller. For example roller or slide bearings could be arranged in order to support rollers 100 between their ends. Alternatively, slide rail 44 , which typically is an integral part with body part 43 , may be provided with several rollers 100 and corresponding mutually spaced indentations (not shown in FIG. 2) which are structured and arranged to receive a corresponding one of said rollers 100 . The indentations are arranged so that the roller 100 is exposed towards loading member 41 in the manner shown in FIG. 2 .
In the embodiment of the invention shown FIG. 2, each roller 100 has only one stop face, whereby a constant rolling friction is maintained between loading member 41 and rollers 100 , and thus their mutual fitting can be made essentially with an absence of play.
Two possible constructions of the roller means 100 discussed above are shown in FIGS. 4 and 5 which depict the loading device according to the present invention in a machine direction. It is noted that the loading member 41 has not been shown in FIGS. 4 and 5 merely to enable the clear viewing of the remaining structural elements of the device. Nonetheless, it is appreciated that loading member 41 is arranged on top of the base member 43 and glide rail 44 as shown in FIGS. 1-3. In one arrangement of the roller means, shown in FIG. 4, a single roller 100 extends substantially across the entire width of the loading device. The roller 100 is coupled at each of its ends to an upright 44 a of the glide rail 44 by means of rotating shaft 110 . Arranged on an upper surface of glide rail 44 are support bearings 105 or the like which are arranged at selected intervals along the length of the roller 100 to thereby assist in supporting said roller 100 . The upper surface of glide rail 44 may be provided with grooves or the like which would function as a seat for the support bearings 105 .
In an another arrangement of the roller means, shown in FIG. 5, multiple rollers 100 are arranged at selected intervals in the cross machine direction. In such an arrangement the slide rail 44 is provided with a plurality of spaced uprights 44 a . A pair of each of the uprights define an indentation, cavity or the like in the slide rail between a respective pair of the upright, the indentation being adapted to receive a roller. Thus, each of the rollers 100 are structured and arranged to fit between two corresponding uprights 44 a as shown. Each roller 100 coupled to two corresponding uprights by a rotating shaft 110 which is coupled at each of its ends to a corresponding one of the uprights 44 a . It is also possible that a single rotating shaft 110 could be employed which would pass through all of the uprights 44 a and rollers and be coupled at each of ends in a manner similar to the arrangement shown in FIG. 5 .
Where a plurality of rollers 100 a employed, it is preferable that each one of the rollers being arranged at uniform intervals of 500 mm over the entire width of the device. It is emphasized that the rollers may be of different lengths and that it is possible to implement a roller structure according to the invention with one roller 100 only.
In both embodiments of the invention, as shown in FIGS. 1 and 2, it is advantageous that the individual rollers 100 are made of a material which withstands the pressure impact to which it is subjected and which significantly reduces friction that significantly impedes the movement of loading member 41 .
Preferably the loading member 41 , base member 43 and slide rail 44 are made of glass fiber and, in addition, a wear-resistant ceramic piece 42 is mounted on the end of lath loading member 41 . In performed tests it has proved advantageous at the lower slide surface of body part 43 to mount a friction-reducing slide piece 45 , which reduces friction between loading member 41 and base member 43 . Slide piece 45 functions to further enable the easy adjustment and movement of loading member 41 relative to the base member 43 . Instead of slide part 45 it is also possible to use ball/round bars in order to reduce friction even more between loading member 41 and base member 43 .
In another embodiment of the invention, shown in FIG. 3, loading device, which extends transversely to the direction of movement of the wire, that is, in the cross machine direction essentially over the entire width of the web, includes a loading member 41 which is also arranged in the CD direction. The device further includes a base member 43 arranged in the CD direction. A top portion of the base member 43 includes a slide part/parts 44 , in relation to which loading member 41 moves towards and away from the wire.
In accordance with the invention, the loading member 41 includes lengthwise a longitudinal groove 54 . The loading member 41 is adapted to move in an up and down manner relative to the wire. The loading member is supported by slide part/parts 44 and ball means 100 which are arranged in the manner shown in FIG. 3 .
The planar and/or inclined upper portion of loading member 41 drags against the wire surface loading the wire, whereby the loading member 41 functions to remove water from the lower surface of the wire.
In the third embodiment of the invention shown in FIG. 3, loading member 41 moves in an up-and-down direction in relation to slide part 44 . To maximize ease of movement, balls 100 are arranged between an internal face of the loading member 41 and an external surface of the slide part 44 . According to the invention, balls 100 are mounted to loading member 41 with the aid of ball bushing 49 .
In third embodiment of the invention, several balls 100 are mounted in the manner shown in FIG. 3 to form a ball stack. A plurality of these individual ball stacks are arranged in the transverse machine direction across the length of the loading device. Preferably each of the stacks are arranged at a selected distance from one another. For example the distance from stack to another may be between 200 and 280 mm in the transverse machine direction. In this embodiment it is preferable that slide part 44 is defined by a plurality of pins or the like formed in the top part of base member 43 and that the top parts of the slide parts 44 are fitted with some play with relation to the ball bushings 49 .
Ball bushings 49 are provided to house each stacks of balls 100 , the ball bushings 49 being secured to loading member 41 . In this manner the ball bushings 49 and balls 100 therein allow a smooth relative movement between slide part 44 defined by said pins and loading member 41 in the up-and-down direction and at the same time preventing slide part 44 and loading member 41 from jamming. The balls 100 fitted into ball bushing 49 preferably form a bearing, the type of which is e.g. SKF LBBR 12-2LS/HV6.
As was described in the foregoing in connection with the first and second embodiments of application of the invention, it is also possible in this third form of application of the invention when desired to mount a friction-reducing slide piece 45 on the lower slide surface of body part 43 , which slide piece reduces friction between 41 and body part 43 .
In all of the embodiments discussed above with reference to FIGS. 1-3, a flexible belt 46 extends along each side of the device as shown. Each flexible belt 46 is joined to the lower edge of the loading member 41 , and the belt is attached to the a part of body part 43 in such a way that U-shaped loops 48 are formed which extend downwardly as shown. Specifically a first longitudinal edge of belt 46 is attached to loading member 44 and a second longitudinal edge of belt 46 is attached base member 43 . The ends of each belt 46 are attached to a groove 56 formed in the loading member 41 and the base member 43 . To the exteriors sides of the loading member 41 , outside belt 46 , are attached shield plates 55 which limit the lateral movement of belt 46 . Belt 46 has a thickness of about. 0.1-3 mm, preferably 1-2 mm, and is preferably made of rubber or some other similar flexible material.
Using attaching elements 58 , the loading device is attached to the other body of the machine. The loading force of loading member 41 is brought about by generating a loading pressure by introducing a pressure medium, such as air, through channel 57 into the space defined by the flexible belt 46 , loading member 41 and base member 43 .
The loading pressure is reduced by lowering the pressure of the medium. Upon removal of pressure the loading member 41 will return to its bottom position as a result of gravity thereby unloading the wire. A vacuum may also be used to promote the return of the loading member 41 back to its lower position.
The examples of the invention provided above are not meant to be exclusive. Many other variations of the present invention would be obvious to those skilled in the art, and are contemplated to be within the scope of the present invention.
|
The invention concerns a loading device for the dewatering a web-forming wire, which supports and/or loads the wire of a paper machine and scrapes water from the wire surface. The loading device is loaded by a pressure medium and includes a movable loading member and a fixed base member. The loading member includes a longitudinal groove which extends the length of the loading member and the base member includes a slide rail adapted to be received in the longitudinal groove for supporting the loading member. In order to eliminate jamming phenomenon of the loading member, the loading member is supported evenly in its position in a cross machine direction and it is adapted to move towards the wire and away from the wire with aid of rollers arranged between the slide rail and the internal walls of the loading member which define the longitudinal groove.
| 3
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to support structures or support systems, and particularly to a portable support structure for supporting heavy loads on one shoulder, such as portable video cameras of the type used by professional television broadcast photographers and "still" cameras equipped with long lenses.
2. Description of the Prior Art
It has long been thought that the only way to secure studio-quality television broadcast film with a portable video camera was to mount the video camera on a stationary tripod, or to steady the video camera against an immovable object such as a wall or pillar. But mounting the video camera atop a tripod means that when it is necessary to move the camera to follow the subject being photographed the tripod must also be moved. Since most commercial tripods of the type sturdy enough to support a heavy professional-type video camera are themselves heavy and awkward to move because of the depending leg structure, it has been a continuing problem to provide the degree of mobility that is often required to photographically follow the action with a tripod-mounted video camera. Accordingly, one of the principal objects of the present invention is the provision of a portable video camera support structure that enables free mobility of the camera to follow the action being photographed, while supporting the camera in a steady state to enable the shooting of studio-quality video film. Applicant has been unable to find prior art in the literature or in photographic supply houses that solves this need.
A professional television broadcast cameraman is required to carry a heavy video camera cantilever-like on his shoulder while aiming the camera at the action being photographed. He must remain free to move bodily from one location to another to follow the action, while attempting to steady the forwardly projecting camera while shooting the scene. Because the camera projects forwardly of the cameraman, the center of gravity of the camera lies anteriorly of the cameraman, thus imposing a downwardly directed weight spaced forwardly from the body that must be supported to enable the camera to be trained on the scene. To support such a weight continuously for any reasonable length of time imposes severe stress and strain on the arm, back and shoulder muscles of the cameraman, resulting in fatigue that often prevents the cameraman from holding the camera sufficiently steady to shoot video film of the quality necessary for live broadcast of a scene. Therefore, another object of the invention is the provision of a video camera support structure that may be worn by the cameraman and which supports the weight of that portion of the video camera that projects forwardly from the shoulder.
Because of the great mobility that is required of the cameraman while shooting some scenes, jolting of the camera supported only by a tired arm incapable of absorbing the inertia of the moving camera causes sharp and sudden deflection of the camera, thus diminishing the quality of the photographed scene. It is therefore another object of the invention to provide a support system or structure to be worn by the cameraman that supports a major portion of the weight of the video camera, and which damps movement of the camera in relation to the cameraman and the support structure to thus enable the shooting of video film of broadcast quality with highly portable video camera.
Years of experience as a professional video broadcast cameraman has taught me that carrying a heavy video camera on one shoulder, as is the custom, results in the body reacting to retain the spine straight against the tendency of the weight of the camera to bend the spine in the direction of the camera. This reaction, in a surprisingly short interval, results in pain in the neck, shoulders, arms and back, and because of the fatigue thus produced, may also result in mediocre photography. Accordingly, a still further object of the invention is the provision of a camera support structure or system to be worn by a cameraman that transfers to the shoulder opposite the one carrying the camera part of the weight of the camera so that the load is balanced on the body, thus eliminating the need for the body to react by generating adaptive stress to support the load.
A still further object of the invention is the provision of a television broadcast type video camera support structure that minimizes the need for a tripod, that enables a surprising degree of steadiness for broadcast quality shooting of wide shots, telescopic and zoom shots, and which enables "air" quality video photography for sport shooting and "walking" shots.
A still further object of the invention is the provision of a video camera support structure or system adapted to be worn by a professional television broadcast photographer that may be worn with a variety of clothing types, depending upon the weather, without modifying the effectiveness of the structure or system.
A still further object of the invention is the provision of a video camera support structure or system adapted to be worn by a professional television broadcast cameraman for supporting the camera while photographing scenes, and which incorporates means for adjusting the degree of damping effect provided to accommodate impact shocks and jolts of the camera.
The invention possesses other objects and features of advantage, some of which, with the foregoing, will be apparent from the following description and the drawings. It is to be understood however that the invention is not limited to the embodiment illustrated and described since it may be embodied in various forms within the scope of the appended claims.
SUMMARY OF THE INVENTION
In terms of broad inclusion, the video camera support structure or system of the invention includes a harness to be worn by the cameraman, the harness for a right-handed cameraman, for instance, providing a main support strap adjustable in length and adapted to pass diagonally upwardly across the body from the lower right front portion of the torso near the hip bone, over the left shoulder and diagonally downwardly across the back and around the waist to join the opposite end of the strap directly at the lower right front portion of the torso, or joined to a support plate to which opposite ends of the strap are secured. At two locations along its length, the main support strap is provided with connecting means, such as D-rings between which an auxiliary retention strap may be connected to pass around the waist from front to back. Mounted at the juncture of the opposite ends of the main support strap is a socket adapted to receive the lower end of a shock absorbing assembly which projects vertically upwardly and terminates in a cushioned upper support end on which the camera is supported. Obviously, a ring adapted to support the shock absorber could be substituted for the socket, but the socket is preferred. Intermediate the upper and lower ends of the shock absorbing assembly, a resilient tether connects the column to the main support strap to thus resiliently limit the extension of the column in a direction away from the body of the cameraman. When appropriate, an encircling cinch strap or belt may have its opposite ends connected to the union of the opposite ends of the main support strap, or to the support plate to which they are attached, and extend about the cameraman's body just above the hip line to lend additional lateral support to the socket member in which the lower end of the upwardly projecting shock absorber assembly is supported.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the video camera support structure, shown apart from the body of a cameraman and without a video camera supported thereon. Portions of the structure are broken away to reveal underlying structure.
FIG. 1A is a fragmentary perspective view of the upper end portion of a shock absorber column incorporating a height adjustment and ram control mechanism.
FIG. 2 is a side elevational view showing the video camera support structure or system worn by a cameraman and supporting a portable video camera in position of use.
FIG. 3 is a front elevational view showing the video camera support structure or system worn by a cameraman and supporting a portable video camera in position of use.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In terms of greater detail, the video camera support structure or system of the invention comprises a harness designated generally by the numeral 2, and adapted to be worn by a cameraman 3 in such a manner that the load imposed on the body of the cameraman by the weight of the video camera 4 carried on one shoulder 6 (here the right shoulder) is partially distributed to the opposite (left) shoulder 7 to thus balance the load between the two shoulders of the cameraman.
Referring to FIG. 1, it will be seen that the harness forming a part of the support structure or system comprises a flexible main support strap designated generally by the numeral 8, and including a flexible anterior strap portion 9 having a spring clip 12 attached to its lower end 13 and a buckle 14 adjacent its opposite end through which the upper end portion 16 of the anterior strap portion may be threaded to adjustably and detachably anchor this end of the anterior strap portion to an anterior D-ring 17. Adjustably and detachably attached to the D-ring 17 is the anterior end portion 18 of the shoulder strap 19, preferably provided with a cushioning pad 21 to absorb some of the pressure exerted on the shoulder by the partial weight of the camera supported on the shoulder, while the remainder of the weight is suspended on the lower end of the main support strap 8. A buckle 22 provides for adjustment of the position of the shoulder strap cushioning pad 21 to fit different individuals.
Posteriorly, the shoulder strap portion of the main support strap terminates in a posterior portion 23 adjustably attached through a posterior buckle 24 to a posterior D-ring 26. To complete the main support strap designated generally by the numeral 8, there is adjustably and detachably attached to the posterior D-ring 26 a support strap extension 27 by means of a buckle 28. From its posterior connection with the D-ring 26, the strap extension 27 is adapted to sweep around the right side of the cameraman's body, terminating in a spring clip 29 anchored to the terminal end portion 31 of the strap extension 27.
Preferably, as shown, the spring clips 12 and 29 at opposite ends of the main support strap 8 are positioned anteriorly of the cameraman's body, positioned above the right hip joint for a right-handed cameraman, and attached to rings 32 and 33, respectively, which in turn are mounted at opposite corners of a generally flat support plate 34. The support plate 34 may conveniently be fabricated from metal, plastic or leather, and lies flat against the body in the general area between the right iliac region and the right lumbar region. In any event, it lies against the body of the cameraman in a position where it will not interfere with flexure of the right leg, as in walking or climbing stairs, and concomitantly, will itself not be displaced as to its positional location by such movements, thus increasing the stability of the support plate as will hereinafter be explained.
To increase the lateral stability of the support plate 34, i.e, to retain it against movement from side-to-side, the support plate may be provided with a loop member 36 through which may be threaded a belt member 37 adapted to encircle the body of the wearer, and having a buckle 38 for adjustment of the size of the belt to provide a snug fit, and a quick-release fastener 39 for attachment and detachment of the belt. The belt 37 is particularly helpful during photography sessions that last all day, but is not considered an essential element of the combination, since the harness is fully operative without use of the belt. In the same manner, to lend additional stability to the harness as a whole, there is provided an auxiliary strap 41 adapted to encircle the left lumbar region of the cameraman as shown, the auxiliary strap being adjustably and detachably secured between the anterior D-ring 17 and the posterior D-ring 26. The fact that the auxiliary strap passes only partially around the body of the cameraman facilitates donning the harness, since all that is required is that the left arm be extended through the loop formed by the main support strap 8 and the shoulder pad 21 be position on the shoulder. It will thus be seen that any downward force exerted on the support plate 34 will cause tension in the main support strap in a diagonal direction across the anterior chest and abdominal regions of the cameraman, thus insuring that the shoulder pad will remain in position, while such diagonally applied force will also cause the auxiliary strap 41 to snugly encircle the left lumbar region as illustrated in FIG. 3. It should be noted however that for particularly active photography, where a maximum amount of stability of the harness is desired, it is possible to connect a second auxiliary strap between the D-rings 17 and 26, but which passes around the right lumbar region of the cameraman. Again, while such a second auxiliary strap may be desirable in certain situations, it is not an essential element of the combination and is therefore not illustrated in the drawings.
To support the weight of the camera at a point spaced anteriorly of the cameraman's body, particularly anteriorly of the right shoulder on which the camera is usually supported by a right handed cameraman as shown in FIGS. 2 and 3, there is provided mounted on the support plate 34 a socket 42 closed at its lower end 43 and open at its upper end 44. The socket is conveniently mounted on the support plate by a strap 46 that encircles the exposed surface of the socket and has its ends riveted to the support plate 34 as shown. Appropriate screws (not shown) pass through the support plate into the socket to further stabilize its mounting on the support plate.
Detachably supported in the socket 42 is a shock absorber assembly designated generally by the numeral 47, and including a lower housing portion 48 containing a coil compression spring 49, and an upper ram member 51 that fits snugly within the lower housing portion in a manner to enable axial displacement of the ram member in relation to the housing portion. Preferably, the slidable arrangement of the ram within the housing is air-tight, so that as the ram is displaced downwardly against the spring the air below the ram is compressed and builds up an internal pressure within the ram higher than atmospheric pressure. To control the degree of pressure buildup, there is provided an air valve 52 on the ram, the air valve providing a measure of adjustment by release of air from the ram interior when the pressure exceeds a selected amount. It will thus be seen that between the spring constant of the spring 49 and the controllable pressure build-up selected for the ram, the linear displacement of the ram may be controlled within close limits determined by the weight of the camera. A very heavy camera may require a shock absorber having greater resistance to displacement, while a lighter camera may require a shock absorber having less resistance to displacement.
To support the camera, the upper end of the ram 51 is fitted with a camera mount, preferably a cushion block 53 upon which the camera may be deposited when it is hoisted onto the cameraman's shoulder. Obviously, many different types of mounts may be utilized to accommodate different makes of cameras or other loads supported by the ram. The cushion block may be flat on its upper surface as shown, or it may include a slight depression in the form of a shallow channel within which the underside of the camera 4 may be cradled. In any event, the resistance of the shock absorber ram 51 is adjusted to carry the weight of the camera distributed to the cushion block, the ram being depressed only sufficiently to maintain the line of sight of the camera lens horizontal as shown in FIG. 2. Under these circumstances, the only force required to be exerted by the right arm of the cameraman is a steadying and guiding force when he aims the camera at the scene he wishes to photograph. The portion of the weight of the camera that is carried by the ram is exerted downwardly on the support plate 34 and is ultimately transferred to the left shoulder of the cameraman through the main support strap 8. The weight of the camera is thus carried on both shoulders and is balanced therebetween so that the adaptive stress the body of the cameraman would otherwise have to exert to carry the unbalanced load if the camera were supported solely on one shoulder is eliminated.
While the mere weight of the camera resting on the cushion pad 53 will lend considerable stability to the upwardly extending and elongated shock absorber assembly 47 by virtue of the frictional engagement between the cushion pad and the underside of the camera, nevertheless, in the interest of safety and additional stability in the cooperation of the shock absorber with the cameraman and the camera, there is preferably provided a resilient tether 54 anchored at one end to the housing portion 48 adjacent its upper end as shown, and anchored at its other end by a detachable spring clip 56 to the anterior D-ring 17. The tether, together with the frictional interengagment of the cushion pad 53 and the camera, functions to retain the elongated shock absorber assembly in an upright attitude of use. While I have shown one form of tether, obviously, other forms may be used. When the camera is not supported on the cushion pad 53, the tether still functions to retain the elongated shock absorber in an upright attitude ready for mounting of the camera thereon.
It is conceivable that in certain instances of photographic activities it is desirable that the axial translation of the shock absorber ram 51 be inhibited either partially or totally. To accomplish this purpose, the embodiment of the shock absorber assembly illustrated in FIG. lA is provided with a rotatable sleeve 57 threadably engaged with the upper end of the housing portion which functions as a collet to bind the ram 51 to the housing with a selected amount of force when the rotatable sleeve is appropriately adjusted. This feature is of advantage when cameras of different weights are used with the same support structure, thus enabling a surprising versatility in the use of the support structure.
Having thus described the invention, what is believed to be new and novel and sought to be protected by letters patent of the United States is as defined in the claims that follow.
|
A support system to be worn by a person who is required to carry heavy loads on one shoulder. The support system includes a strap arrangement that transfers part of the load from one shoulder to the other shoulder so that the load is balanced between the two shoulders. Additionally, the system provides a shock absorber for supporting loads spaced forwardly of the shoulder, thus leaving the load-carrier's hand free to merely guide the load instead of supporting the weight of the load with his free hand.
| 5
|
This is a division of application Ser. No. 08/131,420, filed Oct. 4, 1993.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to control and protection circuitry for refrigeration systems. More particularly, the field of the invention involves circuitry for activating and deactivating a compressor and a fan motor.
2. Description of the Related Art
Motor protection devices generally include electro-mechanical or solid state electronic devices for protection and control of motors or compressors. Conventional motor protection devices seek to regulate the current drawn by the compressor motor under various loads and conditions. By limiting the amount of current provided to the compressor motor, conventional motor protection devices protect the compressor's windings from damaging effects of high currents and high temperatures.
For example, one conventional motor protection device is a snap disc placed in series with the windings of the compressor motor. The snap disc is composed of bi-metallic layers which are in physical contact with the contact points which close the circuit. Typically, a resistive heating element which heats the bi-metallic layers is connected in series with contact points such that when the heat generated by compressor current passing through the resistive element exceeds the allowable threshold, the different metals of the bi-metallic layer expand at different rates, causing the disc to bend. This bending of the disc breaks the connection to the contact points, thereby opening the circuit to the compressor motor. Another arrangement involves placing the snap disc device in close proximity to the compressor motor so that the snap disc device may open and close in response to the temperature of the compressor motor.
Several problems may occur with a conventional snap action bi-metallic motor overload protector. One problem with the snap disc device is that the overload condition may be detected only after a significant amount of time has passed since the condition originally developed. During this lag time, significant damage to the windings of the motor can occur. Also, conventional snap disc overload protection devices are generally imprecise and non-dynamic. For instance, the temperature and current set points of a snap disc cannot account for different environmental or motor loading conditions. Finally, once the snap disc has opened the circuit to the motor windings, the restoration period of the bi-metallic device is typically excessively lengthy.
Additional motor protection devices include solid state electronic devices which control the power delivered to the compressor motor. In contrast with the electro-mechanical snap disc devices, solid state protection devices have the advantages of precision, reliability, and self-regulation. Generally, a conventional electronic protection device includes a thermostat to sense ambient and internal compressor temperatures, control logic responsive to inputs and which controls the corresponding outputs, and solid state power components which are used to apply power to the compressor motor. For instance, thermostats using thermistors as temperature sensing inputs to an electronic motor control circuit are disclosed in U.S. Pat. No. 5,231,848, "REFRIGERATOR COLD CONTROL", issued Aug. 3, 1993, which is assigned to the assignee of the present invention, the disclosures of which are explicitly incorporated by reference.
Prior art motor protection devices typically include power output stages which regulate the application of power to the compressor motor. The output of the control logic circuit drives the output power stage, either by direct electrical connection to the output stage or by indirect magnetic coupling through a relay. Both techniques offer significant advantages in accuracy, reliability, and precision over electro-mechanical methods for controlling and protecting compressor motors.
However, circuits which directly couple the control logic circuit to the power output stage suffer from problems associated with noise induced into the control logic circuit from the high current flow of the power output stage. In order to eliminate such problems, conventional solid state control circuits utilize a relay to control the activation gate of a solid state switch element, such as a SCR or TRIAC. While the use of a relay offers the benefit of electrical isolation of the control logic circuit and the power output circuit, the use of relays in compressor motor protector circuits may also be problematic. For instance, under high temperature conditions the metallic contacts of the relay may melt down and permanently close due to excessive compressor temperatures. Furthermore, the physical contacts within the relay are subject to damage from repeated wear, corrosion, metal fatigue, or other physically degrading conditions.
What is needed is a compressor motor protection device which is not as subject to noise problems or physical degradation as conventional motor protection devices.
Also needed is a motor protection device which is more accurate and precise than conventional electro-mechanical protection devices.
SUMMARY OF THE INVENTION
The present invention combines the control and motor protection functions into a circuit which inductively activates a solid state switch which gates electrical current to the compressor motor. The circuitry of the present invention provides precise control of the compressor motor while electrically isolating the power switching from the more sensitive control and sensing circuitry. Also, the present invention combines the compressor and fan control functions, allowing for more efficient system control by coordinating the operation of the compressor and fan.
The circuitry of the present invention provides many performance features in an efficient and economical arrangement. For example, the relatively quick response of the circuitry limits the duration of a locked rotor condition versus conventional circuitry using snap discs or relays. Also, the circuitry checks against low line voltage or low temperature ambient, and disables the compressor motor in the event of such a condition. Also, by selecting appropriately sized electrical components, the control circuitry provides a selectable temperature hysteresis.
Upon start-up, the circuitry of the present invention includes a start relay for decreasing the equivalent impedance of the run capacitor during motor start-up. Also, an optional start-up delay avoidance circuit is provided to allow, for a limited number of tries, a manual over-ride of the locked rotor protection circuitry. However, the circuit prevents an excessive number of such over-ride attempts.
The present invention, in one form, is a refrigeration system for cooling a chamber, a compressor having a motor adapted for connection to a power supply, and a control circuit for controlling the activation of the compressor motor. The circuit includes a solid state switch for electrically coupling the power supply and the compressor motor. The solid state switch includes an activation gate which opens and closes current flow through the solid state switch. The system further includes an inductive coupling for inducing a current on the activation gate of the solid state switch to actuate the activation gate and thereby provide power to the compressor motor.
The refrigeration system further includes an oscillation device operatively associated with the inductive coupling for driving the solid state switch, and a device for sensing the operating condition of the compressor motor.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself 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 schematic diagram of the components of the refrigeration system of the present invention;
FIGS. 2A and 2B form a schematic circuit diagram of the compressor motor protection circuit of the present invention;
FIG. 3 is a schematic circuit diagram of a manual delay avoidance circuit for the compressor motor protection circuit;
FIG. 4 is a schematic circuit diagram of a portion of a second embodiment of a compressor motor protection circuit;
FIG. 5 is a schematic circuit diagram of a second embodiment of a solid state power control circuit; and
FIG. 6 is a schematic circuit diagram of an alternative embodiment of the output stage.
corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates preferred embodiments of the invention, in several forms, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiments disclosed below are not intended to be exhaustive or 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 utilize their teachings.
The present invention relates generally to compressor motor controllers for refrigeration systems shown in FIG. 1. Controller 7 is electrically connected to thermostat 6, compressor 8, and fan 9. Thermostat 6 is located within chamber 11 to detect the temperature within the chamber, and provide appropriate information to controller 7. Controller 7 activates and deactivates compressor 8 and fan 9 in order to control the temperature in chamber 11.
FIGS. 2A and 2B show a schematic circuit diagram of controller 7 including thermostat 6. The circuit includes NAND gate G1 for combining both motor control and protection functions, which has inputs from thermostat 20, compressor shell temperature circuit 21, fan overheat detection circuit 28, over-ride circuit 23, and motor load sensing circuits 24, 25, and 26. The system outputs, connected to output pin 3 of NAND gate G1, include oscillator 30 connected to power output stage 31, motor start relay 29 connected to TRAIC3 and TRIAC1, compressor shell temperature hysteresis circuit 22, and fan controller 27 which is connected to fan activation circuit 32.
NAND gate G1 accepts inputs from the system's sensors, and controls the compressor motor through resistor R24 and transistor Q9. Pull-up resistor R9 maintains input pin 1 of NAND gate G1 at a high voltage level unless an open-collector device or other input device pulls the voltage at pin 1 low.
Solid state power control to compressor motor M is governed by NAND gate G1, transistor Q9, oscillator 30, and power output stage 31. Power output stage 31 utilizes solid state switches, such as SCR1 and SCR2, or alternatively TRIAC4 shown in FIG. 5, to perform solid state power switching to compressor motor M.
Under normal conditions, oscillator 30, composed of NAND gate G3, feedback resistor R4, and charging capacitor C6, generates high frequency oscillations of a period proportional to the RC time constant which is the product of the values of resistor R4 and capacitor C6. The output waveform produced by oscillator 30 feeds power output stage 31.
Transistors Q8 and Q3, resistor R25, and capacitor C5 form a complementary push-pull amplifier which is connected to the primary side of transformer T1. The push-pull amplifier is used to conduct the signal produced by oscillator 30 during both positive and negative cycles of oscillation.
The secondary side of power output stage 31 is composed of transformer T1, diodes D11 and D12, and reverse blocking triode thyristors SCR1 and SCR2. The high frequency periodic pulses appearing on the primary side of transformer T1 control the gate voltages applied to SCR1 and SCR2 on the secondary side of transformer T1. SCR1 and SCR2, in inverse-parallel arrangement, control the application of power to compressor motor M. Specifically, when diode D11 is forward biased, current travels into the gate of SCR2, thereby activating SCR2 for conduction. Likewise, when diode D12 is forward biased, current travels into the gate of SCR1, thereby activating SCR1 for conduction. Since the frequency of the oscillations produced by oscillator 30 are much higher than the 60 hz line frequency, the inverse-parallel arrangement of SCR1 and SCR2 delivers AC power to compressor motor M utilizing the positive or negative cycles of the AC line voltage, as long as oscillator 30 is running.
The circuit diagram of FIG. 5 shows a second embodiment of power output stage 31. Referring to FIG. 5, secondary winding N2 provides the gate voltage to TRIAC4 through resistor R67. In this configuration, TRIAC4 is used in place of SCR1, SCR2, and diodes D11 and D12. The use of solid state switches such as thyristors, either SCR's or a TRIAC, for controlling the provision of electrical power to compressor motor M ensures that compressor motor M is turned off at the next zero crossing of motor current. With prior art snap discs, motor current is typically interrupted at a point of relatively high current, thereby generating high voltage in the motor windings.
Deactivation of compressor motor M is achieved by stopping the oscillation of oscillator 30. While oscillator 30 begins running when power is applied to the circuit, transistor Q9 controls the subsequent operation of oscillator 30. When the base voltage of Q9 through resistor R24 is low, transistor Q9 turns off, and oscillator 30 drives power output stage 31 thereby activating compressor motor M. When the base voltage of transistor Q9 is high, Q9 conducts from collector to emitter, holding the voltage of input pin 12 of NAND gate 3 low, thereby suspending oscillator 30, which deactivates compressor motor M.
In order to monitor the operation of compressor motor M, voltage sensing and current sensing techniques are employed by the present invention. Voltage sensing is a technique used to determine the present load on compressor motor M. When compressor motor M is in a running state, as the compressor load increases, the voltage across the auxiliary winding decreases. Input pin 2 of NAND gate G1 is connected to voltage reference branch 25, voltage sensing branch 24, and over-ride circuit 23 in order to sense the operating condition of compressor motor M.
Voltage sensing branch 24 includes resistors R7 and R1, and diode D6 which are connected to the auxiliary winding of compressor motor M. Compensating network 26 includes resistor R26 connected to the cathode of zener diode D1. The anode of zener diode D1 is connected to DC ground, referred to as supply reference (SR). Reference branch 25 is composed of resistor R14 and diode D5, whose cathode is connected to AC common.
Sensing branch 24, in conjunction with reference branch 25 and compensating network 26, senses the voltage level across the auxiliary winding of compressor motor M. Under light loading conditions, the voltage across the auxiliary winding of compressor motor M is large, therefore the voltage at input pin 2 of NAND gate G1 is high. However, as the load on compressor motor M increases, the voltage across the auxiliary winding decreases. When this winding voltage declines sufficiently, the voltage @pin 2 reaches the negative threshold of input pin 2, causing the output of NAND gate G1 to jump to a high state, thereby inhibiting oscillator 30, which deactivates compressor motor M through power output stage 31. In this manner, compressor motor M is deactivated when the motor load exceeds allowable limits. NAND gate G2 operates with capacitor C3 and resistor R6 to provide a motor off cycle timer, which latches gate G1 off for about 47 seconds after compressor motor M is deactivated because of excessive motor load.
FIG. 4 shows a schematic diagram of a second embodiment of the solid state motor control. This circuit configuration implements current sensing techniques to determine motor loading. Referring to FIG. 4, transformer T2 has primary winding N p connected in series with compressor motor M. The changing load current traveling through the primary winding of transformer T2 induces a corresponding voltage across the secondary winding, N s , of transformer T2. This changing secondary voltage feeds the base of transistor Q60 through resistor R65. As the load current increases, the base voltage of transistor Q60 also increases relative to the DC supply ground. When the load current has reached the maximum allowable level, transistor Q60 is pulsed on and conducts current through resistor R60 such that the voltage at input pin 2 to NAND gate G1 is pulled low, thereby setting the output voltage of NAND gate G1 high. As a result, oscillator 30 is suspended from driving power output stage 31, thereby deactivating motor M. Once output pin 3 of gate G1 has jumped to a high state, it is necessary to latch input pin 2 in a low state until the motor protector timer, which comprises transistor Q12, capacitor C3, resistors R 5 , R 6 and gate G2, produces an over-ride pulse at pin 2. This latch function is formed by resistor R64 and transistor Q60. Thus, transistor Q60 performs dual functions of current sensing and off-cycle latching.
Following the deactivation of compressor motor M, the motor protector produces an over-ride pulse to charge capacitor C2 to a voltage exceeding the positive threshold of G1 at input pin 2. If motor load current then remains below the trip level as determined by the voltage generated in winding N s of transformer T2, and by the threshold circuitry consisting of transistor Q60, resistors R65, R62, and R63, compressor motor M continues to be energized. Resistors R62 and R63 form a voltage reference at the emitter of Q60 relative to the DC power supply ground.
In addition to sensing the load conditions of compressor motor M, other inputs to the motor protection system provide additional sensing for control of compressor motor M and fan 9.
Thermostat 20 is composed of negative temperature coefficient NTC thermistor R19, potentiometer R20, PNP transistor Q5, and resistors R16, R17, R3. NTC thermistor R19 and potentiometer R20 form a resistive divider which feeds the base of transistor Q5. Potentiometer R20 establishes the temperature set-point within chamber 11. As the temperature within chamber 11 increases above the set-point, the resistance of NTC thermistor R19 decreases, thereby deactivating Q5 and Q6. Transistor Q6 controls the voltage of pin 1 of NAND gate G1.
However, when the temperature within chamber 11 decreases, the resistance of NTC thermistor R19 increases, thereby turning transistor Q5 and Q6 on, which generates a low voltage at pin 1 of NAND gate G1. When the input voltage of pin 1 of NAND gate G1 is low, the output pin of NAND gate G1 deactivates oscillator 30, thereby deactivating compressor motor M.
Compressor shell temperature circuit 21 and compressor temperature hysteresis circuit 22 also provide control inputs to NAND gate G1. PTC thermistor R2 may be located on the exterior surface of compressor 8 to detect the compressor shell temperature. A resistive divider is formed by PTC thermistor R2 and resistor R23. Transistor Q7 is off under normal temperature conditions keeping R12 oat of the divider network. As the temperature of the compressor increases, the resistance of PTC thermistor R2 also increases, thereby decreasing the voltage present across resistor R23. When the compressor temperature reaches the maximum allowable limit governed by R23 and R2, diode D2 is forward biased and pulls the voltage of input pin 1 of NAND gate G1 low, thereby deactivating compressor motor M.
Additionally, when the output voltage of NAND gate G1 is high, transistor Q7 of temperature hysteresis circuit 22 turns on, introducing resistor R12 in parallel with resistor R23 of the lower element of the resistive divider. By reducing the lower element of the equivalent resistance of the resistive divider of compressor shell temperature circuit 21, transistor Q7 and resistor R12 ensure that the compressor cools to a sufficiently low temperature before a restart attempt may be made.
Circuit 23 provides an over-ride input into NAND gate G1 to control the starting of compressor motor M. Over-ride circuit 23 is only active during motor starting, and includes transistors Q11 and Q12, resistors R11 and R5, and NAND gate G2. Note that the emitter of transistor Q12 is not connected, and transistor Q12 functions as a diode having a characteristic of very low current leakage.
Fan overheat detection circuit 28 is composed of negative temperature coefficient thermistor R49, resistor R50, and NAND gate G7. NTC thermistor R49 may be located in thermal contact with the fan motor of fan 9. As the temperature of the fan motor increases, the resistance of NTC thermistor R49 decreases, thereby increasing the voltage present across resistor R50 and at input pin 2 of NAND gate G7. Therefore, when the fan motor temperature exceeds the limit established by thermistor R49 and resistor R50, fan 9 is disabled through NAND gate G7, NAND gate G6, transistor Q23, resistor R27, and TRIAC2.
A manually operated delay-avoidance or over-ride circuit is shown in FIG. 3. This circuit allows the user to start the compressor immediately, avoiding waiting until the expiration of the motor protector "off" period. The delay-avoidance circuit of FIG. 3 includes a normally open momentary push-button switch SW1, resistors R68-R70, transistors Q61 and Q62, diode D16, and capacitor C15. When switch SW1 is momentarily closed, capacitor C15 charges, and transistor Q61 turns on. The emitter of Q61 sets the input voltage of NAND gate G2 to a high level, causing the output of gate G2 to drop low, thereby charging capacitor C2 to a high level and allowing the start-up of compressor motor M.
Motor start relay 29 is operative during starting to provide greater start torque than would be provided by run capacitor CR acting alone. Output of gate G1 drops low to initiate compressor starting. In addition to causing compressor motor M energization, the output of G1 causes current to be established in resistor R31 and the emitter base of Q10. This action raises the voltage at input pin 8 of gate G4, thereby causing the output of gate G4 to drop low, turning on TRIAC3. TRIAC3 turns on TRIAC1 via resistor R8 thereby providing a conductive path through the main terminals of TRIAC1. The main terminals of TRIAC1 in turn connect start components capacitor CS and resistor RS across run capacitor CR to provide an enhancement of start torque. The time duration of activation of start TRIAC1 and TRIAC3 is determined by the RC time constant which is the product of the values of capacitor C7 and resistor R33. Resistor R32 forms a discharge path for capacitor C7 upon motor deenergization.
FIG. 6 shows an alternative embodiment of the compressor motor switching arrangement. Output stage 31' is directly driven by the output of pin 11 of NAND gate G3, and does not require oscillator 30 or any of its related circuitry. The output of gate G3 is connected through resistor R71 to the gate of TRIAC5. TRIAC5 controls the activation of relay 33 comprising coil 35 and contacts 37, and conduction of the DC current from the 14.5 V supply into the gate terminal of TRIAC5 is thus controlled by the output of NAND gate G3. Coil 35 is activated by conduction of TRIAC5 which closes contacts 37 to activate compressor motor M. The embodiment of FIG. 6 provides current isolation between the control circuitry and the power switching circuitry. A suitable relay for output stage 31' is P.&B. KRPA5AG120. Relay 33 may also be a double pole type relay, in which case a contact is connected to each of the two motor terminals. This forms a double break connection, and the relay used for this type connection is commonly called a contactor. Using output stage 31', the circuitry of FIG. 2A would not use transistors Q3, Q8, Q9; resistors R4, R25; capacitors C5, C6; transformer T1; or SCR1 or SCR2. Also, resistor R24 is then connected to the base of transistor Q7.
Fan controller 27 is composed of transistors Q20-Q22, resistors R42-R47, capacitors C10-C11, and NAND gate G5. Fan controller 27 controls the "on" time of the fan via capacitor C10 and resistor R47. The "off" time of the fan is regulated by capacitor C10 and the series combination of resistors R46 and R47. Typically, the "on" time for fan operation is about two minutes, while the "off" time is about eight minutes. Fan 9 is activated by fan activation circuit 32 comprising NAND gate G6, resistors R48 and R27, transistor Q23, and TRIAC2.
The fan timer circuit is adapted to accept commands from a mode selector switch connected at the two terminals of diode D15 to allow fan-on/compressor-off operation, fan-on-timer/compressor-off operation, and fan-on/compressor-on operation. Resistors R45-R47, capacitor C12, and transistor Q22 are configured to monitor both compressor activity and mode selection.
Although the fan control circuitry is disclosed as including a specific arrangement of discrete components, other arrangements may be used, including microprocessor control with preprogrammed software or firmware. The fan control circuitry includes protection circuitry which deactivates both fan 9 and compressor motor M when a fault condition is sensed in fan 9.
The present invention may be practiced by using the following values for the circuit elements described above:
______________________________________Label Value______________________________________R1 1 MΩR2 PTC ThermistorR3 470 KΩR4 33 KΩR5 10 KΩR6 10 MΩR7 150 KΩR8 2.7 KΩR9 270 KΩR10 Selected (120 KΩ, for example)R11 100 KΩR12 10 KΩR14 1 MΩR15 22 ΩR16 33 KΩR17 33 KΩR18 33 KΩR19 NTC ThermistorR20 PotentiometerR23 120 KΩR24 270 KΩR25 47 ΩR26 50 KΩR27 2.7 KΩR28 2.7 KΩR29 2.7 KΩR31 1 MΩR32 4.7 MΩR33 4.7 MΩR35 820 ΩR41 820 ΩR42 100 KΩR43 10 KΩR44 100 KΩR45 10 KΩR46 22 MΩR47 10 MΩR48 33 KΩR49 NTC ThermistorR50 5.1 KΩR51 100 KΩR52 100 KΩR60 3.0 MΩR61 100 KΩR62 24 KΩR63 2.7 KΩR64 33 KΩR65 8.2 KΩR66 820 ΩR67 3.9 ΩR68 22 KΩR69 22 KΩR70 22 MΩR71 2.7 KΩRS 5.0 Ω, 10 WattC2 2.2 μƒC3 15 μƒC4 2.2 μƒC5 0.1 μƒC6 47 pƒC7 0.1 μƒC8 0.1 μƒC9 470 μƒC10 15 μƒC11 0.1 μƒC12 0.1 μƒC13 0.1 μƒC14 0.1 μƒC15 2.2 μƒCS 100 μƒCR 15 μƒD1 28 V, 1/2 w ZenerD2 IN4148D4 15 V, 1 w ZenerD5 IN4004D6 IN4004D9 IN4001D11 IN4148D12 IN4148D14 IN4148D16 IN4148Q3 2N3906Q5 2N3906Q6 2N3904Q7 2N3904Q8 2N3904Q9 2N3904Q10 2N3906Q11 2N3906Q12 2N3904Q20 2N3906Q21 2N3904Q22 2N3904Q23 2N3906Q60 2N3904Q61 2N3904Q62 2N3904G1 CD4093BEG2 CD4093BEG3 CD4093BEG4 CD4093BEG5 CE4093BEG6 CE4093BEG7 CE4093BEG8 CE4093BESCR1 MCR225-6FPSCR2 MCR225-6FPTRIAC1 T2500MTRIAC2 2N6073BTRIAC3 MAC97BTRIAC4 MAC223-6FPTRIAC5 2N6073B______________________________________
It should be understood that the signals generated by the circuitry of the present invention may take many forms, such as voltage levels as disclosed, logic levels, polarity, current levels, etc.
While this invention has been described as having a preferred design, the present invention may 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.
|
The present invention involves an inductively activated silicon switch for a control and protection circuit for motors and compressors. The circuit includes a logic gate for combining both motor control and protection functions. The logic gate has inputs from a thermostat, a compressor shell temperature circuit, a fan overheat detection circuit, a motor start relay circuit, and motor load sensing circuits. The logic gate output is connected to an oscillator for inductively activating the power output stage, as well as a start relay, a compressor shell temperature hysteresis circuit, and a fan timer circuit connected to the fan control circuit. The control circuitry further includes an over-ride circuit for manually allowing a limited number of immediate restart attempts.
| 5
|
BACKGROUND OF THE INVENTION
Description of the Related Art
[0001] Brake fluid tests have been in use for years to predict corrosion, to detect the presence of copper in the brake system, and to detect other problems with brake fluid. Most conventional brake fluid tests currently used are copper-detecting brake fluid test strips. Other conventional brake fluid testing methods utilize moisture test strips and boiling point analyzers. The main problem with conventional brake fluid tests is that they can not determine whether active corrosion of iron components is already taking place in the brake system. Although copper-detecting brake fluid test strips can accurately predict when corrosion may occur, it cannot directly measure active corrosion of iron components in the brake system.
[0002] Conventional copper-detecting brake fluid tests could benefit from another testing parameter besides copper to help determine when brake fluid can no longer perform its design function and comply with the Motorist Assurance Program (MAP) guidelines for brake fluid replacement. Part of the MAP guidelines require that brake fluid be replaced when the corrosion inhibitors are depleted and can no longer protect the brake system from corrosion.
[0003] Current technology is unable to measure the extent of iron corrosion in a vehicle to help determine if further inspection of brake system components is required, to determine whether a vehicle is a candidate for basic brake system service, or to determine if a more involved and expensive service is required. In addition, current technology is unable to estimate a risk factor associated with a vehicle brake system.
[0004] Conventional brake fluid testing methods can also be expensive. In addition, the amount of time to test and analyze the results of a conventional brake fluid testing method can be a lengthy process, requiring at least two weeks time before the results can be returned. For example, to accurately determine whether dissolved iron is present in the brake fluid in a vehicle brake system, a sample of brake fluid must be sent to a testing laboratory for inductively coupled plasma spectroscopy (ICP) testing. This type of laboratory testing is not practical for a service facility to use during regular vehicle inspection procedures. Currently, there is no calorimetric test to identify iron levels and corrosion risk in brake fluid that uses an “in the field” test to determine the corrosion level of the vehicle brake system and without having to withdraw a sample of the brake fluid and send it to a laboratory for analysis.
SUMMARY OF THE INVENTION
[0005] The invention relates to a method, apparatus and test kit for determining a concentration of iron in a brake fluid quickly and in a cost-efficient manner. Another objective of this invention is a method, apparatus and test kit for determining the level of both FE +2 and FE +3 dissolved iron ions in a hydraulic brake system.
[0006] In an embodiment of the invention, a method is provided for visually locating damaged brake system components from active iron corrosion by testing specific locations in the brake system. Another embodiment of the invention involves a method, apparatus and test kit using for visually determining the level of brake system service required and assessing a possible risk factor or risk scale for the current condition of the brake system based on a concentration of iron in a brake fluid.
[0007] The invention further provides a calorimetric test to identify iron levels and corrosion risk in brake fluid that complies with existing guideline for brake fluid replacement, such as the Motorist Assurance Program (MAP) uniform inspection and communication guidelines for brake fluid replacement, which requires brake fluid replacement when the corrosion inhibitors are depleted. Such depletion is inferable from the presence of iron ions in the brake fluid.
[0008] In its preferred embodiment, the present invention comprises a calorimetric reagent that contacts a brake fluid, resulting in a color that varies with the concentration of iron in the brake fluid. An automated embodiment of the invention includes an electronic color detector to automatically determine the results of the test by inserting the colorimetric reagent into the electronic color tester after making contact with the brake fluid to automatically determine the iron level.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will be better understood from a reading of the following detailed description taken in conjunction with the drawings in which like reference designators are used to designate like elements, and in which:
[0010] FIG. 1 shows the results tests for Iron (Fe+2 and Fe+3) concentrations in brake fluid according to the invention.
[0011] FIG. 2 is a schematic illustration of a kit embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] This invention is described in preferred embodiments in the following description with reference to the Figures, in which like numbers represent the same or similar elements.
[0013] The described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are recited to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0014] Applicant's invention comprises a colorimetric reagent that produces a color that varies with the concentration of iron present when said colorimetric reagent makes contact with a brake fluid. New brake fluid has relatively low iron levels, usually less than 6 ppm iron, which can slightly vary depending on the storage container the manufacturer uses. Empirical testing has demonstrated that vehicles with 50-100 parts per million (ppm) iron are experiencing the beginning of active iron corrosion, and, as those levels rise above 100 ppm, the amount of corrosion and pitting of iron component increases.
[0015] Corrosion and pitting of iron components can cause component failure and seal damage, resulting in complete or partial brake failure. Empirical testing has demonstrated that higher iron levels are found nearest the brake component experiencing active corrosion. Conventional brake fluid testing methods are not suitable for determining the amount of iron present in brake fluid when testing a vehicular brake fluid system. For example, a vehicle with a copper level above 200 ppm, indicates that there is a possibility that corrosion exists, but the conventional testing methods have no way to measure the level of iron corrosion.
[0016] Referring to FIG. 1 , dip test strips 10 having colormetric reagent 12 disposed thereon are diped into a sample of brake fluid for one second. The colormetric reagent is 2,2′-bipyridine. After shaking off excess fluid and waiting approximately 3 minutes, the strips show a red coloration that increases in intensity as the concentration of iron increases.
[0017] The colorimetric reagent may further contain an ingredient that reduces trivalent iron to bivalent iron, such a particular reagent may be more sensitive to this type of ion. In certain embodiments, the color reaction causes a gradual change from white to red. In one embodiment, the presence of a red color reaction from the calorimetric reagent can be used as an indication of active iron corrosion within the brake system. A bright red color, indicating 300 to 500 ppm iron, is an obvious sign of accelerated active brake system component iron corrosion.
[0018] Referring now to FIG. 2 , a kit 20 of the invention includes a plurality of substrates (e.g., strips 22 and/or tubes 26 ) upon or within which calorimetric reagent 24 is disposed. A small sample of brake fluid 28 is dispensed from a dropper onto strip 22 or within tube 26 , which may have the colorimetric reagent 24 already disposed within or added separately. Thus, brake fluid sample 28 contacts the colorimetric reagent and may be read manually for color content or with the aid of color testing machines. For example, a strip reading spectraphotometer 30 or tube reading spectraphotometer 32 may be employed to read the resulting color and provide a reading that correlates with the presence of an iron ion in the brake fluid. Of course, the calorimetric reagent may be disposed upon or within materials that are rigid, flexible and of various styles, shapes and sizes.
[0019] In certain embodiments, the test strip includes multiple reaction “zones” for different brake fluid tests testing the presence of active corrosive metal. Active corrosive metals can include iron, copper, zinc, or a combination thereof. In another embodiment, the brake fluid iron test may be performed with fluid from anywhere in the vehicle hydraulics system where access to brake fluid is available, such as at the bleeder screws located at each wheel at various anti-lock brakes (ABS) bleeder screw locations. If a high iron level is detected, i.e., 100 ppm or higher, additional testing may be required at various locations in the brake system in an attempt to identify the location of active corrosion.
[0020] While the preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and adaptations to those embodiments may occur to one skilled in the art without departing from the scope of the present invention.
|
A method and kit for determining a concentration of iron in brake fluid when contacting a calorimetric reagent such that a color results. The level of iron can be used to determine the amount of active corrosion within a brake system and determine if special service procedures are required.
| 6
|
BACKGROUND OF THE INVENTION
The present invention is directed to the problem of providing heart valves for transplantation. More particularly, the present invention is directed to the problem of providing a flow system to assist in transforming a heart valve that is based on a xenograft into an autograft.
There is at present a shortage in the supply of heart valves available for transplantation. Indeed, since 1984, allograft heart valve transplantation in the United States has increased to over 2,400 grafts per year. Because of this increased demand, particularly for pediatric cases, the utilization of cryopreseved heart valves is not limited by the supply of donated human hearts. There remains a need to address this supply problem.
One approach, with which this application is concerned, is to turn to tissue engineering to create a graft. Such a graft would be immunologically acceptable to the recipient and have long-term durability that exceeds presently available homograft or chemically-fixed valves. Furthermore, a low incidence of failure due to leaflet calcification or stiffening would be expected. Based on the extracellular matrix remaining after decellularization of a porcine aortic valve, the remnant scaffold would be recolonized with autogenous fibroblasts recovered from the skin of the intended recipient. Ideally, the repopulating cells could functionally replace the native cells that were removed to enhance the immunologic acceptability of the graft.
Such living heart valves could be tailored to the intended recipient. These living heart valves could replace the diseased and damaged valves with one indistinguishable from the patient's own tissue. These valves would be self-repairing, capable of growth and response with the patient. Despite being the graft of choice for repair of congenital malformations, allograft valves do not grow necessitating additional surgeries to implant larger valves as the heart size increases.
SUMMARY OF THE INVENTION
The present invention is directed towards the development of such tissue grafts. This involves optimizing recellularization in a dynamic state. To accomplish this goal, there is provided a sterile, pulsatile flow loop system/bioreactor wherein a viable aortic tissue valve can be mounted and maintained in a dynamic flow under tissue culture conditions.
Since 1984 allograft heart valve transplantation in the United States has increased steadily to over 2,400 grafts yearly. Because of this increased demand, particularly for pediatric cases, the utilization of cryopreserved heart valves is now limited by the supply of donated human hearts. An objective of the present invention is to provide apparatus to help resolve this tissue valve supply problem through the continued development of a porcine valve substitute which is converted from a xenograft to an autograft. This can be accomplished by first ablating the antigenicity of the porcine valve through removal of native cells and soluble proteins in a manner consistent with valve structural integrity. The acellular, and presumably immunologically neutral, matrix can then be recolonized with recipient dermal fibroblasts under conditions which permit cellular attachment to the matrix, migration throughout the leaflet, and proliferation of the cells to a density and distribution typical of a natural valve. Dermal fibroblasts are chosen because of accessibility and rapid proliferation ex vivo, and because they synthesize types I and II collagens, the structural proteins whose continued renewal is considered important for the long-term durability of the tissue. In the prsent invention, a unique flow loop is provided, wherein intact, unfixed porcine valves can be subjected to pulsatile flow conditions reflecting those experienced by aortic heart valves in vivo while maintaining sterility and substrate exchange. The system then permits examination of the effects of flow rate, cycle frequency, and pressure non-depopulated porcine valves. This permits optimization of conditions for retention of cells reseeded onto the leaflet matrix, and investigation of how these physical forces affect the cellular activity of dermal fibroblasts (normally in a tension-regulated einvironment). These studies should permit development of production criteria for a tissue-engineered heart valve, while ensuring appropriate biosynthetic activity of the repopulating fibroblasts at time of implantation.
Flow systems have been used for in vitro hemodynamic studies and accelerated wear testing of devices of chemically fixed stented and non-stented heart valves. To date, none has been reported which can regulate flow rate, pulse frequency, pulse width, and back pressure within the physiologic range of each of these parameters for valves with living cells nor does once exist which can be operated under sterile conditions and for an extended period of time (>24 hr). A flow loop is provided which allows assessment of the impact of these parameters on the cellular functions of native and tissue engineered heart valves. The system can be validated with available glutaraldehyde-fixed stented aortic valves.
The system also is useful in helping to determine how flow dynamics modulates fibroblast function in viable porcine aortic valves. Despite the fact that heart valve leaflets must function in a dynamic flow environment, the activity of the important interstitial cells of these vital tissues is understood only from static cultures. The present system permits critical examination of the effects of critical flow parameters on the regulation of collagen and elastin gene expression and collagen and glycosaminoglycan biosynthesis.
A third goal of this system is that it will permit one to optimize the effects of flow on the repopulation of acellular porcine heart valve leaflets with human dermal fibroblasts; and examine how flow might be used to foster cell adhesion and cell function.
The understanding of the impact of flow on leaflet fibroblast metabolism obtained from the studies made possible by the system disclosed herein permits further progress toward the goal of developing the conditions necessary to make a living heart valve. Pulsatile flow can be used to modify both exogenous cell adhesion, migration, and activity so that we can achieve cell densities and function typical of native leaflet interstitial cells.
The ideal aortic heart valve replacement should be as similar as possible to the native valve. Homograft heart valves are an obvious choice. Unfortunately, donor tissues such as these are in short supply. The most readily available tissue valves(bioproshetics) are those from other species and are known as xenografts. Porcine valves are the most common xenograft. Unlike mechanical heart valves, bioprosthetics have a natural trileaflet structure and should have similar flow characteristics as human valves. To prevent immune responses to the cellular components of the valve, xenograft tissues are treated with chemical cross-linking agents such as glutaraldehyde. While this approach is successful in limiting acute rejection of these grafts, two detrimental consequences occur: first, leaflet flexibility is compromised, with bending stiffness of the leaflets markedly increased; second, glutaraldehyde fixation also increases the incidence and extent of leaflet and aortic conduit calcification, particularly in younger recipients. These factors combine to make bioprosthetic valves less durable and more prone to failure than natural valves.
Because of chemical fixation, current bioprosthetic grafts are composed of dead tissue. It is possible that the lack of biosynthesis of extracellular matrix proteins and mucopolysaccharides contributes to the failure of these valves. The goal of the tissue engineered aortic graft project is to develop a non-fixed tissue valve with a viable cellular component, phenotypically similar to that of a natural valve. If the native cells of the porcine tissue were removed, and if the leaflet was covered with human cells, the recipient's immune system would not detect the porcine tissue as foreign. By not chemically fixing the valve the leaflets would retain more of their natural flexibility and should thus function more efficiently. They might be less susceptible to calcification. Finally, the viable cells would provide for replacement of structural proteins damaged during leaflet motion, with resultant improved performance and durability of the valves.
Important questions remain as to adherence of repopulating cells of the leaflets and their functionality when exposed to the high stress environment of blood flow exiting the heart. Valve leaflets are exposed to several mechanical forces which may influence how well cells will grow and function on the leaflets. When the valve is closed during diastole, the valve must support systemic pressure, a normal stress that would directly affect the cells on the aortic side on the leaflets (lamina fibrosa). This stress may also be transmitted to cells within the tissue aligned to collagen fibers. The ventricular surface of the leaflets, on the other hand, experiences a fluid shear stress during systole when blood is ejected through the valve. Numerical simulations of flow through a stented valve indicate that this shear stress may exceed 130 dyne/cm 2 at peak systole. Bending stresses arise from the motion of the leaflets during the course of the cardiac cycle, and their effect on cell behavior is clearly seen in the elevated content of proteoglycans within the leaflet nearest the aortic wall. While several groups have studied these three types of stresses (1,2), particularly the normal and bending stresses, none has considered their effects on cellular function in a model which could isolate their influences separately.
During repopulation of a tissue matrix it is expected that fibroblasts initially will be deposited on the surface of the leaflets, but after static culture a fraction does recolonize the leaflet matrix. Those cells found at the surface would be exposed directly to flow in a vascular environment, while those within the collagenous matrix should be aligned with collagen fibers as in the native leaflet. The most extensive studies of the regulation of cellular activities in a flow environment have described responses of endothelial cells on the surfaces of vessels. In particular, these studies have modeled shear stress, the tangential frictional force acting in the direction of flow along a vessel's surface (3). The principal component of hemodynamic forces acting on the vessel wall is pressure-stretch which imparts compressive and tensile forces to both the surface cells as well as to the cells (smooth muscle, fibroblast) within the wall (4,5). Finally, both shear stress and hydrodynamic pressure effects are imposed in a cyclic manner as a consequence of the cardiac cycle; these phasic changes impose their own effect on cellular functions (6).
Though the cellular events altered by combinations of shear stress, pressure, and cycle frequency are numerous, of particular interest in considering how flow conditioning might affect the interactions of exogenous cells with a tissue matrix include adhesiveness of cells, proliferation rates, migration rates, and the ability of the cells to make extracellular matrix proteins. Among the adhesion proteins found on cell surfaces the strongest forces between cells and the extracellular matrix are mediated by the integrins (7). Each of these proteins has specificity for particular matrix proteins: collagen a 1 B 1 and a 2 B 1 : fibronectin - a 5 B 1 ; and a B 1 ; laminin - a 6 B 1 ; vitronectin - a 1 B 3 ; and the basement membrane receptor - a 6 B 4 . Synthesis of integrins and expression of their mRNAs is regulated in endothelial cells at even very low levels of shear stress 1.5 dyne/cm 2 of shear (8). Flow not only affects integrin synthesis but is also instrumental in reorganizing the localization of these proteins on the cell surface to increases resistance to detachment (9).
Fibroblasts within connective tissues are not exposed to shear stress, but they can be shown to respond to mechanical forces in their environment. These reactions appear to involve an interplay between the cells and their contained stress fibers, the extracellular matrix, and tensile forces developed by stretching or by application of pressure. Cardiac pressure overloading directly causes ventricular fibroblasts to proliferate and increase synthesis and deposition of types 1 and III collagens (10,11). Other cells are also pressure-responsive and much of the increased proteoglycan synthesis in cartilage remodeling is in response to this force (12,13). Fibroblasts obtained from the flexor tendons and cultured on elastic membranes are stimulated to proliferate, migrate, and increase collagen biosynthesis if subjected to cyclic tension changes; fibroblasts in wounds demonstrate traction-dependent changes in cell alignment (14-16).
Again, it is the direct action of the force which stimulates fibroblast proliferation and collagen synthesis. These functions are maximal in cells cultured in mechanically stressed substrata like anchored collagen gels (17,18). Relief of the stress is accompanied by progression of the cells to a quiescent state, with elevated expression of collagenase activity indicative of tissue remodeling rather than biosynthesis. Therefore, it should be expected that the ultimate localization of the cells either on the surface of, or within the matrix would significantly affect the result of repopulation of the acellular scaffold envisioned for those grafts. Indeed the strengthening of collagen gels used as wound models correlates with the contraction of these gels by the cells (19); similarly, the strengthening of ligament model systems correlates with applied traction on the collagen fibers. This elevates collagen cross-linking activity (20) and increase the diameter of newly synthesized collagen fibers (21), but only if the cells are embedded within the matrix.
These observations suggest that a bioreactor capable of physically preconditioning a living heart valve prior to implantation will be a necessary component of the process of manufacture of these tissue-engineered grafts. The application of optimal conditions of flow, pulsation rate, and pressure should provide an implant which displays physiologic levels of cellular activity, and provide a graft with extended durability and performance.
BRIEF DESCRIPTION OF THE FIGURES
For a more complete understanding of the invention, reference should be made to the figures, in which:
FIG. 1 is a graph showing reducible and non-reducible collagen cross-links in cryopreserved porcine aortic valve leaflets obtained from adult or juvenile hearts.
FIG. 2 is a schematic illustration of certain geometric parameters for simulations of shear stress on the leaflet surface. Flow through the aortic valve is modeled as flow through an axisymmetric nozzle. The leaflets are shown in the fully open position. The outflow from the valve can recirculate behind the leaflets.
FIG. 3 schematically illustrates an in vitro flow loop for analyzing aortic valve function. The left ventricular model is shown, and the inset figures illustrate the compliance/resistance element and the gas exchange/temperature control unit.
DETAILED DESCRIPTION
The applicants efforts in developing a tissue engineered heart valve prosthesis have been funded both by corporate funds and by two NIH Phase I SBIR grants.
1. 1R43 HL46607-01 Jul. 12, 1991-Dec. 12, 1991 Repopulation of Xenograft Heart Valves with Fibroblasts
2. 1R43 HIL53088-01 Aug. 1, 1994-Jan. 21, 1995 Xenograft Heart Valves: Biomechanics/Collagen Structure
In the following summary, these grants are referred to as SBIR 1 or SBIR 2.
1. (SBIR 1) Porcine heart valves have been depopulated according to an autolytic procedure. Through the use of hypotonic buffers and nucleases, cells of cryopreserved porcine leaflets were made sensitive to lysosomal enzymes present in the native fibroblasts, which caused substantial removal of immunogenic components within 2 weeks of initiation of treatment. (Reduced inflammatory response has been verified in subdermal implant studies in rabbits and in sheep). This approach was taken, as the original use of cryopreservation and gamma irradiation in concert with repeated rapid freeze-thawings resulted in leaflet tissues clearly in disarray due to ice crystal formation, an effect not prevented by the addition of a variety of colloidal substances. Furthermore, use of detergents such as CHAPS<Triton X-100, or SDS were either found not to allow leaflet depopulation or to actually damage the tissue, shown by uniaxial biomechanical studies. In contrast, applicants final method retains leaflet ultimate tensile strength despite the likelihood of release of collagenase from the disrupted cells. This result is likely due to removal of divalent metal cations from the cell lysis solution and the consequential limitation of metalloproteinase activity.
The depopulation scheme does not remove the α-gal-gal epitopes of pig tissues that appear to bind preexisting xenoantibodies. However, these can be removed by treatment of the intact valve leaflet with appropriate galactosidases. The epitopes can be removed from the conduit except in the endothelial lining of small vessels that invest the aortic wall.
Extensive uniaxial biomechanics studies have compared depopulated leaflets with fresh and cryopreserved tissues. The ultimate strength of the tissues are well preserved during depopulation at 37° C. Also, the extensibility of the leaflets either in radial or circumferential dimensions is not different from that of cryopreserved tissue; this is significant since the leaflets might otherwise have a propensity to prolapse.
(SBIR 2) Valves obtained from young (<75 lbs) pigs were compared with those from adult (>250 lb) animals both for biomechanical properties as well as for collagen cross-links. Because of the large size of valves from older animals and the smaller size of the human recipient population which could benefit from a viable tissue valve, we compared the biomechanical properties of the leaflets of these valves. Ultimate load to failure, maximum stress, and high modulus (change in stress with change in strain) in the tissues from young animals were each about half the adult value in either circumferential or radial samples (Table 1). These differences appeared to be the result not of the extent of collagen crosslinking, but rather of the type of collagen crosslinks present. The leaflets were rich in non-reducible collagen crosslinks, a pattern more like that of load bearing cartilage than that of skin. The content of these crosslinks is lower in leaflets from young animals (FIG. 1).
TABLE 1______________________________________ULTIMATE TENSILE PROPERTIES OF AORTIC LEAFLETSComparison of Porcine vs. Human Aortic Heart Valve LeafletsPorcine Adult Juvenile______________________________________Ultimate Load(g) 1915 ± 622 834 ± 75 p < .01Maximum stress (MPa) 6.09 ± 0.62 3.54 ± 1.57 p = .001High Modulus (MPa) 28.5 ± 3.2 18.2 ± 1.7 p < .001Human Adult JuvenileUltimate Load (g) 498 ± 93.5 350 ± 109Maximum Stress (MPa) 1.19 ± 0.2 1.72 ± 0.4High Modulus (MPa) 8.26 ± 1.43 9.88 ± 2.75______________________________________
FIG. 1 plots reducible and non-reducible collagen cross-links in cryopreserved porcine aortic valve leaflets obtained from adult or juvenile hearts. Tissues were processed as described above. Content of reducible cross-links was higher in juvenile tissues as compared to adult; levels of HLNL and HHMD were almost undetectable in the adult. In contrast, non-reducible cross-links, PYR and D-PYR were elevated in adult tissues relative to the juvenile. The content of reducible cross-links in this soft connective tissue structure is unusual and is more like the pattern of cross-links in mineralized collagenous tissues. This may reflect the mechanically active environment of the heart valve. Furthermore, the increase in non-reducible cross-links with age may indicate that the type of cross-link present is sensitive to the increase in systemic pressure that occurs during development. The collagen crosslinks do not change with the process of leaflet depopulation according to the currently used methods.
Leaflet and conduit repopulation have been attempted in tissues cut free from the valves; the repopulating cells have been sheep, rabbit, bovine, and human dermal fibroblasts. The selection of the dermal fibroblast as the repopulating cell type was chosen because: 1) it is accessible in a potential valve recipient; 2) biochemically, this cell synthesizes types I, III:, and V collagens in the same proportions (85:15:5) as are present in the heart valve leaflet (22)) and synthesizes proteoglycans (1,23) which are apparently important in reducing bending stress in the leaflets (2); and 3) endothelial cells do not seem to be necessary to prevent thrombus formation in cryopreserved aortic or pulmonary valves and they synthesize type IV collagen, the basement membrane collagen, which does not have a role as a structural protein.
The "best" repopulation has been with human dermal fibroblasts. Under conditions of static (no flow) culture, dermal fibroblasts will attach to the surface of the leaflets and, over a 2 week period, will migrate into the matrix of the tissue. The cell density of the repopulating cells does not reach that of either porcine or human aortic leaflets during this period; procedures to improve the degree of internal repopulation still have to be developed. These may include: 1) depopulation treatments that increase subsequent cellular access to the matrix; and 2) dynamic flow enhancement of cell proliferation and phenotypic expression after exposure to repopulating cells.
The cells that migrate into the tissue are functional. Autoradiographic analyses of tissues prelabeled with collagen precursor amino acids indicate that the repopulating cells are active in making this structural protein. Limited use of in situ hybridization also suggests that the repopulating cells are expressing type I collagen RNA.
Finite element, computational fluid dynamic (CFD) analysis of shear stress on the leaflet surface is of interest in this matter. The fundamental issue with engineering a living valve is to keep the repopulating cells adherent to the matrix; without this, the ability of the cells to function is unimportant. The shear stress on the leaflet surface is the least characterized mechanical force acting on the leaflet. To obtain an order of magnitude estimate of the shear stress on the leaflet surface, numerical simulations have been performed using a finite element solver, the Fluid Dynamics Analysis Package (FIDAP). In a finite element solution, the flow field is broken down into thousands of smaller regions called elements. The conservation equations that govern fluid flow are then solved in each of these elements to define a solution for the entire flow field. Although the eventual goal for the tissue engineered valve is a stentless design, flow through a stented aortic valve has been simulated. This geometry has a convergent flow filed that produces higher shear stresses on the leaflet surface, representing a worst case scenario for shear stress. Flow through the valves is modeled as flow through an axisymmetric nozzle rather than a full three-dimensional problem, which greatly reduces the computational time.
A geometry that the invention models is shown in FIG. 2. Flow enters the valve from the left ventricular outflow tract (4.6 cm long). This inlet length allows FIDAP more freedom in converging to a solution but it is not long enough to allow flow to become fully developed before entering the valve. The diameter of the valve annulus is 23 mm, a typical valve size. To simulate a stented valve, the flow filed tapers as a nozzle over the next 1.15 cm to a typical stented valve outlet diameter of 21 mm. This differential of 2 mm approximates the difference observed in the subannular diameter and the supracoronary sinus aortic diameter. The leaflets are in a fill open position along the sides of the nozzle. The outflow from the valve enters a short (11.5 cm) segment of the aorta. This outlet length also helps the problem converge to a solution. The nozzle is contained within the aorta, so flow can recirculate behind the leaflets, which are 1 mm thick. The fluid properties are taken to be Newtonian with values modeling those of whole blood (density=1.05 g/cm 3 ; viscosity=3.5 cP). Although whole blood is a non-Newtonian fluid, it behaves as a Newtonian fluid at the high flow conditions seen at the aortic valve.
Four different inlet flow conditions were simulated. The first two cases are simple laminar flows at a cardiac output of 5 L/min, entering the model as a flat or parabolic profile with a mean velocity of 20 cm/s. We also considered a turbulent flow at 30 L/min (120 cm/s) to simulate the flow rate at peak systole at a cardiac output of 7.5 L/min. The fourth case is a pulsatile flow. The cardiac cycle is approximated as a half sine wave at a normal resting frequency of 60 bpm. The systolic (ejection) phase occurs over the first half of the cycle, with a peak velocity of 120 cm/s. Although we have not yet done so, this waveform could be varied in frequency, peak velocity, or systolic duration. One problem with modeling the cardiac cycle is deciding whether the flow is laminar or turbulent. Flow is initially laminar, but becomes turbulent near peak systole, and during the deceleration phase. However, in FIDAP and most other simulation packages, the user must choose between the two flow regimes and apply that choice to the entire flow cycle. Since higher shear stresses are expected near peak systole, we solved this problem as a turbulent flow to model peak systolic conditions more closely. Turbulent solutions used the k-6 model with a separate algorithm to capture near-wall behavior.
As flow converges into the nozzle (through the valve), its mean velocity must increase by conservation of mass. While the centerline velocity increases, the velocity at the wall must remain at zero by no slip conditions. As a result, steeper velocity gradients develop near the wall, causing higher shear stresses on the leaflet surface. The shear stress should reach a maximum at the nozzle outlet (leaflet tips), the point of maximum convergence. In pulsatile flow, the highest shear stresses should be observed near peak systole, when flow through the nozzle is accelerating in time as well as accelerating due to the converging geometry. Recirculation should be apparent downstream of the nozzle outlet. These patterns have been observed in all of our simulations. The maximum shear stresses observed are listed in Table 2. The highest shear stresses were observed on the nozzle tip and reached a maximum of 135 dyne/cm 2 .
TABLE 2______________________________________Summary of shear stresses on the leaflet surface observed insimulations of flow through a stented valve ShearInlet Condition Stress (dyne/cm.sup.2)______________________________________Flat, laminar profile at 20 cm/s 12Parabolic, laminar profile with mean of 20 cm/2 8Flat, turbulent profile at 120 cm/s 124Pulsatile flow with peak of 120 cm/s 135______________________________________
It is difficult to relate this shear stress estimate to behavior on the cell monolayer. Early attempts to determine the strength of cell adhesion involved increasing the shear stress until the cells sheared away. Aortic endothelial cells, normally exposed to shear stress of 15 dyne/cm 2 is reached (25). Whether the cell will shear away from the leaflet surface depends upon the number and strength of the bonds that anchor the cell to the surface. Most cell adhesion research has focused on the cells of the immune system, such as leukocytes and neutrophils, which can roll along the endothelium to find and adhere at sites of inflammation. Examining neutrophil adhesion to the endothelium, Springer (19) has found that the strength of one characteristic bond is 110 pN; a similar value was found by Evans, et al. (26) with agglutinated membrane capsules. Several such bonds are required to cause adherence. For example, micropipette experiments demonstrated that the force required to separate a sarcoma cell from an endothelial cell or fibroblast is on the order of 100 μdyne (27). Hammer and Lauffenberger (28) developed a mathematical model of the adhesion of isolated blood-borne cells to a cell surface to predict conditions favorable to cause adherence. For example, micropipette experiments demonstrated that the force required to separate a sarcoma cell from an endothelial cell or fibroblast is on the order of 100 μdyne (27). Hammer and Lauffenberger (28) developed a mathematical model of the adhesion of isolated blood-borne cells to a cell surface to predict conditions favorable to cell adhesion. If the fluid shear stress is strong enough to prevent or disrupt the formation of these bonds, the cell will not adhere. However, the adhesion of a monolayer of cells bound to their extracellular matrix has not been modeled. The adhesion molecules typically involve in these two processes are different. Immune cells typically begin attachment to the endothelium through selectins, while cell adherence to the extracellular matrix is generally due to integrins (25).
The shear stress estimate can be refined by the addition of several small but important details. The left ventricular outflow tract (LVOT) is not straight but tapers slightly proximal to the aortic valve. More importantly, the leaflets are not perfectly straight in vivo, as depicted in this model. They bend during the cardiac cycle in response to changing flow conditions. A simple nozzle predicts that the maximum stress will occur at the leaflet tips, but a curved leaflet may have larger stresses near the plane of the curvature. One limitation of FIDAP, however, is that the solid boundaries cannot move, so fully mobile leaflets cannot be simulated. Instead, we will try to model various stages of the opening phase of the systole by a pseudo-steady state approach, using reduced flow rates, with leaflets having varying degrees of curvature, and more convergent outflow (orifice) diameters.
As noted above, there is a need, which is addressed herein, to develop a sterile, pulsatile flow loop systemibioreactor wherein a viable aortic tissue valve can be mounted and maintained in a dynamic flow under tissue culture conditions.
Despite the fact that cells in heart valve leaflets operate in a mechanically dynamic environment, most studies of leaflet cell metabolism have been carried out in static culture. In the few exceptions to such observations, leaflet energy charge and protein labeling having been examined during the period after death as the valves reprogram from a dynamic environment to a static condition. Both phosphorylated adenylates (29,30) and protein biosynthesis (31,32) were observed to decline in logarithmic fashion over a period of days despite provision of standard cell culture conditions; leaflet cellular viability declined during this period as well. The reasons why leaflet fibroblasts could not be maintained within the leaflet matrix for longer periods are not clear, as primary cultures of fibroblasts made from explants of such tissues can be cultured as monolayers for many doublings and passages before undergoing senescence (Goldstein, unpublished observations). One significant difference may be the absence of key physical input since valves in static culture are not subjected to usual dynamic flow forces while fibroblasts in monolayer culture are in physical tension with the substrate. A bioreactor is presented to study effects of physical inputs to heart valve leaflet biochemical functions; an In vitro flow loop for simulating aortic valve environment.
The first phase is to study the cellular activity of a normal, living porcine aortic valve under physiologic conditions in an in vitro flow loop. The in vitro flow loop models the left heart and consists of a mechanical mitral valve, a bladder simulating the left ventricle, a test section with aortic valve samples mounted in parallel, a downstream compliance and resistance element, an oxygenator, and a heat exchanger (FIG. 3). A piston pump (Vivitro Model SPS 3891) can be used to drive the pulsatile flow, since its motion can be programmed with a waveform generator (Vivitro Model WG 5891), allowing the flow waveform to be changed easily. The left ventricle is approximated by a flexible rubber bladder mounter inside of a Lexan chamber filled with water. The piston can displace the water; this in turn will squeeze the flexible bladder and propel the blood analog fluid out through the aortic valve test section. In this way the piston pump controls flow through the system without actually contacting the sterile fluid in the loop. The piston motion will be programmed to produce a flow that simulates the cardiac cycle as the half sine wave previously described, but with variable frequency from 60-120 bpm and a cardiac output of 2-7.5 L/min. This pulsatile flow will be applied continuously for the duration of the experiments.
Porcine aortic valves are obtained at slaughter. The porcine root are slid inside the simulated aorta made from a silicone elastomer. The inflow and outflow edges of the valve are attached to the aortic model by a continuous line of blanket stitching using 5/0 and 4/0 suture, respectively. This prevents the leaflets from prolapsing back into the left ventricle during diastole. Both lines of stitching are sealed with a silastic medical adhesive to prevent leakage. We have used these techniques previously in flow studies with nonstented, glutaraldehyde-fixed porcine aortic valves (33). Since experiments may last for a week or more, it would be advantageous to test valves in parallel. This can be accomplished by splitting the inflow into three separate paths, each with its own aortic valve assembly. Gate valves will separate each path, allowing one line to be isolated from the others should problems develop. We have calculated the displacement capacity of the piston and the volume of the flow loop and have estimated that it is possible to study three valves simultaneously.
A mechanical prosthetic valve is needed in the mitral position to keep flow going in the proper direction. Either a tilting disc valve or a bileaflet valve will be used. An adjustable resistance and compliance element (FIG. 3) is placed downstream to simulate the peripheral resistance of the circulation. Compliance will be provided by allowing the fluid to collect in a Lexan tank and to push against a flexible membrane. The membrane serves to separate the sterile fluid from the unfiltered air. The pressure in the air space above the membrane can be varied to adjust the compliance through a physiologic range of values. Westerhof et al. (34) found that a compliant volume of roughly 900 cm 3 should adequately duplicate the physiologic capacitance of 0.008 cm 3 /mm Hg. Resistance is provided by raising this tank above the rest of the loop. This creates a pressure head against which the fluid must flow to enter the tank. Additional resistance could be provided by clamping down on a flexible tube included downstream. These measures should adequately duplicate the physiologic resistance of roughly 1200 g cm -4 s 1 (34). The downstream compliance and resistance will be adjusted to provide physiologic aortic pressures of 120 mm Hg systolic and 80 mm Hg diastolic, duplicating the back pressure on the aortic valve.
The fluid used must contain nutrients to support the metabolism of the living tissue of the hear valve. Whole blood is difficult to use experimentally because of its clotting properties, so a tissue culture medium will be used. Plasma expanders, such as hydroethyl starch, polyethylene glycols, or polyvinylpyrrolidone will be added to increase the viscosity of the fluid to that of blood. Oncotic pressure will be provided by proteins in fetal bovine serum used as a source of growth factors. To avoid introducing potentially harmful impurities into the system, all materials that may contact the fluid (tubing, fittings, probes) must be sterilized. The tubing will be made from a grade of Lexan (GR series, General Electric) which is sterilizable by ethylene oxide gassing. All flow loop components will be sterilized with ethylene oxide gas; local vendors will provide rapid turn-around time between successive valve mountings. Medical grade tubing connectors will be used. The flow loop will be constructed from transparent materials so that its internal cleanliness may be visually inspected throughout the course of the experiments. The sterility of the fluid will be analyzed daily by withdrawing a small sample from each parallel flow path and checking it for contaminants.
Although nutrient replacement should not be required over short-term experiments (1-2 weeks), gas exchange will be necessary to maintain oxygen tension and regulate bicarbonate levels. The temperature of the fluid must also be maintained at 37° C. Oxygenation and temperature control will occur in a specially designed unit (FIG. 3). In this unit termostated water flows through the glass core tube, while medium flows through a gas-permeable silicone tube coiled around the core. A feedback control loop could be employed to adjust the temperature of the incoming water to maintain the proper medium temperature. A Lexan tube encloses the glass core. A CO 2 /air mixture will be supplied to the annular space, allowing oxygen to diffuse into the silicone tubing and waste gases to diffuse out. Spent gas can be vented from the annular space.
Due to the length of the experiments, conditions will not be monitored continuously. However, parameters such as temperature, flow rate, pressure, and pH must be checked periodically to evaluate the performance of the flow loop and contained heart valve. These conditions will be monitored every 6 hours using a sophisticated on-line, 12-channel data collection, display, and analysis system (CardioMed, Model CM-4008, Norway). It can display up to 6 signals in real time, including differences between two waveforms (such as pressure drop). Time derivatives of any waveform can be displayed, and integration can be performed over a specified time interval (for example, stroke volume can be found by integrating the flow waveform over one cycle). Each parallel path will be equipped with an ultrasonic flow probe (Transonics Systems, Model 24N) distal to the aortic valve, two pressure taps, and a port for withdrawing fluid samples. Absolute pressure transducers (Baxter, Uniflow) will be located both upstream and downstream of the valve to allow both the aortic pressure and the pressure drop across the valve to be recorded. The pressure transducers will be interfaced to a bridge amplifier. Flow and pressure waveforms measured in each path will be compared to verify that each valve experienced similar flow conditions. High-speed videography (Kodak EktaPro System) will be used to monitor the opening and closing characteristics of the valve. This will necessitate a right angle outflow window on the heart valve mount; this position of the video window will be preferable to imposing a non-inline flow path on the inflow side of the test valve.
To characterize the flow field near the aortic valve, the system should be amenable to noninvasive flow analysis by color Doppler flow mapping (CDFM), spectral Doppler analysis, or laser Doppler anemometry (LDA) All three of these techniques are available for this system. CDFM and spectral Doppler analysis can be performed on an ultrasound machine (Sonolayar SSA-270A, Toshiba). CDFM color codes the velocity field through the valve, giving a sense of the overall flow field. Spectral analysis can be done with either continuous wave (CW) or pulsed wave (PW). CW measures the velocity distribution along a specified lim while PW measures the velocity at a particular region of interest. Thus CW could be used to measure the peak velocity through the valve at the centerline, while PW could be used to estimate the fluid velocity at the leaflet tips. Three-component LDA (Aerometrics) could provide a more accurate estimate of the velocity at the tips since it has a smaller interrogation volume (0.3 mm in length) than is possible with PW. This estimate could be used to calculate the shear stress on the leaflet surface, providing a potential validation of our numerical simulations (see Preliminary Results). Each of these techniques--CDFM (35), spectral Doppler analysis (33), and LDA (36,37)--have been used extensively in Dr. Yoganathan's laboratory for the past 15 years.
Before experiments begin with fresh porcine valves, the overall performance of the loop should first be tested to verify that the desired flow conditions can be achieved in a sterile environment. These initial tests require two phases. First flow conditions should be verified. These tests would not need to be run under sterile conditions, allowing any necessary modifications to be made to achieve the correct conditions. At this stage, mechanical valves could be used in the aortic and mitral positions, and the fluid should still simulate the viscosity of the tissue culture medium. Once the flow conditions are verified, the flow loop materials will be sterilized and tested again with stented bioprosthetic valves in place. This will serve to test the ability to maintain sterile flow conditions over a short (24 hr) period of time. Once these conditions have been verified, the materials will be realized again before proceeding with the fresh porcine valve experiments described below.
A further aim of is to determine how flow dynamics modulates fibroblast function in viable porcine aortic valves. At least three types of cellular functions have been associated with mechanical regulation of connective tissue strength: collagen biosynthesis vs. degradation, i.e., net collagen accumulation; collagen fiber diameter, and collagen cross-link density including the nature of the cross-links formed. These functions may be directly responsive to mechanical forces, but may also respond seconds to changes in the amount and nature of extracellular matrix factors such as proteoglycans produced by fibroblasts or to autocrine or paracrine factors. Produced by fibroblasts or neighboring cells. Proteoglycans appear to have specific influences on collagen deposition and structure (38). Furthermore, the distribution of proteoglycans is topographically restricted in native heart valve leaflets (1,2,39); their density is greatest in the hinge region Of the leaflet (sites nearest areas of extreme bending moment near the aortic wall) as opposed to the region of the leaflet proximal to the coaptive areas where tensile loads are noximal.
Besides the differential expression of extracellular matrix biosynthetic activity, physical stress also appears to confer a contractile cell-like phenotype to the fibroblasts of the leaflets (40). After collagenase digestion of the leaflets, the need cells grew as monolayer cultures morphologically similar to typical dermal fibroblasts. They contained vimentin filaments, and expressed fibronectin, chondroitin sulfate, and prolyl-4-hydroxylase activity typical of fibroblasts. Specialized differentiation of these cells was indicated, however, by the presence of (α-smooth muscle actin fibers.
A connection between the stresses experienced by heart valve leaflets and their biosynthetic activities was postulated by Schneider and Deck (1). Through autoradiographic analysis using precursors specific to protein or glycosaminoglycans, they found that cells actively engaged in the biosyntheses of collagen were more likely to be found in regions of the leaflet subjected to the greatest amount of loading forces. (In vivo measurements in dogs allowed measurement of bending stresses and pressure and membrane stresses in the hinge region of the leaflets (2)). In contrast, sulfate accumulation (presumably representing sulfated glycosaminoglycans) was greatest near the hinge region between the leaflet and adjacent aortic conduits These results confirmed the earlier report of Torii, et al. (41) who postulated that glycosaminoglycan synthesis in leaflets is inversely proportional to imposed pressure.
Direct demonstration of the effects of pressure on leaflet metabolism was obtained from studies of heart valves from spontaneously hypertensive rate (10). Proliferation index measures, collagen labeling, and types I and III collagen gene expression were all increased after mean arterial pressure was elevated by 25% in the affected animals.
The effects of the differing forces of pressure and bending were apparent in presence of myofibroblast like cells in the leaflets (42). These cells appeared more numerous in the distal portions of the leaflets and were distinguished phenotypically by their content of α-smooth muscle action. After explant culture, these cells retained ability to contract with application of a variety of pharmacologic agents (40), suggesting a possible role for these cells in leaflet motion. Again, physical forces may be important not only as a regulator of fibroblast function, but also of cellular differentiation.
Mechanical loading (tension) affects dermal fibroblast replication and collagen production independently of autocrine, paracrine, or endocrine factors (14). Pressure overloading of the heart causes cardiac hypertrophy which involves, in addition to cardiomyocyte hypertrophy, the replication, and elevated synthesis of collagen by cardiac myofibroblasts (10,11). While collagen synthesis appears to require more than 24 hr of increased tension to be upregulated in fibroblasts, the transduction of physical forces into other cellular responses may vary according to cell type, physical force involved and the end-point measurement. For example, there is a hierarchy of appearance and disappearance of effects of flow on endothelial cells (7) in which shear stress requires from 6 to 48 hours to produce alterations in adhesion molecule appearance on the cells. While short times may be required to provide maximal rates of expression of integrins, reorganization of cells within the extracellular matrix may take longer as is shown by the time it takes randomly arrayed endothelial cells to reorient to minimize shear stress once flow has begun (43).
In light of these observations, we will utilize the system described above to expose fresh (unfixed, viable) porcine aortic heart valves to normal blood flow conditions; frequency will be 70 bpm with a diastolic pressure of 70 mg Hg and a flow rate of 5 L/min. Collagen biosynthesis (total and differential based on type I and type III collagens), type I, III, and IV collagen RNAs and elastin mRNA, and glycosaminoglycan synthesis will be examined after continuous treatment for up to 5 days. The distribution of the cells engaged in the synthesis of collagen versus glycosaminoglycans will be assessed by autoradiographic analysis of lengthwise cross-sections of leaflets. Other samples will be tested for ultimate tensile strength. The influence of elevated rate (120 bpm), elevated pressure (120 mm Hg), and elevated flow rates (7.5 L/min) on these measures of leaflet metabolism will then be inspected. It is likely that most of the metabolic changes which might occur in response to changes in pulsatile flow will occur within 24-48 hr (v.s.).
Finally, leaflet specimens from each of these conditions will be immunostained with antibodies selected from those listed in Table 3. One aim is to examine the effects of flow dynamics on the adhesion and proliferation of dermal fibroblasts reseeded onto an acellullar aortic valve matrix. Pulsatile flow may modulate the expression of critical proteins involved in fibroblast adherence to the collagenous matrix of the leaflet. These immunostaining studies will provide the first data on the interaction of flow and fibroblast integrin expression and cell distribution. This will provide the tools to optimize porcine matrix preconditioning and bioreactor flow conditions to produce a "normal" living heart valve.
TABLE 3______________________________________IMMUNOHISTOCHEMISTRY REAGENTS ANTIBODY EPITOPE orTARGET LOCATION LECTIN SOURCE______________________________________MHC Class I Mammalian Cell H58A VMRD, Inc.Antigen Membranes Pullman, WAMHC Class II Human Cell H34A VMRDAntigen MembranesMHC Class II Porcine Cell MSA3 VMRDAntigen MembranesCarboxyl terminal Fibroblast Anti-pC John HopkinsDomain of Type I Cytoplasm UniversityProcollagenFibroblast Mammalian Cells RCV508C1 Washington StateAntigen University Monoclonal Antibody Center (Dr. Bill Davis)α-Smooth Muscle Smooth Muscle NCL-SMA NOVO CastraActin PhenotypeDesmin Contractile Cells Clone Sigma DIG10VL2Integrin α.sub.2 β.sub.1 Collagen Receptor Chemicon InternationalIntegrin α.sub.2 β.sub.1 Collagen, Laminin M0608 DAKO Receptor______________________________________
A further aim is to optimize the effects of flow on the repopulation of acellular porcine heart valve leaflets with human dermal fibroblasts; examine how flow might be used to foster cell adhesion and cell function.
The tissue engineering concept guiding the development of this heart valve is an attempt to mimic, as closely as possible the distribution of cells and the expression of cell activities found in a native leaflet that are considered important for long-term leaflet durability. We have been able to remove the porcine cells from the heart valves without reducing the strength of the tissue. We have also replaced the cells in the porcine heart valve with human dermal fibroblasts demonstrating that the leaflets can be recellularized. The next phase of this project is to optimize the recellularization process in a dynamic system.
Background--Cell adhesion in the flow environment--Endothelial cell seeding of small caliber vascular graft surfaces has been attempted to reduce the natural thrombogenicity of both synthetic and natural conduits used as bypass grafts. When cells were seeded immediately before implantation of a graft into a high flow environment (44-46), or even if they were cultured with the graft material under static, tissue culture conditions (47), poor endothelial cell retention resulted and clot formation due to the graft remained accelerated (47). Duration of graft patency was short. However, when endothelial cell seeded grafts were exposed to graded increases in shear stress over time, and then exposed to arterial shear stress (25 dyne/cm 2 ), short-term cell adhesion and prevention of clot formation were improved (47). Similar improvements in graft patency resulted when endothelial cell adhesion was supplemented with an exogenous biocompatible fixative (fibrin adhesive) and the cells were allowed to maximize intercellular bonding *48). The linkage between shear stress and endothelial cell adhesion molecule expression was clear as physiologically relevant levels of shear stress (>2.5 dyne/cm 2 ) upregulated ICAM-1 gene expression and insertion into cell membranes (49).
Fibroblasts seeded onto an acellular matrix would experience forces different from those found within the leaflet matrix. Stress is force per unit area. Blood pressure acts normal to the surface and creates a compressive stress. Friction force of flowing blood generates a shear stress acting tangentially tot he cell surface. Distention of the substrate due to a pressure pulse transmits tensile stress to cells through the contacts with the extracellular matrix. Cell deformation as a response is expressed as stain and depends on the mechanical and structural properties of the cell. Cells within the matrix will be exposed to tensile strain (stretch), the change of length per unit length. Torsional stresses may be imposed across the cell if it behaves as a solid.
While it is clear that fibroblasts have a tensional force sensor mechanism, the question remains whether shear stress or pressure can be utilized to optimize their adhesiveness to a mobile substratum such as a leaflet and increase the efficiency of repopulation. To examine this, valves will first be seeded with dermal fibroblasts under static culture conditions. After a 3 hr attachment phase, the valves will be placed in the flow loop which will be utilized to slowly increase flow rate (starting at <10 ml/min); to this we will add a cycling flow parameter to induce leaflet flexion. In another paradigm, a constant pressure field will be applied, again starting at low levels and ultimately ramping up to normal diastolic levels. The studies of pressure field will be applied, again starting at low levels and ultimately ramping up to normal diastolic levels. The studies of pressure can be carried out without the flow loop as the initial studies will examine this force independent of flow rate or cycle frequency. In each case, leaflet integrin expression will be compared to valves incubated in static culture for the same time as the dynamically loaded valve leaflets.
Is likely that cellmigration will be affected due to the tension on the collagen fibers produced by elevated force levels. To assess cellular distribution, valves will be conditioned at reduced or elevated (compared to normal) flow rate, frequency, and pressure and leaflets exposed to these treatment conditions will be radiolabeled with protein and proteoglycan precursors and analyzed by autoradiography to provide data on distribution and activity of viable cells within the leaflet matrix. Samples will also be submitted for in situ hybridization to examine distribution of cells specifically expressing types I, III, and IV collagen mRNAs and elastin mRNA.
MATERIALS AND METHODS
a. Materials
Pig Tissues--Approximately 20 pig hearts can be obtained weekly at slaughter from AVCO Meats, Gadsden, Ala.: this facility is 2 hours from CryoLife, Inc. These hearts are from adult animals weighting 90-300 kg. Hearts will be rinsed at the slaughterhouse in sterile saline and transported on wet ice in Dulbecco's modified Eagle's medium. At CryoLife, Inc., the aortic valves will be dissected free in a class 100 clean room and incubated in an antibacterial/antimycotic solution at 37° C. for 24 hr. The treated valves are washed in antibiotic-free DMEM and transferred to 4° C. DMEM containing 10% DMSO and 10% fetal bovine serum (Gibco/BRL) and placed in heat-sealable pouches. Finally, the valves will be cryopreserved in a controlled rate freezer (CryMed) using liquid nitrogen to reduce temperature at 1° C./min to-80° C. Then, they will be transferred to liquid nitrogen (-196° C.) until use. Pig leaflets from cryopreserved tissues have metabolic heat production rates up to 90% of those of fresh tissues (S. Goldstein, unpublished results). Prior to use, the pouches containing the frozen valves will be plunged into 37° C. water to rapidly thaw the tissue to prevent formation of ice crystals and consequent structural damage. DMSO will be removed with sequential washes in sterile lactate Ringer's solution containing 5% dextrose.
Human Dermal Fibroblasts--Upper thigh skin will be obtained from cadaver material after receiving appropriate research consent. Fibroblasts will be grown by culture of˜1 mm 3 explants in 35 mm culture plates placed in a humidified, 37° C., 5% CO 2 environment. Fibroblast outgrowth can be achieved within 2 weeks. The cells will then be passaged by trypsinization, washed, and plated in 75 cm 2 culture flasks. The cells will be fed twice weekly with DMEM containing 10% fetal bovine serum. The cells will be passaged at confluence and utilized between passages 4 and 9.
b. Methods
1. Microscopic Methods
a) Light microscopy-histology and staining procedures; immunohistochemistry
Paraffin-embedded or frozen sections will be stained with hematoxylin and eosin for routine screening of tissues. Cell counting will be performed with the aid of a micrometer eye piece at 100× magnification. Ten regions will be chosen randomly along the length of each hematoxylin- and eosin-stained cross-section of leaflet for counting of intact cells and for evidence of pycnosis. Function and species-specific antibodies will be used to assess depopulation (porcine MHC class II and fibroblast antigen). Reseeded human cells will be detected with MHC Class II antigen. Type I procollagen will be used to monitor fibroblast function while smooth muscle actin and desmin will be monitored to detect differentiation to a myofibroblast phenotype. Collagen dependent cellular ligands will be detected with antibodies to integrins α 2 β 1 and α 3 β 1 . Identification of these antibodies will employ a system of biotinylated secondary antibodies. In addition, avidin/biotin blocking and Vectastain Elite ABC kits (Vector) with immunoperoxidase staining and a Harris hematoxylin counterstain will be employed. Differentiation of viable versus non-viable cells will be provided by fluorescence microcopy of sections stained simultaneously with nucleic acid probes that fluoresce different colors based on permeation into live or dead cells (Molecular Probes, Eugene, Oreg.).
b) Electron Microscopy
Selected leaflet sections will be analyzed by electron microscopy to define effects of depopulation and flow conditioning on collagen fibril integrity. Samples for transmission electron microscopy will be post-fixed in 2% osmium for 1 hr and dehydrated through an alcohol series, followed by Epon embedding. The specimens will be cut in a-2 μm sections and stained with toluidine blue. Based on this staining, representative areas will be selected and ultra thin sections made and stained with a saturated solution of uranyl acetate in water and lead citrate for positive staining, or with phosphotungstic acid at neutral pH for negative staining. Leaflet surfaces will be examined by scanning electron microscopy. Samples for SEM will be post-fixed in 2% osmium in phosphate buffered saline for a minimum of 4 hr, washed with PBS, treated with thiocarbohydrazide for 1 hr and then reexposed to osmium. The sections will be studied with an electron microscope at the Yerkes primate Center (Emory University) and examined qualitively by Rob Apkarian.
c) Autoradiography
After exposure to variations of pulsatile flow and pressure conditioning (v.s.), selected leaflets will be dissected and metabolically labeled in the presence of 3 H-proline or 3 H-sulfate to label proteins and glycosaminoglycans, respectively. After labeling, the tissues will be treated with 10% trichloroacetic acid. then they will be extensively washed to remove unincorporated label and fixed in 10% neutral buffered formalin. The fixed tissue will be frozen in OCT and cut in 6 μm sections. the sections will be mounted on chrome alum-coated positive-charged glass slides. Each tissue block will be cut into three pieces per slid, with three test slides and three experimental slides allowing for optimization of exposure time. the embedding medium (OCT) is then removed and the tissue defatted with successive dilutions of ethanol in water. A photographic emulsion (Kodak NTB2) will be applied to the slides, and development will proceed at 4° C. At selected times, the exposed emulsion will be developed (d-19 developer) and fixed (Kodak Polymax T fixer), and the tissues counterstained with Harris hematoxylin and eosin. the distribution of cells active in metabolism of the particular precursor will be determined microscopically. video imaging software (Simple, C-Imaging, Pittsburgh, Pa.) will be used to automatically map developed grains as indicators of cellular activity.
2. Heart Valve Leaflet Metabolism Studies
a) Heart Valve Leaflet Viability Testing
Tissue viability will be assessed by measurement of 3 H-glycine or 3 H-proline incorporation into trichloroacetic acid (TCA) precipitable proteins (50). Leaflets will be placed in polystyrene tubes containing 12 μCi of tritiated substrate in μl of DMEM supplemented with 15 μg/ml ascorbic acid. Samples will be incubated at 37° C. for 48 hr in a 5% CO 2 atmosphere. Tissues will be washed four times with phosphate-buffered saline, dehydrated with ethanol, washed with ether, and weighed. Tissues will be rehydrated with 200 μl of water, and then solubilized by addition of 1M NaOH, incubation at 60° C. for 1 hr, and sonication twice for 20 sec each. Homogenates will be centrifuged at a 12,000 xg for 5 min, and 100 pl aliquots for the supernatants will be placed on Fisher GFC glass fiber discs. The filter discs will be dried and proteins precipitated by addition of 10% TCA for 30 min followed by five ethanol and two ether rinses, and drying. Discs will be placed in 10 ml of Cytoscint scintillation fluid and tritium incorporation will be measured by scintillation spectrometry. This approach permits estimation of total proteins accumulated in the intra- and extracellular spaces of the leaflet, but does not account for any proteins which might not be incorporated into the extracellular matrix of the issues, i.e., released into the medium prior to cross-linking. Clarification of whether there is significant synthesis of proteins not localized in the extracellular matrix would provide a more complete picture of overall protein synthesis in this tissue. Additionally, this approach does not clarify the distribution of synthesis between collagen and non-collagen proteins, this will be evaluated as described below.
b) Collagen Biosynthesis
Weighted tissue fragments will be incubated at 37° C. in serum free Dulbecco's modified Eagle's medium containing 5 μCi/Ml L- 2, 3- 3 !proline and supplemented with 50 μg/ml ascorbic acid for optimal collagen biosynthesis and 50 μg/ml μ-aminopropionitrile to retard cross-linking (51). the medium will be separated from the tissue, and phenylmethylsulfonyl fluoride (0.5 mM), EDTA 20 mM), and N-ethylmaleimide (10 mM) will be added to inhibit proteolysis. The tissue will then be washed three times with ice-cold phosphate buffered saline and extracted with 0.5M acetic acid plus 1 μg/ml pepstatin and 10 mM N-ethylmaleimde. The extracts will be further dialyzed against acetic acid and clarified by centrifugation; medium samples will also be dialyzed against acetic acid. After precipitation ion 10% TCA, the recovered proteins will be dissolved in 0.05M NaOH and an aliquot removed for total 3 H-proline incorporation. Relative collagen synthesis will then be assayed by measuring the radioactivity that remains TAC-soluble after limited digestion with bacterial collagenase. This enzyme will be purified to remove non-specific protease activity by Sepharose S-300 column chromatography according to Peterkosfy and Diegelmann (52). Samples will be incubated with or without collagenase (approx. 25 units) plus 10 mM N-ethylmaleimide for 5 hr at 37° C. bovine serum albumin (50 μg/ml) will be added to the extract as carrier protein; trichloroacetic acid will be added to a final concentration of 10% and tannic acid to 0.025%, and the mixture kept at 4° C. for 60 min. Precipitated proteins will be collected by centrifugation (5,000 ×g for 5 min) and washed three times in 5% TCA. The relative rate of collagen synthesis to noncollagen synthesis will be calculated after counting the radioactivity in both fractions and multiplication of the noncollagen protein radioactivity by 5.4 to correct for the relative abundance of imino acids in collagen (22.2%) versus noncollagen proteins (4.1%) (53).
C) Oualitative analysis of collagens (collagen typing)
Interrupted gel electrophoresis, as described by Sykes, et al. (54) will resolve type I, III, and V collagen, the main subtypes found in leaflets. After radiolabeling with 3 H-proline, the tissue will be electrophoresed on nonreducing 5% SDS polyacrylamide gel in the presence of 0.05M urea until the dye front has migrated approximately 1/3 of the total run distance. Then 20 μl of β-mercaptoethanol will be added to each well. Since type III collagen is disulfide bonded, its migration is retarded relative to the α chains of type I and V collagen until the reducing agent is added. Therefore, the α1(III) chain can be resolved from the α1 (I) chain. The α1(V) and α2(V) chains migrate between the α1(I) and the α1(III) chains. The gel will be soaked in 10 volumes of sodium salicylate (pH6.0) for 30 min to enhance 3 H emission intensity 955) and exposed to Kodak SB X-ray film for fluorography. The ratio of type III to type I collagen will be determined by scanning densitometry.
d) Cyanogen Bromide Isolation of Elastin from Collagen in Tissues
Separation of elastin and collagen is based on the fact that elastin contains no methionine and so resists digestion by cyanogen bromide. Leaflet pieces will be treated with 50 mg/ml cyanogen bromide in 70% formic acid under nitrogen for 24 hr at room temperature. The extract is removed and residual material washed five times with water at 90° C. the extract and washes contain collagen and other solubilized proteins. The insoluble residue is taken as elastin. This material can be solubilized by multiple extractions with 0.25M oxalic acid at 98° C. The extracts will be dialyzed against water at 4° C. to prevent coacervation.
e) Glvcosaminoglycans
Tissue will be labelled in culture medium with 10 μCi/ml 6- 3 H! glucoasime (specific activity 30 Ci/mmole) for 24 hr at 37° C. After labeling the issue will be washed five times to remove unincorporated label, lyophilized, and extracted with 1M acetic acid. The samples will be precipitated with 20% trichloroacetic acid, and radioactivity measured by liquid scintillation spectrometry.
3. Molecular Biology Techniques
a) Nucleic acid cloning
cDNA probes for type I collagen chains, type III collagen, type IV collagen chains, and elastin will be subcloned into transcribable vectors (pGEM4Z or pGEM7Z, according to requirements for particular restriction endonuclease sites in the polycloning sites). These constructs can be used to transform competent E. coli (56) which are replicated in large-scale cultures to generate additional plasmid and inserts.
The constructs to be used are:
______________________________________ CLONINGLOCUS (INSERT) VECTOR SITE I CLONING SITE II______________________________________COL1A1 (Hf677) pGEM7Z EcoR1 EcoR1COL1A2 (Hf32) pGEM7Z EcoR1 AaIICOL4A1 (pE123) pGEM4Z EcoR1 EcoR1COL4A2 (pE18) pGEM4Z EcoR1 HindIIICOL3A1 (Hf934) pGEM4Z EcoR1 HindIIIHDE-3 (elastin) pGEM4Z EcoR1 SacI (+Sp6 = sense) (+T7 = antisense)______________________________________
For ligation of DNA to a cloning vector both the insert DNA and the plasmid (5 μg of each) will be digested with appropriate restriction enzymes to produce complimentary termini. The DNAs will be precipitated to remove extraneous proteins and salts. When a single enzyme is used, the plasmid is dephosphorylated with calf intestinal alkaline phosphatase (CIAP) in the presence of 1 mM ZnCl 2 to remove 5 1 -phosphate groups and prevent recircularization during litigation CIAP-treated plasmids will be repurified, or else they will affect ligation and transformation efficiency (57). the insert and vector DNAS are mixed in molar ratios of 1:1, 1:3, and 3:1 and reacted with T4 ligase at 4° C. overnight (58). The JM109 strain of E. coli will be used for all transformations and is purchased from Promega as competent cells. Aliquots of the ligation mixtures containing up to 50 ng of cloned DNA will be mixed with cells, chilled on ice for 10 min, and then heat shocked at 42° C. for 50 sec. The transformed cells will be allowed to proliferate without selection antibiotic for 1 hr and will then be streaked onto antibiotic-containing (50 μg/ml ampicillin) Luria-Bertani (LB) medium plates. After overnight incubation, single cell colonies will be picked and grown overnight in LB medium containing ampicillin. DNA is isolated by the SDS-NaOH lysis (59), digested with appropriate restriction endonucleases, and electrophoresed on 1% agarose gels containing 0.089M Tris; 0.089M borate and 0.002M EDTA (IX TBE) to UV-light visualize insert DNA after ethidium bromide staining.
Large scale preparations of plasmid DNA will be prepared from positive clones by twice expanding bacteria volume 100-fold in overnight incubations in the presence of antibiotic. the bacteria will be recovered by centrifugation, washed in pH 8.0 buffer and frozen at -80° C. to aid lysis. the bacteria will be treated successively with 20% sucrose in 50 mM Tris-Cl, pH 8.0; 10 mg/ml lysozyme in water, and 0.25M EDTA, pH 8.0 to limit nuclease activity, and then lysed in 2% Triton X-100, 40 mMTris-Cl, pH 8.0 and 60 mMEDTA. the lysates will be cleared of debris by centrifugation for 45 min at 15,000 xg. Plasmid DNA is separated from chromosomal DNA and RNA protein by equilibrium centrifugation (48 hr at 15,000 xg) in cesium chloride at a density of 1.386 g/ml and ethidium bromide at 0.74 mg/ml. The closed circular plasmid DNA bands at a higher density than nicked circular or linear DNA, or protein. After removal from the tube, ethidium bromide is extracted by multiple n-butanol washes, and the DNA dialyzed to remove CsCl. After digestion of RNA with 10 μg/ml RNAase A and proteins with 50 μg/ml proteinase K, plasmid DNA is precipitated from 0.3M sodium acetate with 70% ethanol. (59).
b) Nucleic Acid Labeling
DNA or RNA probes will be non-radioactively labeled with digoxigenin-II-UTP, a sterol not found in biological materials, thus reducing background staining (60). After excision and purification of the cDNA from the construct, labeled double stranded DNAs will be prepared by the random priming reaction using the Klenow fragment of DNA polymerase (61). Labeled RNA probes will be synthesized by in vitro transcription of DNA. Both the pGEM4Z and pGEM7Z plasmids contain SP6 and T7 RNA polymerase promoters flanking opposite ends of the multiple cloning site. By linearizing the plasmid at the end of the insert opposite from the selected polymerase promoter, antisense or sense RNA probes can be prepared depending upon orientation of the insert and the RNA polymerase used.
The α1(I) collagen and α1(IV) collagen probes both have 5' and 3' EcoRI ends and so could be cloned in either direction. Before being used for in situ hybridization as riboprobes, the directions of insertion will be analyzed according to restriction endonuclease digestion and mapping of the fragments.
Assessment of Collagen and Elastin mRNA
i. in situ hybridization
In situ hybridization will be used to assess gene function as the technique permits detection of a specific mRNA in a heterogeneous cell population; therefore functional vs. non-functional cells can be differentiated. the probes are to be labeled with digoxigenin so that non-radioactive detection can be used. This permits more rapid analysis, eliminates health hazards of radioactivity and permits more detailed detection of the site of hybridization.
Under RNAase-free conditions, 5-10, μm thick cryosections of liquid nitrogen frozen leaflets will be mounted on silane subbed slides (62). Fixation in 4% paraformaldehyde is used to preserve morphology and improve retention without cross-linking proteins thereby making cell ectoplasm impermeable (63). As it will be used here, hybridization is detected with an alkaline phosphatase conjugate. the high alkaline phosphatase activity of fibroblasts (64) will be inhibited by washing the sections in 0.2M HCl to reduce potential background (65). The acid treatment can improve signal-to-noise by permeabilization of the fixed proteins and may be augmented by brief digestion with proteinase K (66). When cDNA probes, the sections are also treated with acetic anhydride in triethanolamine buffer to neutralize positive charges and reduce non-specific binding of the probes (67). Prehybridization at 37° C. will be used to block non-specific binding and to equilibrate the sections with buffer. Prehybridization buffer contains: 50% formamide; 0.6M NaCl, 10 mM Tris-Cl, pH 7.5; 0.02% each of Ficoll type 400, polyvinylpyrrolidone, and bovine serum albumin; 1 mM EDTA, 0.05% each of salmon sperm dNA and yeast tRNA; and 20 mM β-mercaptoethanol. The prehybrization buffer will be replaced with hybridization buffer which will contain, in addition to the above components, 10% dextran sulfate and prove at 2-100 fmol/μl. Both cDNA and RNA probes will be used to establish conditions of optimal detection of MRNA. After hybridization, the sections will be washed with buffers of increasing stringency (decreasing salt concentration and increasing temperature). Eghbali, et al. have reported an extensive washing process for in situ detection of collagen mRNAs in rat hears (68). With RNA probes, RNAase digestion is used to demonstrate specific binding RNAase digestion before hybridization with cDNA probes is used for the same purpose). To detect bound probe specimens will be treated with non-fat dry milk to block non-specific antibody binding, reacted with the rabbit anti-digoxigenin serum, and developed with X-phosphate/NBT substrate for alkaline phosphatase.
Experiments with in situ hybridization include: 1. detection of distribution of collagen and elastin mRNAs in normal leaflet tissue as well as in the myocardial band and the aortic conduit; 2. examination of expression of these same messenger RNAs by cultured fibroblasts; and 3. examination of expression in fibroblasts in repopulated porcine heart valves.
ii. Northern blotting
Total RNA will be isolated from dermal fibroblasts in culture and flow-conditioned repopulated tissues using a modification of the SDS lysis/acid phenol technique of Stalcup and Washington (69) which has been used by the P.I. to isolate hepatocyte RNA in high yield (70). RNA will be separated by electrophoresis on 1.2% formaldehyde agarose gels, blotted onto charged nylon hybridized with α1(I) collagen, α2(I) collagen, type III collagen, α1(IV) collagen, α2(IV)collagen, or elastin cDNAs labeled with digoxigenin-II-UTP, and washed under high stringency to obtain specificity of hybridization. The blots will be reacted with an anti-digoxigenin antibody/alkaline phosphatase conjugate and reacted with BCIP/NBT substrate. Relative abundance of MRNAs will be determined with laser densitometry (Emory University). The blots can be decolorized with N,N-dimethyl formamide (55° C.) and stripped of probe with 0.2N NaOH, 0.1% SDS for reprobing.
4. Biomechanical Testing
Tensile tests, performed using a calibrated Instron Model 5565 materials tester and Series IV personal computer interfact software and custom-designed specimen clamps require the following sequential tasks:
cut leaflet from valve
punch leaflet into "dog bone" shaped specimens circumferential or radial)
measure specimen thickness with a low-mass conductivity device
mount and precondition specimen to 300 to 150 kPa (circumferential or radial, respectively)
test load versus elongation specimen to 300 or 150 kPa (circumferential or radial, respectively)
test load versus elongation and plot stress versus strain curves
test and plot stress-relaxation curves
test and plot ultimate failure curve to provide estimates of ultimate tensile strength, high modulus, and extensibility.
The effect of load on tissue extensibility is depicted in stress versus strain curves where strain is calculated as the change in length compared to fully relaxed tissue, and the measured load is converted to stress by normalizing to load-bearing cross-sectional area.
E. BIBLIOGRAPHY
1. Schneider, P J and Deck, J D, Cardioavas. Res. 15:181-189, 1981.
2. Deck, J D, Thubrikar, M J, Schneider, P J and Nolan, S P, Cardiovasc. Res. 22:7-16, 1988.
3. Reinhart, W H, Experientia 50:87-93, 1994.
4. Carosi, J A and McIntire, L V, Eur. Respir.Rev. 3:598-608, 1993.
5. Owens, G K Physiol. Rev. 75:487-517, 1995.
6. Patrick, C W, Jr. and McIntire, L V, Blood Purif 13:112-124, 1995.
7. Ley, K and Tedder, T F, J. Immunol. 155:525-528, 1995.
8. Ando, J, Tsuboi, H, Korenaga, R, Takada, Y, Toyama-sorimachi, N. Miyaska, M and Kamiya, A, Am. J. Physiol. Cell Physiol, 267:C679-C687, 1994.
9. Davies, P F, Physiol. Rev. 75:519-560, 1995.
10. Willems, IEMG, Havnith, M G, smits, J F M and Daemen, M J A P, Lab. Invest. 71:127-133, 1994.
11. Butt, R P, Laurent, G J and Bishop, J E, Ann. N.Y. Acad. Sci. 752:387-393, 1995.
12. Wiklund, L. Nilsson, B, Berggren, H and Nilsson, F. Scand. J. Thor. Cardiovasc. Surg. 29:1-6, 1995.
13. Kim, Y-J, Bonassar, L J and Grodzinsky, A J, J. Biomechanics 28:1055-1066, 1995.
14. Mauch, C, Hatamochi, A, Scharffetter, K. and Krieg, T., Exp. Cell Res. 178:493-503, 1988.
15. Kolodney, M S and Wysolmerski, R B, J. Cell Biol. 117:73-82, 1992.
16. Tomasek, J J, Haaksma, C J, Eddy, R J and Vaughan, M B, Anatom. Rec. 232-359-368, 1992.
17. Nishiyama, T. Tsunenaga, M, Nakayama, Y, Adachi, E and Hayashi, T, Matrix 9:193-199, 1989.
18. He, Y and Grinnell, F, J. Cell Biol. 126:457-464, 1994.
19. Yamato, M, Adachi, E, Yamamoto, K and Hayashi, T, J. Biochem. Eng. 21:289-305, 1993.
20. Huang, D. Chang, T R, Aggarwa, A, Lee, R C and Ehrilich, H P, Ann. Biomed. Eng. 21:289-305, 1993.
21. Moeller, H D, Bosch, U and Decker, B, J. Anat. 187:161-167, 1995.
22. Bajpai, P. Biocompatibility of tissue analogs, vol. 1, edited by William, D.f CRC Press, Inc. Boca Raton: 1985, p. 5-25.
23. Armiger, L C, Gavin, J B and Barratt-Boyes, B G, Pathology 15:67-73, 1983.
24. Kamiya, A. and togawa, t. Am. J. Physiol. 239:H14-H21, 1980.
25. Fry, DL, Circ. Res. 22:165-197, 1968.
26. Evans, E. Berk, D and Leung, A, Biophys. J. 59:838-848, 1991.
27. Delobel, J. Yang, J, Offerman, M K and Zhu, C, Adv. Bioeng. 22:391-394, 1992.
28. Hammer, D A and Lauffenberger, D A, Biophys. J. 52:475-487, 1987.
29. St. Louis, J. corcoran, P. Rajan, S. Conte, J. Wolfinbarger, L. Hu, J. Lange, PL, Wang, Y N, Hilbert, S L, Analouei, A and Hopkins, R A, Eur. J. Cardio-thorac. Surg. 5:458-465, 1991.
30. Domkowski, P W, Messier, R H, Jr. Crescenzo, D G, Alay, H S, Abd-Elfattach, A S, Elbert, S L, Wallace, R B and Hopkins, R A, Ann. Thorac. Surg. 55:413-419, 1993.
31. Mochtar, B, van der Kamp, AWM, Roza-de Jongh, EJM and Nauta, J. Cardiovasc. Res. 18:497-501, 1984.
32. McGregor, CGA, Bradley, J F, McGee J O and Wheatley, D J, Cardiovasc. Res. 10:389-393, 1976.
33. Yoganathan, A P, Eberhardt, C E and Walker, P G. J. Heart Valve Dis. 3:571-580, 1994.
34. Westerhof, N. Elzinga, G and sipkema, P. J. appi. Physiol. 31:776-781, 1971.
35. Walker, P G, Kim, T Y, Muralidharan, E, Miyajima, Y, Delatore, J and Yoganathan, A P, Echocardiography 11:11-28, 1994.
36. Yoganathan, A P, Woo, Y R and Sung, H W, J. Biomechanics 19:433-442, 1986.
37. Fontaine, A A, Ellis, J T, Hopmeyer, J and Yoganathan, A P, ASAIO J. 1995 (In Press)
38. Dell'Orbo, C, De Luca, G, Quacci, D and Soldi, C, Histol. Histopathol. 10:583-588, 1995.
39. Spray, T L and Roberts, W C, Am. J. Cardiol. 40:319-330, 1977.
40. Messier, R H, Jr., Bass, B L, Alay, H M, Jones, J L, Domkowski, P W, Wallace, R B and Hopkins, R A, J. Surg. Res. 57:1-21, 1994.
41. Torii, S. Bashey, R I and Nakao, K, Biochim. Biophys. Acta 101:285-291, 1965.
42. Lester, W. Rosenthal, a. Granton, B and Gotlief, A I, Lab. Invest. 59:710-719, 1988.
43. Grabowski, E F and Lam, F P, Thromb. Haemost. 74:123-128, 1995.
44. Hammer, D A, Tempelman, L A and Apte, S M, Blood Cells 19:261-277, 1993.
45. Koveker, G B , Burkel, W E, Graham, L M, Wakefield, T W and Stanley, J C, J. Vasc. Surg. 7:600-605, 1988.
46. Wechezak, A R, Coan, D E, Viggers, R F and Sauvage, L R, Am. J. Physiol. Heart Circ. Physiol. 264:H520-H525, 1993.
47. Ott, M J and Ballermann, B J, Surgery 117:334-339, 1995.
48. Gosselin, C. Ren, D, Ellinger, J and Greisler, H P, Am. J. Surg. 170:126-130, 1995.
49. Nagel, T. Resnick, N, Atkinson, W J, Dewey, C F, Jr. and Gimbrone, M A, Jr. J. Clin. Invest. 94:885-891, 1994.
50. McNally, R T and Brockbank, K G M, J. Med. Eng. Tech. 16:34-38, 1992.
51. Werb, Z, Tremble, P and Damsky, C H, Cell Differentiation and Development 32:299-306, 1990.
52. Peterkofsky, B and Diegelmann, R, Biochem. 10988-994, 1971.
53. Buckley,, A, Hill, K E and Davidson, J M, Methods Enzymol. 163:674-694, 1988.
54. Sykes, B, Puddle, M, Francis, M and Smith, R, Biochem. Biophys. Res. Commun. 72:1472-1484, 1976.
55. Chamberlain, J P, Anal. Biochem. 98:132-137, 1979.
56. Promega Protocols and Applications Guide. 2nd Edition. Promega Corporation, Madison: 1991, pp. 51-57.
57. Perbal, B. A practical guide t omolecular cloning. 2nd edition. John Wiley and Sons, 1988, pp. 403-405.
58. Birnboim, H C, Methods Enzymol. 100:243-255, 1983.
59. Molecular cloning. A laboratory manual, edited by Sambrook, J., Fritsch, E. F. and Maniatis, T. Cold Spring Harbor Laboratory Press, Cold Spring Harbor: 1989, p. 1.33-1.52.
60. Arnold, N Seibl, R, Kessler, C and Wienberg, J, Biotech. Histochem. 67:57-67, 1992.
61. Feinberg, A P and Vogelstein, B, Anal. Biochem. 137:266-267, 1984.
62. Signer, R H, Lawrence, J B and Villnave, C, BioTech. 4:230-249, 1986.
63. Wilcox, J N, J. Histochem. Cytochem. 41:1725-1733, 1993.
64. Fedde, K N, Cole, D E and Whyte, M P, Am. J. Hum. Genet. 47:776-783, 1990.
65. Lum, J B, BioTech. 4:32-39, 1986.
66. Guiot, Y and Rahier, J, Histochem. J. 27:60-68, 1995.
67. Hayashi, S, Gillam, I C, Delaney, A D and Tener, G M, J. Histochem. Cytochem. 36:677-679, 1978.
68. Eghbali, M, Blumenfeld, O O, Seifter, S, Buttrick, P M, Leinwand, L A, Robinson, T F, Zern, M and Giambrone, M, J. Mol. Cell Cardiol. 21:103-113, 1989.
69. Stalcup, M R and Washington, L D, J. Biol. Chem. 258:2802-2810, 1983.
70. Goldstein, S, Sertich, G. Phillips, L S and LeVan, K R, Molec. Endo. 2:1093-1100, 1988.
|
A closed, sterile pulsatile flow loop for studying tissue valves. The system provides both a tool to examine heart valve leaflet fibroblast function and differentiation as these are affected by mechanical loading, as well as an apparatus to provide heart valves seeded with suitable cells. The sterile pulsatile flow system provides a left heart duplicator, which exposes viable tissue valves to a dynamic flow environment imitating that of the aortic valve.
| 2
|
BACKGROUND OF THE INVENTION
The present invention is directed to a tank system for cold fixing a toner powder on a paper as it is conducted through a fixing station of a non-mechanical high speed printing and/or copying device by exposing the printed paper to an atmosphere enriched with vapors of a fixing agent. The tank system includes a fixing station having an injection tank containing the fixing agent and having means for creating a vapor of the agent in the fixing station, means for collecting a condensate of the vapor of the fixing agent and delivering the condensate to recovery means for separating the fixing agent from the collected condensate and supply means for providing an agent to the injection tank including an exchangeable feed container.
In copiers and non-mechanical high speed printers, the toner powder, which is transferred to a data carrier for example a web of paper, can be fixed with the assistance of vapors of a solvent which is a fixing agent. In this process which is known as a cold fixing process, the endless paper, which is covered with black synthetic powder, is conducted through a chamber in which an atmosphere enriched with the solvent causes the synthetic particles to dissolve and to adhere and thus produces a cross linking adhesion of the powder to the paper. In order to supply the fixing station with the solvent, it has already been proposed that a tank system be used. In this tank system the fixing station itself is preceded by an injection tank through which a liquid fixing agent is sprayed onto a hot plate in the fixing station and is thus vaporized. The injection of the agent from the injection tank is controlled by a sensing device or means which determines the amount or concentration of the vapor in the fixing station and maintains the concentration at a theoretical value. The fixing station itself will also contain a cold sluice in which the consumed fixing agent will be condensed and deposited and is thus mixed with water. The system also has a fixing agent recovery system which contains a water separator which enables recovering of the fixing agent by precipitation from the water. A pump system is used to return the solvent of the fixing agent to the injection tank in the fixing station after appropriate filtering. The recovered agent is then mixed with fresh fixing agent which is supplied from an exchangeable bottle or container.
An essential problem with regard to the transportation of the solvent, which has a decisively low boiling point, occurs when conventional liquid pumps are used. This is due to the low pressure on the suction side of the pump possibly in combination with the increased temperature of the agent resulting in expansion and evaporation which will substantially reduce the conveyance efficiency of the pump and can lead to disturbances resulting from gas formation.
These characteristics of the solvent also necessitate that the entire tank system be hermetically sealed from the environment so as to prevent the undesirable escape of the solvent. Critical zones of such tank systems consist on the one hand in the region of the cold sluice of the fixing station and on the other hand of the coupling zones between the solvent feed containers, which consist of bottles, and the tank system itself.
In order to ensure continuous operation, in particular in non-mechanical high speed printers, it is necessary that the exchangeable feed container should be such as to permit a rapid and problem free exchange or replacement. The supply of solvent to the fixing station should not be interrupted during this exchange process.
SUMMARY OF THE INVENTION
The object of the present invention is to design a tank system of the above mentioned type in such a manner as to ensure reliable and easy handling of the fixing agent contained in exchangeable feed containers together with functionally accurate and environmentally harmless replenishment of the fixing agent and in this way to facilitate undisturbed transportation of the fixing agent.
This object is realized in an improvment in a tank system for cold fixing a toner powder on a paper as it is conducted through a fixing station of a non-mechanical high speed printing and copying device by exposing the printed paper to the atmosphere enriched with vapors of the fixing agent. The tank system includes a fixing station having an injection tank containing the fixing agent and having means for creating a vapor of the agent in the fixing station, means for collecting a condensate of the vapors of the fixing agent and delivering the condensate to recovery means for separating the fixing agent from the collected condensate, and supply means for providing additional amounts of the agent to the injection tank including an exchangeable feed container. The improvement comprises the tank system including a pressure tank having an outlet connected to the supply means, a buffer tank for receiving the agent from the recovery means being connected to the pressure tank by a conduit with a valve, pump means for applying an air pressure on the pressure tank to cause a flow of the agent in the pressure tank into the feed container and to the injection tank and control means for actuating the pump means in response to a sensed low level in the injection tank.
Preferably, the buffer tank is connected to the pressure tank by both a supply pipeline or conduit having a first valve and by a ventilating pipeline or conduit which contains a second valve. The supply means for providing an additional amount of the agent to the injection tank has a pipeline or conduit extending from the container to the pressure tank having a third valve and a branch line with a fourth valve being connected between the third valve and the container and extending to the pressure tank.
In order to be able to exchange containers, the supply means includes an arrangement for sealing and receiving a container of the agent which means after insertion of the container in a sealed relationship opens the valve on the container to communicate it with the pipelines or conduits of the supply means.
The tank system in accordance with the present invention enables a disturbance free transportation of the solvent without the formation of gas within the system. When the feed containers, which are in the form of bottles, are exchanged, solvent is unable to escape into the surrounding atmosphere since the operating pressures must not be broken during the exchange process. Since the exchangeable feed container itself serves as an intermediate tank for the recovered solvent, the number of buffer tanks in the system is reduced to a minimum. Hermetic seals of the entire system results in an enviromentally safe design and a functionally reliable mode of operation. Since no mechanical pumps are used to transport the solvent, no disturbances can occur as a result of the wear phenomena particularly since the use of compressed air for the transportation of the solvent produces a self cleansing effect in the tank.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic presentation of the tank system in accordance with the present invention;
FIG. 2 is an enlarged cross sectional view of a coupling device between the feed container and the tank system with the feed container removed therefrom;
FIG. 3 is a cross sectional view similar to FIG. 2 of the coupling device with the tank being connected thereto; and
FIG. 4-7 schematically illustrate a locking device or arrangement which serves to secure the feed container on the coupling device with FIG. 4 illustrating the locking device with the container just being inserted therein; FIG. 5 illustrating the device with the container being substantially received therein; FIG. 6 showing the container entirely inserted within the device and FIG. 7 illustrating the first step of removing the container during an exchange of containers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The principles of the present invention are particularly useful in a tank system which is schematically illustrated in FIG. 1 and generally indicated at 100. The tank system 100 is for cold fixing of a toner powder on paper for a non-mechanical high speed printer which contains a fixing station 1. The station 1 has a chamber through which a web of endless paper covered with a black synthetic powder is conducted. An atmosphere enriched with the solvent is present in the chamber and causes the synthetic powders to dissolve and become attached and thus produces a cross linking adhesion to the paper. The fixing station 1 contains an injection tank 2 with a float 3 which serves as a level regulating means. The float 3 is part of control means which has a level sensor 126 that will be discussed hereinafter. Disposed in the fixing station 1 is a sensor 26 which monitors the solvent concentration and emits a signal that open and closes a magnetic valve 4 which controls flow from the injection tank 2 through an injection pipe line or conduit 5 which extends to a bottom portion of the fixing station to discharge solvent onto a heated bottom wall of the station 1 to create a vapor.
In a known manner, the fixing station 1 contains a cold sluice, which serves to condense the solvent in the region of the outlet point for the endless paper and to supply the solvent enriched with water via a condensate outlet 6 through an associated filter 7 to recovery means including a water separator 8. This water separator serves to remove the water contained in the solvent from the solvent whereupon the dehydrated solvent is fed via a supply pipeline or conduit 9 to a buffer tank 10. To enable ventilation of the system, the supply pipe 9 is connected via a branch 11 to the fixing station 1. In addition, another conduit or pipeline 12 serves to drain off water from the water separator 8.
The buffer tank 10 is connected to a pressure tank 17 by a first pipe line or conduit 13 that has a first magnetic valve 14. In addition, a ventilating pipeline or conduit 15 with a magnetic valve 16 also extends between the pressure tank 17 and the buffer tank 10. The pressure tank 17 is supplied with compressed air from pump means 18 which creates a flow of air that passes through a non-return or check valve 19. The pressure tank 17 has an outlet which is connected to a branch line 80 and has a magnetic valve 20. The branch line 80 is connected to a line or another branch 81 at a junction with a supply conduit or pipeline 25. The branch or conduit 81 has a filter 21 and is connected to a coupling means or adapter 22 which couples a feed container 23 to the line 81. The pipeline 25, which has a magnetic valve 24, extends to the injection tank 2 so that by selectively closing the valves 24 and 20, the pressure tank 17 can be connected to the container 23 or the container 23 can be connected directly to the injection tank 2 and be disconnected from the pressure tank 17.
The actual function of the tank system 100 is as follows. So that the black toner powder may be fixed on the endless paper, a constant concentration of the vapor of the solvent must be produced in the fixing station 1 in order to ensure uniform fixing. Since printed paper proceeds at a high speed through the fixing station 1, drifting and condensation on the paper gives rise to a certain discharge of the vapor. This discharge of the vapor can, in fact, be kept very small and entirely harmless both toxicologically and in terms of work safety laws but must nonetheless be compensated for in order to maintain a fixing quality. The same applies to loss of solvent, which occurs as a result of condensation of the vapors of the solvent in the cold sluice and the draining off thereof in the water precipitator or separator 8. For this purpose, a sensor 26 which monitors the concentration of the solvent emits a drive signal to the magnetic valve 4. In response to the drive signal, the magnetic valve 4 will permit a certain quantity of the solvent to flow from the injection tank 2 via the injection pipeline or conduit 5 into the fixing station 1. Since the pipeline 5 discharges near a heated base of the fixing station, the solvent discharged into the station will be rapidly evaporated and thus enrich the vapor concentration of the solvent in the station 1.
The solvent is fed through the tank system via an aerosol container 23. In this special application the aerosol container 23 is filled with solvent to only approximately 90% of its volume with the remaining 10% of the containers volume being filled with normal air. Consequently, the aerosol container contains no propellent gas additives. The aerosol container 23 itself can be inserted in an accommodating device with the assistance of a snap closure and a special coupling component which will be referred to in the following description as an adapter 22. The adapter 22 ensures further sealing from the exterior and at the same time opens the aerosol valve which is provided on the container.
The injection tank 2 contains a level regulating device in the form of the float 3, which will monitor the level of the solvent. If the level falls to a specific value, the level sensor 126, which is coupled to the float 3 will emit a start signal for the refilling process which will be described in the following. It should be noted that the solvent continues to be supplied as to the station 1 when it is required from the residue in the injection tank to the fixing tank 1 via the magnetic valve 4 independently of the other processes. When the level sensor 126 responds to a low level indication, the magnetic valves 14 and 16 are closed simultaneously whereupon the magnetic valve 20 is opened and the air pump 18 is switched on. In this way, the air pump 18 is able to build up a cushion of compressed air, which in this case amounts to approximately 2 bar, in the pressure tank and in the branch lines 80 and 81 as well as in the aerosol container 23. When the magnetic valve 24 is opened, the cushion of compressed air is able to displace the solvent out of the aerosol container 23 into the injection tank 2. If the sensor 126 reports that an adequate level has been reached in the tank 2, the magnetic valve 24 is closed in order to interrupt the refilling process. If after an elapse of a determined preset length of time the sensor 126 reports that an adequate level has still not been reached, this absence of a signal is interpreted as an indication that the aerosol container is empty and a display of this condition is set forth on a warning display 27 which may be a luminous display. The aerosol container 23 can then be exchanged for a full one. The injection tank 2 will contain an adequate reserve quantity of solvent in order to bridge the time loss for the phases of recognizing that the container 23 is empty, exchanging it and/or the transit time of one entire pressure cycle.
While the device is in operation and while the desired vapor concentration of the solvent is being maintained, the condensate is produced continuously in the fixing station to a greater or lesser degree. For reasons of economy this condensate is returned to the filling system. Since the condensate contains water, the water must be separated before returning the solvent to the system in order to avoid disturbances in the operating flow in which case an accumulation of water in the injection tank can lead to damage to the regulating properties of the overall system. Since the specific densities of the solvent and the water are distinctly different, these substances can be easily separated with the aid of a water separator 8 which contains a simple chamber system.
From the water separator 8, the water which is separated from the condensate is discharged through a pipeline or conduit 12 to a vaporizer system 28. The pure solvent condensate will flow through the conduit or pipeline 9 to the buffer tank 10. From the buffer tank 10 the solvent can then pass through the conduit 13 and through the magnetic valve 14, which is open between the pump phases, into the pressure tank 17. Simultaneously to the magnetic valve 14 being opened, the magnetic valve 16 in the ventilation conduit 15 is also opened so that the pressure tank is ventilated during the filling process. If the level sensor 126 in response to the float 3 reports that the solvent is required in the injection tank 2 as already described, the magnetic valves 14 and 16 are closed and the magnetic valve 20 is then opened as the air pump 18 is switched on. During this pumping process, the solvent content of the pressure tank 17 is thus displaced into the aerosol container 23 and is thus returned to the filling system or supply means.
At the end of the pumping process, the valve 20 is closed and the pump 18 is switched off. This time, a corresponding inner pressure prevails in the pressure tank 17 and when the magnetic valves 14 and 16 are opened, this pressure will lead to a powerful blowing through of these two valves. This blow through can thus be used for the cleansing of these valves and conduits. The pressure subsequently falls in the considerably larger buffer tank 10 and is finally dissipated in the water separator 8. Here again, the temporary repression can be exploited to remove dirt deposits from the feed conduits or pipes for the solvent outlet which will extend some distance to the base of the water separator. Finally, the pressure is completely removed via the ventilating pipe 11 which extends to the fixing station 2.
The adapter 22 or coupling means is best illustrated in FIGS. 2 and 3 and is provided in the tank system to enable the exchangeable coupling of an aerosol container 23 into and out of the system. This adapter consists of two tubes 31 and 32 which are engaged telescopically within one another with the lower stationary tube 32 being connected via an opening 33 to the line such as 81 of the tank system. The tube 31 is illustrated as being integrally connected to a spring mounted bearing plate 36 which possesses a central opening 34 for the aerosol container valve 35. The upper surface of the bearing plate 36 is provided with an annular sealing bead 40, which has a groove which receives a sealing ring such as an O-ring 41. The bearing plate 36 is loosely attached to an accomodating housing 38 by threaded members such as 39 and as illustrated is biased away from the housing 38 by a spring 37. When the aerosol container 23 is coupled to the adapter, the sealing bead 40 together with the sealing ring 41 cooperate with a bead 42 of the aerosol container and seal off the valve chamber before the valve 35 is opened.
For the opening of the valve 35, a core tappet 44, which can be displaced via a spring 43 and which is provided with a central opening 45, is arranged centrally in the tube 31. A stop means 46, which forms part of the upper tube 31 ensures the necessary spacing between the core tappet 44 and the valve 35 so that during the actual coupling process the valve chambers is sealed via the bead 40 before the core tappet 44 actuates a valve 35 by shifting it in a direction of arrow 90 (FIG. 3). At this time as illustrated in FIG. 3, the entire weight of the aerosol container 23 is supported by the bearing plate 36 and the bearing plate is lowered as illustrated with the tubes 31 and 32 engaged telescopicly. The telescopic connection between the tubes 31 and 32 is sealed by a pair of sealing rings such as O-rings 47.
The lower tube 32 is received in a cup like guide tube 49, which is suspended in the housing 38 with the position of the tube 32 being determined by stop means such as 48 which are part of the tube. The inner space between the lower tube 32 and the guide tube 49 serves to accomodate a portion of the spring 37 which supports the plate 36.
A snap closure locking system is illustrated in FIGS. 4-7 and is provided to facilitate a simple coupling of the aerosol container 23 to the tank system. This locking system consists as schematically illustrated with a tubular bottle guide 50 which is supported on the housing 38. A swing lever 51 is pivotally mounted adjacent the upper edge of the guide 50 and has an associated locking attachment 52. The locking attachment 52 curves slightly inward so that when the aerosol container is introduced into the guide 50, as shown in FIG. 4, the aerosol container 23 will move the swing lever 51. When the container 23 has been inserted into the guide 50 as shown in FIG. 5 by overcoming the spring force of the spring 37, the locking attachment 52 will become engaged over the base of the aerosol container 23 as a result of a counter weight 53 so that the aerosol container is secured in the bottle guide as illustrated in FIG. 6. When the aerosol container is to be removed, the closing weight 53 is gripped as illustrated in FIG. 7 and moved or swung upward in a clockwise direction as indicated by the arrow. The aerosol container is thus released and the spring 37 decouples the container from the tank system. It can then be easily picked up and removed from the bottle guide.
Although various minor modifications may be suggested by those versed in the art it should be understood that I wish to embody within the scope of the patent granted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
|
A tank system for cold fixing a toner powder on a paper as it is conducted through a fixing station of a non-mechanical high speed printing and copying device characterized by the printed paper being conducted through an atmosphere enriched with the vapor of a fixing agent. The tank system includes an injection tank which is connected to a replaceable feed container containing the agent with the injection tank being controlled to inject the agent into the fixing station to maintain the desired concentration of the vapor. The system also includes a recovery device including a water separator which separates condensed fixing agent from the water of the condensate. The system also includes a buffer tank which receives the recovered fixing agent, a pressure tank which is coupled to the buffer tank and has an outlet with a valve connected to the supply system, and an air pump to supply compressed air to the pressure tank to return any agent in the tank into the feed container and/or into the injection tank.
| 6
|
BACKGROUND OF THE INVENTION
[0001] This is a continuation-in-part of application Ser. No. 10/822,240, filed Apr. 9, 2004, entitled Utility Knife For Glaziers.
[0002] 1. Field of the Invention
[0003] This invention relates to utility knives for operations such as glazing, roofing carpeting and sheet rock fabrication wherein the knife is used in close proximity to window edges or close-by walls; and more particularly to a knife that facilitates cutting in a direction perpendicular to the surface appointed to be cut while, at the same time, minimizing injury to the user.
[0004] 2. Description of the Prior Art
[0005] Tools have long been used for line cutting in glazing and sheet rock installation. U.S. Pat. No. 2,242,900 to Bender discloses an adjustable tool holder and cutting device appointed for cutting paper, fabric, leather, felt, packing, cardboard, flowers, and the like. Holders of this type have conventionally been used by glaziers. The holder comprises a handle having a longitudinal guide slot to accommodate a cutting tool. A screw passes through the guide slot and engages a locking nut to secure the cutting tool in various extensions and positions. The tool holder is constrained to lie in the plane of a longitudinal guide slot parallel to the wide side of the handle, and is therefore in-line with the handle. No alignment pin or other structure is used to positively and rigidly mount the blade and prevent extension of the tool to a significant extent.
[0006] U.S. Pat. No. 2,304,332 to Bodkin discloses a scraping and cutting device comprising a holder adapted to retain a single-edged razor blade. The blade has a recess or aperture therein and a reinforcing member tightly clamped around one of the razor blade's edges. The holder comprises a pair of handle members, each of which is pivotally secured adjacent one end. A spacing member holds the handle members apart sufficiently to permit insertion and movement of the razor blade between the handle members. The opposite ends of the handle members have their ends formed obliquely to the axes of the members. A longitudinally extending channel in each of the handle members is provided for receiving the reinforcing member of the razor blade so as to either hold it within the handle or to project it in a cutting position beyond the oblique ends of the handle. A bolt and screw clamping means passes through slots in the handle members and through a recess of the blade. The clamping means may be loosened to permit movement of the blade within the holder or tightened to securely engage the blade in cutting or scraping position. Each handle member is further provided with a transverse channel extending across the width of, and substantially parallel to the oblique end of, the handle member. The reinforcing member of the razor blade may be placed in the transverse channel and the clamping means tightened to hold the blade in the scraping position. With this arrangement, the blade is in line with the handle and the blade extension is small and is controlled by position of the blade in the channel. In addition, there is lacking any alignment pin or similar means for positively locating the extension of the blade. Consequently, the device must rely solely on friction that results from the tightening of a bolt and screw tightening means.
[0007] U.S. Pat. No. 2,679,100 to Ehler discloses a knife for cutting linoleum and the like. The knife comprises a handle holding a removable blade. The handle comprises two halves, each having a blade-receiving end with a channel of the width of the blades the handle is to receive. The halves are assembled by using a screw. Pins are provided in one half for insertion in corresponding sockets in the opposite half to assure proper association of the halves upon assembly. A blade-locating lug extending from the wall of the channel engages a slot in the blade. In one embodiment the blade projects generally along the long axis of the mating halves of the handle. In another embodiment, the blade extends from the bottom edge of the handle at an angle obtuse a predetermined degree suitable for linoleum cutting in the handle plane. Significantly, there is no disclosure concerning a knife having transverse angulation of its cutting blade, maintaining the angularity of the knife blade with respect to the handle. Instead, the blade is constrained to be located in a recess in one of the sides of its handle. With this configuration, the blade of the knife is substantially co-planar with the inside surfaces of the sides of the assembled handle and has no ability to produce perpendicular cuts to a surface in close location, such as that required in glazing and sheet rock operations.
[0008] U.S. Pat. No. 2,784,489 to Reise discloses a hand holder for utility blades used by craftsmen and others for cutting roofing materials, linoleum, and the like. The blade holder is said to have a forwardly movable guard for protecting the blade when not in use and provision for ready adjustment of the blade projection, convenient replacement of the blade, and storage space for extra blades. The holder has an open, forward end containing a rectangular cavity adapted to receive the guard in sliding association. The guard has a blunt nose-shaped forward end, side grooves, a rectangular recess adapted to receive the blade and a flat cover piece, and an elongated opening through the upper portion of the guard. A finger knob protrusion is provided in the rear bottom portion of the guard to allow a user to slide the guard backward and forward. Sliding the guard backward into the cavity of the holder exposes the blade, while sliding the guard forward shields the blade. A bolt penetrates one side of the holder. The bolt passes through the blade guard, an alignment notch atop the blade, and the cover piece; and thence through the opposite side of the holder, where it is engaged by a nut. Tightening the nut secures the blade and guard in position. The blade is in-line with the handle and not transversely angled and rigidly mounted.
[0009] U.S. Pat. No. 2,788,574 to Marcmann discloses a utility knife having a handle and blade which may be fixed in a number of different positions therein to suit different cutting purposes. The blade may be set to project in a straight line from one end of the handle to provide blades of different lengths and with different amounts of cutting edge and different degrees of rigidity or stiffness. The blade may also be set at an angle to the length of the handle for cutting linoleum and similar materials. The blade is not symmetrical with respect to its first opening. It has one end located at a greater distance from the first opening, and is inclined to the longitudinal axis of the blade at a greater angle than the opposite end. The blade may thus be mounted in the holder in a plurality of alignments which provide different lengths of exposed cutting edge and different degrees of blade rigidity. The blade may further be provided with a second opening so that the locating pin may be passed through the second opening while one end edge of the blade abuts one side of the recess in the second part. When so mounted the blade projects downwardly at an angle from the holder. The blade is in-line with the handle and not transversely angled and rigidly mounted.
[0010] U.S. Pat. No. 3,107,426 to Robinson, Jr. discloses a utility knife having a knife blade adapted for slidable movement between a safety position within the knife handle and an extended cutting position. The knife comprises an elongated handle having a blade-receiving slot at one of the ends thereof. The handle comprises two elongated members detachably secured and separable along a longitudinal plane extending rearwardly from the slot opening. A carrier is reciprocally mounted on one of the elongated members for movement toward and away from the slot opening. A blade is supported on the carrier and has parallel edges that engage side flanges extending from the base of the carrier. An elongated tongue extends rearwardly from the carrier and engages a locking cam surface on the handle. A button is fixed to the tongue and may be depressed to move the tongue out of engagement with the locking cam surface, and to slidably reciprocate the tongue within the handle. The knife may further comprise a compartment for storage of spare blades. The members of the handle are secured by a screw. Significantly, the knife blade retraction mechanism requires that the blade and the inside surfaces of the handle halves be substantially coplanar. The knife, therefore, lacks transverse blade angulation.
[0011] U.S. Pat. No. 3,324,548 to Mascia discloses a tool-holding knife comprising a handle, a bifurcated tool holder, and blade. The knife is said to be especially useful for cutting linoleum, vinyl, carpeting, and the like. The tool holder is provided with two branches, spaced apart by rivets which also serve to buttress various of the blades which are usable with the tool holder and appointed to be situated between the branches. Several positions are described for mounting the blades in the holder, including a straight knife position, a generally perpendicular scraping position, and a downwardly angled position for cutting linoleum or the like. A blade must be inserted between two closely spaced branches of the device and is held by friction. Here again the blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0012] U.S. Pat. No. 3,380,159 to Winston discloses a cutting device for opening shipping containers and the like of cardboard or similar material. The cutting device is designed to prohibit the damage of merchandise contained therein. The device is preferably formed of two flat sheets of heavy gage sheet metal pivotally affixed to one another at one end by a pivot pin. The sheets are formed to provide oppositely disposed cavities between them for storage of spare cutting blades. The ends of the sheets opposite the pivoted end are formed to provide a cutting blade retainer. The edges of the sheets form a straight edge on the retainer, which is angularly disposed with respect to the handle to provide a clearance for the knuckles and fingers of a user of the cutting device. The cutting blade retainer has a recessed blade cavity of substantially the same depth and width as the thickness and width, respectively, of a cutting blade seated in the retainer. A shoulder bolt is inserted through aligned apertures in the blade and the sheets, and engages a nut to fasten the blade and sheets together. The end of one of the sheets further comprises an extended end formed to provide a runner support and a runner extending below and substantially perpendicular to the runner support and in a parallel spaced relationship to the straight edge, thereby forming a slot. The runner preferably has a semi-round cross-section to give it sufficient strength to pierce cardboard without buckling or flexing. The runner also has an outwardly curved surface facing away from the slot to provide protection for the merchandise contained within the shipping container by allowing only a minimal amount of the runner to be in touch with the merchandise Significantly, the runner structure of the knife limits the extent of blade penetration and thus severely limits the utility of the knife for glazing and similar operations wherein a blade is expected to penetrate to a substantial depth perpendicular to the cutting surface. Moreover, the lack of transverse angulation of the in-line cutting blade further restricts suitability of the device for outside cutting operations.
[0013] U.S. Pat. No. 3,906,625 discloses a utility knife comprising a handle and a blade removable therefrom. The handle comprises a sleeve-like handle member having a cavity portion therein and a blade carrier member. The cavity portion comprises a longitudinal slot with the handle being open at its base and at one end of the slot. The carrier is pivotally mounted to the handle at the other end thereof opposite from the open slotted end for pivotal movement into and out of the cavity. The carrier has a longitudinal extent substantially equivalent to that of the longitudinal handle and has a plurality of studs at its end adapted to support a perforated cutting blade in a plurality of orientations relative to the handle. The blade carrier also comprises an integral, resilient clip portion for fixedly holding replacement blades for storage and resilient protrusions, which assist in holding the blade carrier within the handle in the closed position. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0014] U.S. Pat. No. 4,575,940 to Wenzel discloses a carpet layer's knife having a handle and blade holder for demountably securing a heavy-duty, razor-style blade having two generally parallel sharpened edges and an open center section with a slot elongated in a direction parallel the sharpened edges, for mounting the blade in the handle. The holder comprises two body sections, which part along a medial longitudinally extending plane. The body sections have blade-holding portions at one end. A screw connecting means, which tightens to clamp the blade between the blade holding portions, connects the body sections. A shoulder formed in the blade-holding portion of one of the body sections passes through the center slot in the blade and provides support against rotation of the blade in its plane during use of the knife. Resilient means comprising a spring, surrounds the screw connecting means to urge the body sections apart when the screw connecting means is loosened, thereby facilitating insertion and removal of blades. The screw connecting means is provided with a manually engageable extension such as a D-ring for applying torque to the screw without necessity of an additional tool, such as a screwdriver, when changing blades. A blade compartment may be provided for storage of spare blades. Significantly, the knife is angulated longitudinally: the blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0015] U.S. Pat. No. 4,713,884 to Dunnagan discloses a hand-held knife for use in cutting carpet pads. The knife comprises a handle having a pair of handle members generally abutting at a median plane, a blade is positioned therebetween, and a releasable fastener clamps the handle members together and secures the blade. The use of the knife depicted is said to reduce the propensity of carpet pad to wrinkle while being cut, thereby improving the accuracy of the cut and decreasing the fatigue experienced by the carpet pad installer. The knife comprises a handle portion, a forwardly projecting blade support portion formed at generally an angle of 30 to 45 degrees with respect to the long dimension of the handle, and a heel at the transition between the portions. A raised boss present on the inside surface of one of the blade support portions of the right side member of the handle is sized to be received in a longitudinal slot present in a knife blade of conventional design. The orientation of the boss establishes the angle of the blade cutting edge with respect to the handle. A thumbwheel having a threaded extension penetrates an aperture in one half of the handle generally at its heel and engages a corresponding internally threaded aperture in the opposite handle half to clamp the halves together and secure the blade in position. The handle members may optionally comprise a storage compartment for spare knife blades. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0016] U.S. Pat. No. 4,884,342 to McNamara et al. discloses a cutting device including a handle and a blade particularly adapted for cutting wallpaper. The handle is elongated and comprises two half-handles secured together. At least one of the half-handles has a lengthwise internal passageway in its sidewall and at least one of the half-handles has a lengthwise external opening in its sidewall, the opening and the passageway being at least partially coextensive. An elongated blade is slidably and retractably mounted between the sidewalls and is extendable from the front end of the handle. A protruding member is slidably mounted within the internal passageway and is removably fixed to the blade. A biasing means is positioned against the blade to hold the blade against the protruding member. A releasing means is provided for moving the blade laterally against the biasing means so as to allow the blade to be released from the protruding member, thereby facilitating replacement of the blade. An adjustment means slidably mounted in the opening allows the extension of the blade from the handle to be varied. A roller means is situated at the front end of the handle to guide the blade along a cutting path. A guidance mechanism is rotatably connected to the handle. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0017] U.S. Pat. No. 5,014,429 to McNamara discloses a utility knife including a mechanism for detaching individual segments from a segmented knife blade. The knife includes a housing having two mating, spaced side wall portions with a channel therein to house and guide a blade. One end of the channel terminates within the housing, while the other end opens to form an exit slot from which the blade may protrude. An adjustment mechanism is disposed for back and forth sliding movement within a slot in the sidewall. A boss is provided on the adjustment mechanism to engage an aperture in the blade. One of the sidewalls also has a recess to accommodate a spring member which provides a force both to bias the blade against the opposite side wall portion, thereby presenting rattling or lateral displacement of the blade, and to bias the blade against the adjustment member to maintain engagement of the boss with the blade. The sidewall further accommodates a mechanism to allow individual segments to be severed from the blade and capture the severed piece in a safe manner for disposal. The mechanism comprises a transversely oriented plunger which, when depressed against the blade, causes fracture of the blade along a pre-formed segmentation line. Opposite the plunger in one of the sidewalls is a recess appointed to receive the severed blade segment, thereby restraining it from flying away from the knife uncontrollably. An aperture is provided in the recess, from which the severed segment may be removed at the user's convenience. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade
[0018] U.S. Pat. No. 5,241,750 to Chomiak discloses a utility razor safety knife having a handle and a blade and a blade guard attached thereto. The blade guard comprises an open-bottomed hood pivotally secured to the handle by a screw and biased to the closed position by springs whose bottom ends terminate on footing rests on the sides of the yoke and whose top ends engage a yoke attached to the top of the handle. The screw also acts to secure the blade between complementary halves of the handle. In the closed position, the blade guard both protects the user from the blade cutting edge and protects the blade from being inadvertently nicked or dulled. The knife is used by grasping the handle and pressing the open side of the hood into the article to be cut, thereby causing retraction of the biasing springs and exposure of the blade edge. The footing rests serve to maintain the blade generally perpendicular to the surface being cut and to limit the depth of penetration of the blade. After completion of the cut and withdrawal of pressure on the handle, the springs again urge the blade guard into the closed position. The knife lacks transverse angulation of its blade. In addition, the blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0019] U.S. Pat. No. 5,490,331 to Gold provides a utility knife adapted both for cutting and scraping. The knife is provided with a retractable blade having a sharpened bottom edge for cutting and a sharpened front edge for scraping. A holder comprises two half-hand grips secured by a screw having a threaded shank and a large diameter cylindrical knurled head. Preferably the head extends laterally of the knife approximately 0.5 inch when tightened to provide additional grip when the knife is drawn rearwardly during cutting use of the knife. The holder is further provided with a downwardly projecting, finger-contacting member which serves as a stop for the user's hand when the knife is being forwardly pushed, as during a scraping stroke of the knife. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0020] U.S. Pat. No. 5,890,294 to Keklak et al. discloses a locking safety utility knife that includes a body and an operating lever, which is squeezed to deploy a retractable cutting blade from within the body. The blade can be locked in its retracted position by means of a ratchet-like mechanism including a pawl adapted to be released by manipulating a cam operator. The pawl engages teeth formed on the outside of a door, which closes the rear of a compartment formed in the operating handle to house spare blades. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0021] U.S. Pat. No. 5,906,049 to Butts discloses a double-ended utility knife with a blade at each of its ends. The two blades are independently reciprocally extendible from respective compartments within the body of the knife and may be of different shapes. The knife comprises a generally rectangular base member having a front side and a backside and front and back covers adapted to be attached to the front and backsides. Each of the covers extends less than the total length of the base member. The provision of separate covers partially covering the respective front and back sides of the base member allows either of the blades to be changed independently without exposing the other and possibly allowing it to be inadvertently dislodged. Each of the blades extendible from the knife is coplanar with the base member of the knife. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0022] U.S. Pat. No. 5,940,970 to D'Ambro, Sr., et al. discloses a utility knife including a holder having two mating halves, a first cavity at a proximal end of the holder for receiving a blade for active use and a second cavity located toward a distal end of the holder for receiving and storing a supply of replacement blades. The mating halves are joined by a hinge at the distal end of the holder and a captive screw closure extending between the mating halves at a position intermediate the first and second cavities. The first cavity incorporates a magnet for engaging the active blade, while the second cavity incorporates a magnet for additionally engaging one or more replacement blades. The knife blade in the patented utility knife is situated generally coplanarly with the mating interior surfaces of the halves of the blade holder. Hence, the blade extends straight from the holder without angulation. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0023] U.S. Pat. No. 6,192,589 to Martone et al. discloses a utility knife including a main body, a blade holder assembly movably mounted within the body, and a manually engageable member slidably mounted on the main body. The blade holder is movable between a retracted position wherein the blade is disposed within the body and an extended position wherein the blade protrudes outwardly from the main body to enable a cutting operation. The manually engageable member is operatively connected with the blade holder assembly and is movable to extend and retract the blade holder assembly. The utility knife further comprises a blade storage member pivotally connected with the main body. The blade storage member is appointed to carry a supply of spare blades. The utility knife also includes a locking structure constructed and arranged to releasably lock the blade storage member in its closed position. Significantly, the knife blade retraction mechanism requires that the blade and the inside surfaces of the handle halves be substantially coplanar. The blade is in-line with the handle and lacks rigid mounting needed for an angled blade.
[0024] Utility knifes of various kinds, which have been described and used by prior art workers, all place the knife in-line with the handle and minimize protrusion of the knife to reduce blade breakage. Any angulation suggested is within the plane formed by the handle and the plane of the knife. This arrangement of the knife components fails to solve a troublesome problem encountered by glaziers and sheet rock workers, namely the need to make perpendicular cuts in tight corners. Such cuts require long blade lengths and close placement of a worker's hand in tight corners increasing the risk of injury. An in-line placement of blade and handle prevents a close approach of the knife to the wall edge, due to the size of the worker's hand and in-line location of the blade; it clearly increases the risk of injury.
[0025] Key factors that would be desirable when constructing a utility knife for glaziers include transverse angulation to prevent the worker's hand from being in the path of the blade. The transverse angulation would also permit closer knife approaches to corners. It would enable maintenance of a vertical cut and provide adequate blade support to minimize breakage of the angled blade, which encounters substantial pressure during use. However, structures which provide the functionality requisite for achieving these key factors have not previously been proposed by prior art workers.
[0026] As a consequence remains a need in the art for a utility knife for glaziers and sheet rock workers, which provides transverse angulation and adequate blade support. Also there is need for knifes usable by left-handed and right-handed users. This need has heretofore not been met by conventional utility knives.
SUMMARY OF THE INVENTION
[0027] The present invention provides a double-edged utility knife having a transverse angulation feature that enables carpet cutting and glue scraping, roof work, glazing and sheet rock operations to proceed in a safe, efficient and reliable manner. Generally stated, the double-edged utility knife has a two-piece handle comprising a left section and a right section. A reversible double-edged detachable blade with an anchoring hole is mounted on a locating pin, and attached firmly to the left section or right section. The locating pin locates the blade from forward or reverse motion. The blade is held firmly between the left and right sections, within a channel by clamping the sections together and fixing them in the clamped condition using a fastening means such as a pair of screws, a countersink and threaded tap-hole, which locate the blade firmly in the horizontal plane. A channel in the right side member firmly captures the top and bottom edge of the double-edged knife blade against the top and bottom edges of the milled channel and locates the blade in the vertical plane. This rigid attachment means grips the blade firmly by the blots within the channel located by the locating pin and allows longer protrusion of the blade, more than 50% of the length of the blade, without excessive blade bending meeting the needs of glaziers, roofing contractors, carpet installers and sheet rock workers. The right section has a hollow portion providing a milled compartment in the right side member for holding one or more blades.
[0028] Each of the double-edged blades has symmetrical geometrical structure with four cutting edges and two or more sharp corners. The double-edged blade is therefore reversible end-to-end and side-to-side to provide a fresh cutting edge. The double-sided blade may be replaced with a new blade from the storage compartment within the right side of the handle. If the utility knife is exclusively used for left-handed or right-handed use, the blade may be turned upside down to provide a fresh unused sharp edge. The blade has two holes, which match with the locating pin. The double edge blade is suited for use as a utility knife for left-handed or right-handed cutting without any blade adjustment.
[0029] As a consequence of the transverse angulation of its handle, the utility knife is especially convenient for use in window glazing applications, roof cutting or carpet cutting, since the hand is not located in-line with the blade. The transverse angulation may be in the range of 10 degrees to 80 degrees and more preferably between 30 to 45 degrees. The knife no longer needs to be angled in making cuts in tight corners and cuts, which is essentially perpendicular to the surface can be easily made since the size of the hand is accommodated by the transverse angulation of the handle. The utility knife can be used in right angle applications such as scoring of linoleum or sheet rock in tight places, such as corners and the like. Previous utility knives have been stubby and straight. These prior art configurations prevented facile operation of the knife, owing, in part, to interference from the operator's hands.
[0030] The double-edged utility knife of this invention is designed to address a common system for window glazing that comprises use of a frame having a right-angled open channel to accommodate a glass pane. The glazing is accomplished by placing a bed of putty or similar glazing compound along the inside vertex of the channel and then inserting a pane of glass into the bedding compound. The pane is pressed to extrude any excess putty and assure complete coverage of the edge and a fully hermetic seal. The pane may then be secured with glazing points or similar fasteners.
[0031] This system is intended to allow replacement of broken glass in a simple manner. However, extraction of the old pane frequently requires use of a sharp knife or similar flat cutting instrument to break the putty seal between the flat surface of the glass near its edges and the sides of the right-angled frame generally parallel thereto, requiring a perpendicular cut. Conventional straight utility knifes, putty knives, or razor blades are often used for this task but have proven to be poorly suited and, in some cases, even hazardous to the artisan. With each of these tools, the user's hand gripping the handle prevents the blade from being aligned with the perpendicular plane of the gap between the window and the frame. The user may attempt by downward pressure against the glass to bend the blade to align and insert it in the gap for cutting. However, the bending and pressure entail significant risk of injury, as the generally brittle blade may snap and project sharp fragments or the glass may fracture and expose the user's hand to laceration. In marked contrast, the transverse angulation of the present knife and stable knife support system obviates these difficulties. Inadvertent breakage of blades is reduced or eliminated. The present utility knife allows making cuts, which are essentially perpendicular to the surface easily, a feature unavailable in knifes where the handle is in-line with the knife blade. The force applied by the user against the glass is significantly lower than that heretofore required to bend the blade of prior art glazing knives. This, in turn, greatly reduces the risk of injury to the artisan from broken glass or blades. The present knife is also far less likely to nick or otherwise damage the window frame.
BRIEF DESCRIPTION OF DRAWINGS
[0032] The invention will be more fully understood and further advantages will become apparent when reference is had to the following detailed description and the accompanying drawings, in which:
[0033] FIG. 1 a is a perspective view of a double-edged utility knife at 10 , which accepts a variety of double-edged blades suited for various applications including carpet installers, roofers and glaziers in the as supplied condition, showing the front view and top view of the transversely angulated knife;
[0034] FIG. 1 b is top view of double-edged utility knife of FIG. 1 a;
[0035] FIG. 2 a is a front view of the details of right side member 14 ;
[0036] FIG. 2 b is a top view of the details of right side member 14 of FIG. 2 a;
[0037] FIG. 3 a is a front view and top view of the details of left side member 12 ;
[0038] FIG. 3 b is a top view of the details of left side member 12 of FIG. 3 a;
[0039] FIG. 4 is a perspective view of the details of a corner utility blade knife element 16 in a configuration as a wallboard blade;
[0040] FIG. 5 is a perspective view of the details of a corner utility blade knife element 16 in a configuration as a combination carpet/scraper blade;
[0041] FIG. 6 is a perspective view of the of a corner utility blade knife element 16 for a roofing blade configuration; and
[0042] FIG. 7 is a perspective view of the of a corner utility blade knife element 16 for a glazier blade configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] As used herein, the term “double-edged utility knife” means that the utility knife is capable of making perpendicular cuts to surfaces which are in close proximity preventing conventional in-line knifes to be used due to their stubby construction as well as inability of hand which grips the handle to approach the region to be cut with the blade in a vertical position. The double-edged utility knife also has the ability to expose a fresh unused edge by reversing the blade side-to-side or left-to-right or use a new knife blade from the holding compartment. Since the double-edged knife blade is omni dexterous it may be used conveniently for left-handed or right-handed use. The double-edged blades have two holes which mate with a locating pin when the blade is rotated by 180 degrees. In both cases, the double-edged utility knife has a left and a right side member which holds the knife using a locating pin attached to the right side member and the two sides are securely held together using two set of bolts. The knife blade sits in a channel milled in the right side member so that it does not move. The knife is entirely locked in position within the handle and its position is not maintained by friction. The term ‘transversely angulated’ means that the knife blade is nominally perpendicular to the plane defined by the blade and the handle and the transversely angulated angle is the angle between the long direction of the handle and the long direction of the blade.
[0044] Key features of the design and application of the double-edged utility knife include 1) means for providing support for the knife in all three directions and providing a stable knife blade capable of cutting in the transverse angulated location which applies momentum to the blade; 2) means of clamping the blade in the transverse angulated position using a left side member, right side member, locating pin and clamping screws; 3) means of using the double-edged blade in a left-handed or right-handed configuration; 4) means of reversing a blade to expose fresh unused edges of a double-edged utility knife; and 5) providing four sharp edges per blade which may be exposed by either reversing or turning a blade upside down so as to maintain left-handed or right-handed use.
[0045] Referring to FIG. 1 a there is shown the front view and directly below it in FIG. 1 b a top view of a right-handed utility knife for wallboard use in 10 . It shows an extended knife blade element at 16 , where it protrudes more than 50% of its length and is held by the left side member 12 and the right side member 14 . The left hand member 12 is shown as a transparent body in FIG. 1 b to illustrate the details of placement of the double-edged wallboard blade 16 . The knife blade element 16 is held tightly between the left and right side member by the clamping means of a bolt 20 that passes through left side member and is threaded into a hole at 27 in the right side member 14 . The clamping method may be other than use of a bolt as indicated in the drawing. The holes in the knife blade element 16 mate with a pin or ball protrusion 18 in the right side member 14 , and the knife blade element rests in a milled channel 17 in the right side member 14 . Alternatively, the pin may be attached to the left side member or may be located in holes drilled in the left and right side members. The tip 24 of left side member 12 slides inside a shoe like protrusion in the right side member at 23 . The knife blade is easily removed by loosening the bolts 20 , and separating the left side member and the right side member. The right side member 14 has a milled cavity at 19 to hold extra knife blade elements 22 . Since the double edges blade element 16 is symmetrical it may be used in a left-handed or right-handed configuration without any modification to the double-edged blade.
[0046] Structural details concerning the double-edged utility knife are shown in FIGS. 2 a , 2 b , 3 a and 3 b . In FIG. 2 a there is shown a front view detailing right side member 14 . Directly below, in FIG. 2 b , a top view of the right side member is depicted. A channel 17 is milled in the inclined portion to accept the knife blade. The width of the milled channel is exactly same as the width of the double-edged knife blade and is designed to fit as a loose fit. The depth of the milled channel is slightly less than that of the double-edged knife blade thickness so that when the left and right side members are clamped, the knife blade is firmly held. It also shows the milled opening which houses at least three spare knife blades at 19 . The right side member carries the locating pin or ball protrusion 18 within the milled channel 17 , as shown to receive the hole in a knife blade element. It has a threaded hole at 27 to accept the bolt 20 , which accomplishes the clamping action of the left and right side members. Right side member 14 has a shoe-like protrusion at 23 to accept the tip 24 of the left side member. The threaded portion of the bolt is only as deep as that of the right side member and the bolt fits as a sliding fit into the left side member. Thus, the shoe firmly holds the knife blade element in between the left and right side member even when force is applied to the knife blade.
[0047] FIG. 3 a illustrates the details of the front view of left side member, 12 and its top view is shown in FIG. 3 b . The tip 24 of left side member 12 is designed to slide into shoe 23 of the right side member slides and capture the knife blade element 16 . The hole at 28 is a clearance hole for the bolt 20 .
[0048] Referring to FIG. 4 , the detail of the double-edged knife blade element 16 of FIG. 1 configured as a wallboard blade is shown at 40 . The double-edged wallboard blade has two sharp edges at 42 and two locating holes at 44 . The double edge wallboard blade has four sharp corners suited for scoring wallboards at 43 . This double-edged wallboard blade may be used in the forward direction or reversed direction for left-handed or right-handed operation.
[0049] Referring to FIG. 5 , there is shown further structural details concerning the double-edged knife blade element 16 of FIG. 1 . As illustrated by FIG. 5 , the double-edged knife blade is configured as a combination carpet/scraper blade, shown generally at 50 . The double-edged carpet/scraper blade has a sharp edges at 52 and two locating holes at 54 . The double edge carpet/scraper blade has four sharp corners suited for scoring carpets at 55 . The sharp edge at 53 is used for scraping carpet glue. This double-edged carpet/scraper blade may be used in the forward direction or reversed direction for left-handed or right-handed use.
[0050] Referring to FIG. 6 , the detail of the double-edged knife blade element 16 of FIG. 1 configured as a roofing blade is shown at 60 . The double-edged roofing blade has sharp hook like corners 63 , with sharp cutting edges 62 and two locating holes 64 . This double-edged roofing blade may be used in the forward direction only for left-handed or right-handed operation.
[0051] Referring to FIG. 7 , the double-edged knife blade element 16 of FIG. 1 is configured as a glazier blade, shown generally at 70 . The double-edged glazier blade 70 has a sharp edge 73 and two locating holes 74 . The double edge blade has two sharp corners suited for cutting into rubber bead of glass windows at 72 . This double-edged glazier blade may be used in the forward direction or reversed direction for left-handed or right-handed operation.
[0052] Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to, but that additional changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims. For example different locating member mechanism and blade clamping means may be used to retain the double-edged utility knife blade in the device.
|
A double-edged utility knife for carpet installers, roofers, glaziers and sheet rock workers has a two-part handle. The handle clamps a detachable reversible double-edged blade at a transverse angulated position with respect thereto. Vertical cuts can be made in tight corners without applying excessive force. The transversely angulated knife blade affords access permitting vertical cuts in tight corners. During cutting the user's hands are displaced from the cutting line, and kept from being inline with the cutting blades. Operation-induced injuries are virtually eliminated. The double edge blade is provided with a geometry especially well suited for wallboard, roofing, carpet cutting/glue scraping and glazier use.
| 1
|
BACKGROUND OF THE INVENTION
The present invention relates generally to cylinder locks, and more particularly to cylinder locks that use a complementary configured key and sidebar in conjunction with conventional lock mechanisms, such as tumblers. The sidebar is positioned at a precise axial position by a key positioning mechanism on the key, wherein the sidebar can engage grooves on the side of the key blade. This positioning facilitates the shifting of the sidebar from a locked position to an unlocked position and the key can rotate the cylinder plug.
Cylinder locks for locking doors and other similar structures are well known in the art. Typically these cylinder locks include a cylinder shell, cylinder plug located within the cylinder shell and tumblers extending there through. Further, a locking member, such as a deadbolt, rotates with the cylinder plug to lock or unlock the door, cabinet or other structure.
WO93/09317 (Prunbauer) describes a lock and a key system that utilizes a sidebar mechanism to prevent a cylinder from rotating, but is silent on the axial movement of the sidebar. Further, U.S. Pat. No. 5,797,287 (Prunbauer) is directed to a key, but discloses a system similar to Prunbauer WO093/09317.
German Patent DE2828343, issued to Perkut, discloses yet another key and lock system that uses tumblers to match up with the key ridges and further discloses a ball to use with the sidebar to facilitate rotation. U.S. Pat. No. 5,615,566, issued to Brandt, discloses a lock that has an axially sliding member at the back of the plug, as a secondary locking mechanism, used in conjunction with conventional tumblers.
Further, U.S. Pat. Nos. 6,477,875 and 6,945,082, both issued to Field et al., disclose a lock system that combines an axially sliding member operated by a contact tab integrally formed on a key, to facilitate release of the separate sidebar.
Notwithstanding the prior art, there still remains a need for a lock and key system that, among other things, combines the functions of an axially sliding member and a sidebar. Benefits of such a system include minimizing of moving parts, preferably making lock breakdown less likely, and increasing security of the lock itself.
SUMMARY OF THE INVENTION
In light of these and other benefits, a cylinder lock and a key to position an axially moving sidebar is disclosed herein. The cylinder lock of the present invention, generally, has a cylinder shell, a cylinder plug and a key. Additionally, it is preferred to use the present invention in conjunction with other conventional locking mechanisms, such as tumblers (discussed in detail in the prior art references mentioned above).
A door, cabinet or other structure houses the cylinder shell. The cylinder shell houses a rotatably mounted cylinder plug. The cylinder plug, broadly, has a spring loaded sidebar, a sidebar slot and a key path. The sidebar has a shoulder and an engraved face and is located within the sidebar slot. The sidebar slot has a first sidebar engagement region, a second sidebar engagement region, and a sidebar receiving area. The sidebar slot extends longitudinally substantially parallel to the key path; the key path being configured to facilitate receiving the proper key.
The key has a key positioning mechanism and short grooves that are both configured complementary to the side bar. The key positioning mechanism cooperates with the side bar positioning mechanism upon insertion of the key into the key path. The short grooves are configured complementary to the engraved face of the side bar to receive said engraved face. A proper key precisely positions the sidebar between the first sidebar engagement region and the second sidebar engagement region, in the sidebar receiving area. At this precise position, the sidebar can be shifted inward and the short grooves can receive the engraved face of the sidebar.
This foregoing description was meant to be general in nature and a more detailed description will explain the invention further. As previously mentioned, this novel cylinder lock and key are meant to be used in conjunction with other conventional locking means well known in the art and described in detail in references such as those previously mentioned.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut away sectional side view of the cylinder plug and an embodiment of an axially displaceable sidebar according to the present invention.
FIG. 2 is a side view of an embodiment of a key corresponding to a sidebar according to the present invention.
FIG. 3 is a bottom view of an embodiment of a key corresponding to a sidebar according to the present invention.
FIG. 4 is a cut away side view of the cylinder plug and an embodiment of an axially displaceable sidebar according to the present invention, wherein the axially moving sidebar has been precisely positioned in the sidebar receiving area.
FIG. 5 is a side view of a cylinder plug.
FIG. 6 is a sectional view from line A-A in FIG. 5 .
FIG. 7 is a side view of an embodiment of the sidebar.
FIG. 8 is a side view of an alternative embodiment of a sidebar according to the present invention.
FIG. 8A is a sectional view from line A-A in FIG. 8 .
FIG. 9 is a side view of an alternative embodiment of a sidebar according to the present invention.
FIG. 9A is a sectional view from line A-A in FIG. 9 .
FIG. 10 is a side view of an alternative embodiment of a sidebar according to the present invention.
FIG. 10A is a sectional view from line A-A in FIG. 10 .
FIG. 11 is a side view of an alternative embodiment of a sidebar according to the present invention.
FIG. 11A is a sectional view from line A-A in FIG. 11 .
FIG. 12 is a side view of an alternative embodiment of a key according to the present invention.
FIG. 12A is a bottom view from line A-A in FIG. 12 .
FIG. 13 is a side view of an alternative embodiment of a key according to the present invention.
FIG. 13A is a bottom view from line A-A in FIG. 13 .
FIG. 14 is a side view of an alternative embodiment of a key according to the present invention.
FIG. 14A is a bottom view from line A-A in FIG. 14 .
FIG. 15 is a side view of an alternative embodiment of a key according to the present invention.
FIG. 15A is a bottom view from line A-A in FIG. 15 .
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will be described in detail, specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.
It will be understood that like or analogous elements and/or components, referred to herein, are identified throughout the drawing by like reference characters. In addition, it will be understood that the drawings are merely representations, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.
Beginning with FIG. 1 , a cylinder lock according to the present invention broadly includes a cylinder shell 11 , a cylinder plug 10 , and a key 12 . The cylinder shell 11 is preferably located within a door, cabinet, or other structure. The cylinder shell 11 houses cylinder plug 10 . The elements not shown are well known in the art and one of ordinary skill in the art would be able to understand these separate elements and their relation to the present invention. It is preferred, although not required, to construct all of the components out of a metal, for example brass.
The cylinder plug 10 has a sidebar slot 14 , key path 16 and a sidebar 18 . The cylinder plug 10 further includes a face 20 and a posterior 22 . Extending from the face 20 substantially longitudinally throughout the cylinder plug 10 toward the posterior 22 is the key path 16 . Located within the key path 16 , the cylinder plug 10 has first and second configured faces 24 , 68 located on opposite sides of the key path 16 . Running relatively parallel to the key path 16 is the sidebar slot 14 . The sidebar slot 14 has a first sidebar engagement region 26 located proximate the face 20 and a second sidebar engagement region 28 located proximate the posterior 22 . Located between the first and second sidebar engagement regions 26 , 28 is the sidebar receiving area 66 . Positioned within the sidebar slot 14 is the sidebar 18 .
The sidebar 18 has a rear engagement wing 30 , a beveled projection edge 32 , a front engagement wing 34 , an engraved face 36 and a side bar positioning mechanism 38 shown here in the form of a shoulder 70 . The sidebar 18 is front-biased, preferably through the utilization of a spring 40 , and axially moveable. The rear engagement wing 30 is located proximate the posterior 22 and configured to operate with the second sidebar engagement region 28 . The beveled projection edge 32 extends outwardly away from the key path 16 and is received in a notch in the lock shell, not shown but well known in the art. The front engagement wing 34 is located proximate the face 20 and configured to operate with the first sidebar engagement region 26 . The engraved face 36 is located on a portion of the sidebar 18 that is exposed to the key path 16 . The side bar positioning mechanism 38 extends a distance into the key path 16 . Both side bar positioning mechanism 38 and engraved face 36 are configured to correspond with a key 12 .
A key 12 has a bow 42 and a blade 44 . The blade 44 has a front tip 46 and a base 48 . The blade 44 also can have a flat edge 50 located opposite a bitted edge 52 and a grooved face 54 located opposite a channeled face 56 . Not shown, but known in the art, is a key blade that has both edges bitted. As is well known in the art, the channeled face 56 contains a pattern of longitudinally running channels 58 which can be configured to correspond with the first configured face 24 of the key path 16 and the grooved face can be configured to correspond with the second configured face 68 of the key path 16 .
The grooved face 54 of the key 12 contains short grooves 60 and a key positioning mechanism 62 shown here as a contact tab 72 . The short grooves 60 run substantially perpendicular to the horizontal axis of the key B-B, but can also be at one or more unique predetermined angle 64 for each lock and key system. The short grooves 60 are configured to correspond to the engraved face 36 of the sidebar 18 .
The key positioning mechanism 62 may be located on the grooved face 54 of the key 12 . Alternatively contemplated, but not shown in this embodiment, is a key positioning mechanism 62 located on the channel face 56 of the key 12 . The key positioning mechanism 62 is configured complementary to the sidebar positioning mechanism 38 . The relationship of the key positioning mechanism 62 to the location of the short grooves 60 is configured complementary to the relationship of the sidebar positioning mechanism 38 to the engraved face 36 of the sidebar 18 .
There are many different embodiments of the key positioning mechanism 62 and sidebar positioning mechanism 38 . In a first embodiment of FIGS. 1 and 2 , the key positioning mechanism 62 may be a contact tab 72 which extends outward a distance on the blade 44 from the base 48 to a distance shorter than the length of the entire blade 44 . The sidebar positioning mechanism 38 for this embodiment is the shoulder 62 .
In a second embodiment shown in FIGS. 8 and 12 , the key positioning mechanism 62 is a channel 74 , which is shown, but not limited to, as being milled into the grooved face 54 of the key 12 . The side bar positioning mechanism 38 in this embodiment is a foot 76 . The channel 74 engages with the foot 76 towards the rear of the side bar 18 that may extend beyond the engraved face 36 .
In a third embodiment shown in FIGS. 9 and 13 , the key positioning mechanism 62 is a second contact tab 78 extending outward a distance from the grooved face 54 . It is also contemplated that the second contact tab 78 extends outward a distance from the channeled face 56 . Additionally, it is further contemplated to utilize the second contact tab 78 on both faces of the key 12 . The second contact tab 78 engages with the sidebar positioning mechanism, 38 , which in this embodiment comprises a notch 80 in the sidebar 18 .
In a fourth embodiment shown in FIGS. 10 and 14 , the key positioning mechanism 62 may be the channel 74 in the grooved face 54 , but the sidebar positioning mechanism is a peg 82 that extends away from the sidebar 18 into the key path 16 .
In a fifth embodiment shown in FIGS. 11 and 15 , the key positioning mechanism 62 may be multiple channels 74 , 74 ′ in the grooved face 54 , and the sidebar positioning mechanism may be multiple pegs 82 , 82 ′ extending away from the sidebar 18 into the key path 16 . The pegs 82 , 82 ′ must be precisely aligned vertically and axially with the multiple channels 74 , 74 ′ in the grooved face 54 . One or more of these multiple pegs 82 , 82 ′ can be configured to allow for multiple layers of masterkeying.
The bitted edge 52 of the blade 44 is meant to operate with conventional tumblers, well known in the art but not shown in the drawings. Also contemplated, but not shown, is the use of a second sidebar having a second sidebar positioning mechanism, a second set of short grooves and a second key positioning mechanism. This would even further increase the security measures of the novel cylinder lock and key blank. The novel cylinder lock will now be described in operation in conjunction with the novel key blank.
In preferable operation, the present invention operates to prevent rotation of the cylinder plug 10 when an improperly configured key 12 is inserted into the key path 16 of the cylinder plug 10 . When a properly configured key 12 is inserted into the key path 16 , the cylinder lock plug 10 can be rotated to disengage a functionally attached deadbolt, or other similar structure well known in the art.
The front tip 46 of the blade 44 of the key 12 can be inserted into the key path 16 . As previously stated, only a key 12 with a channeled face 56 configured to correspond to the first configured face 24 of the key path 16 and a grooved face 54 configured to correspond to the second configured face 68 of the key path 16 can be inserted; while, improper keys will be precluded from entering the key path 16 .
Prior to insertion of the key 12 , the sidebar 18 sits in a locked position. ( FIG. 1 ). In the locked position, the first sidebar engagement region 26 blocks the sidebar 18 from moving inward by contacting the front engagement wing 34 . As the blade 44 slides axially to the posterior 22 of the cylinder plug 10 , at a predetermined distance the key positioning mechanism 62 will engage the sidebar positioning mechanism 38 . As the blade 44 continues sliding further in the same direction, the sidebar 18 can move correspondingly because of the cooperation between the key positioning mechanism 62 and the sidebar positioning mechanism 38 .
At a precise distance when the proper key 12 is fully inserted, the key positioning mechanism 62 will have pushed/forced the sidebar 18 into the precise location (see FIG. 4 ) for enabling rotation of the key 12 , and, in turn, locking or unlocking the cylinder plug 10 . At this precise distance the front engagement wing 34 can clear the first sidebar engagement region 26 and the rear engagement wing 30 can clear the second sidebar engagement region 28 . ( FIG. 4 ). As a result of this precise axial positioning, the sidebar 18 will be able to shift inward to, in turn, enable operative engagement with the key 12 .
If a key 12 with an improper key positioning mechanism 62 is inserted, the sidebar 18 cannot be moved the precise distance. If the key positioning mechanism 62 is too far forward or if it is located at the improper location vertically to engage with the sidebar positioning mechanism 38 , the sidebar 18 will not be precisely positioned in the sidebar receiving area 66 because the front engagement wing 34 cannot clear the first sidebar engagement region 26 . On the other hand, if the key positioning mechanism 62 is too far to the rear, the sidebar 18 will be pushed too far toward the posterior 22 of the cylinder plug 10 causing the rear engagement wing 30 to become blocked/obstructed by the second sidebar engagement region 28 . Both of these scenarios will prevent the sidebar 18 from shifting inward toward the key blade 44 .
However, if a key 12 with a proper key positioning mechanism 62 is inserted, the sidebar 18 will be forced a precise and operative axial position within the cylinder plug 10 . (see FIG. 4 ). At this precise axial distance, the sidebar 18 can be shifted inward toward the key blade 44 . This inward shifting is typically achieved though cooperation of the beveled projection edge 32 and the notch. As the key bow 42 is turned, the cylinder plug 10 can rotate as well, in turn, rotating the sidebar 18 in the sidebar slot 14 of the cylinder plug 10 . At this point, the notch operates with the beveled projection edge 32 to shift the sidebar 18 inward toward the blade 44 .
As the sidebar 18 shifts inward toward the blade 44 , the engraved face 36 can abut the short grooves 60 . A blade 44 with short grooves 60 configured complementary to the engraved face 36 can receive the engraved face 36 , and the sidebar 18 can fully shift inward, allowing rotation of the cylinder plug 10 , and, in turn, the locking or unlocking of the door as described above. If the blade 44 has short grooves 60 that are not configured complementary to the engraved face 36 , the sidebar 18 can be prevented from shifting inward, thus preventing the rotation of the cylinder plug 10 .
As previously mentioned, this locking system is meant to be incorporated into a cylinder lock which incorporates standard and conventional locking elements, such, for example, tumblers which engage the bitted edge 52 of the blade 44 and the description has been limited to those novel elements of the present invention.
The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention.
|
A cylinder lock plug that utilizes an axially moving sidebar. The sidebar is displaced axially by a key positioning mechanism on the blade of a uniquely configured key. Also on the key are unique short grooves on the lateral sides of the key blade running substantially perpendicular to the longitudinal axis of the key blade. The short grooves are configured complementary to an inner surface of the axially moving sidebar. Only the properly configured key can receive the sidebar as the key is turned to rotate the cylinder lock plug and the short grooves receive the inner surface. The invention is meant to be used with additional locking mechanisms, such as, for example, tumblers.
| 4
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a mechanism for cutting a thread reserve of the spindles in a continuous spinning machine, which can secure a quick, effective and clean system for this operation.
[0002] When the continuous spinning machines were developed, it was necessary to replace the tubes already filled with thread with new clean tubes in an operation called “doffing-and-replacing” which was carried out by hand. This operation was modernized to become automatic in that the thread begins to be wound on the tube without hand intervention. At the moment when the doffing-and-replacing ends, before withdrawing the tube filled with a thread, some turns of them are wound, approximately within three and seven, at the lower part of the spindle. These turns of the thread are called “reserve”, which thereafter shall be removed. Then the tube with the thread is replaced with a new empty tube, and a new cycle starts automatically. It is then necessary to cut the reserve and to clean the spindle so that no debris of thread remain which could hinder the following automatic replacement of the tube.
[0003] For cutting of the reserve, several kinds of mechanisms have been developed. One of them is an individual mechanism for a spindle attached to a continuous machine, such as for example a thin film fixed in front of the spindle and driven by the traveling cleaning mechanism. The other mechanism is common to several spindles and is attached on the continuous machine, so that it travels through guideways located along the whole length of the continuous machine in front or on the rear of the spindles eliminating the reserve. These mechanisms can be driven by a device of the continuous machine or by an external element, such as for example a traveling cleaning device arranged over the continuous machine. All these mechanisms however are characterized by difficult regulation, high maintenance cost and low effectiveness, especially due to the difficult alignment of the guideways with respect to the spindles and their guide length which exceed 40 meters.
SUMMARY OF THE INVENTION
[0004] Accordingly, it is an object of the present invention to provide a mechanism for cutting a thread reserve of spindles in continuous spinning machines, which avoids the disadvantages of the prior art.
[0005] It is a further object of the present invention to provide a mechanism of the above mentioned general type, which cleans the reserves and secures that the spindle remains clean, in a simple and greatly efficient way.
[0006] In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a mechanism for cutting a reserve of thread of spindles of continuous spinning machines, comprising a cutting blade; an element which is draggable and which is adjustable without contacting an area of a spindle where there exists a thread of a reserve to be cut and removed; and means for regulating an adjustment of said element.
[0007] When the mechanism is designed in accordance with the present invention, it is formed as a single mechanism which is common to all spindles of one phase of the continuous machine, and for its displacement it is dragged by a second mechanism of the continuous machine or by an external element, such as a traveling cleaning mechanism as in the already existing systems.
[0008] The present invention is not affected by either the amount of spindles to be simultaneously cleaned, or the amount of spindles for which a single displaceable mechanism is applied or the way of dragging.
[0009] The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a side view schematically showing an external dragging element and the area of contact of a guiding element with a lower cylindrical part with a spindle of the inventive mechanism;
[0011] [0011]FIG. 2 is a view substantially corresponding to the view of FIG. 1 of the internal dragging element in the area of contact of the guiding element which prevents a direct contact with the lower cylindrical part of the spindle;
[0012] [0012]FIG. 3 is a view showing the dragging element of the continuous machine at its rear part in accordance with the present invention;
[0013] [0013]FIG. 4 is a view showing an enlarged detail of the dragging element of the continuous machine of FIG. 3;
[0014] [0014]FIG. 5 is a schematic plan view of a roll spindle and a roller which is moving copying the spindle or a protecting guideway as well as the dragging element of the mechanism;
[0015] [0015]FIGS. 6 and 7 show a further embodiment in a schematic side view of a triangle-shaped external dragging element in a schematic plan view in a row of spindles; and
[0016] [0016]FIGS. 8 and 9 are views showing a further embodiment of the inventive mechanism for simultaneously cleaning several spindles.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] A mechanism for cutting a thread reserve of spindles in a continuous spinning machine has a cylinder-shaped element 1 which is either composed of steel 9 , or coated with a slightly abrasive material, or is composed of metal with a final superficial treatment, or of some non-metallic material depending on its construction.
[0018] Depending on the kind of thread 14 (cotton, etc.), the above mentioned element can adapt one or another shape and one or another superficial finish. It can freely rotate, or can be driven or fixed. This element is a part of the mechanism which is suitably adjusted without contacting the area 2 of the spindle 9 , where the thread 3 to be removed, called reserve, exists.
[0019] The adjustment is regulated by a spring or an element for providing pressure 8 , a second element roller or guiding bearing 4 depending on the construction, the parts 5 for fastening them, and the support 16 attached to the frame 21 of the cleaning element which in turn is fixed on the dragging element 16 or 15 .
[0020] A guiding part for such as a roller or a rotating bearing or a flat part, etc. is provided. In the event that the element 1 and the guiding element 4 are cylinder-shaped, both elements can have a common axis or not, according to the construction and the type of the continuous machine. The spindles 9 of the machine can be slightly out of alignment with each other. The guideways 10 and 10 ′ which support the clearing mechanism called also mouse, can be also out of alignment. Therefore the cutting elements for the reserve developed up to now can not secure a correct and suitable adjustment between the element 1 and each of the spindles 9 , remaining too seperated from some of the spindles which thus are not cleaned, or too close to other spindles so as to come in contact with the risk of damaging the mechanism or the spindle.
[0021] The guiding element comes to directly and tangentially contact a copying part of the outline of the lower area 11 of the spindle 9 at its front or rear end. This part is generally cylindrical and forms a continuation with a similar cylindrical part 2 where the thread 3 to be cleaned is fixed. The spindle 9 or the guiding element 4 comes to contact with an equivalent element 12 , by means of which it can copy and know the accurate position of the spindle and which can be fixed for example in the spindlehead or bed, which has movement or not.
[0022] The roller 4 then accurately copies the position of each spindle 9 , locating itself at the position which always secures the correct adjustment between the element 1 and the area 2 of the spindle 9 where the thread to be cleaned or the reserve 3 is located. Thus, for copying of each spindle, the roller 4 can contact the cylindrical lower part 11 of the spindle 9 itself, or an equivalent element 12 as shown in FIG. 2, which allows to carry out the same “position copying” functions. Applying the roller 4 in the lower part of the spindle or on the equivalent wrapping element 12 does not limit the object of the present invention.
[0023] A spring or a similar pressing element 8 allows that the cleaning assembly and copier proper recovers the position. In addition, it allows the movement between the assembly support 16 and the frame 21 . The spring allows to accurately copy the position of each spindle 9 . Finally, a cutting element or blade is provided for the thread 3 .
[0024] [0024]FIG. 5 schematically illustrates the way the spindles 9 or equivalent element 12 copies by means of the roller or guiding bearing 4 .
[0025] The above disclosed mechanism allows to copy the spindle accurate position. In the event that the mechanism loses its vertical position shown in FIGS. 3 and 4, with the sham axis 19 it would not recover it. The vertical position can be lost, depending on the guiding system for the cleaning mechanism which can be installed in each kind of continuous machine, so that a mechanism for recovering the vertical position has been provided. This mechanism is optional and can be used or not.
[0026] The mechanism for recovering the vertical position is located close arranged to the cleaning mechanism. To the already known cleaning mechanism, a rotating movement with respect to the location point 17 and the spring or pressing element 18 are added as shown in FIGS. 3 and 4. When the spring 18 applies pressure and the cleaning mechanism is not located in front of any spindle, the axis 20 which is common to the cleaning mechanism 1 and the guiding rollers 4 remains inclined with respect to the sham axis 19 as shown in more detail in FIG. 4. Then, when the roller or guiding bearing 4 contacts a spindle 9 or equivalent element 12 by the spring or pressing element 18 and the relation of movement between the different elements of the system, such as the actual axis 20 and the sham axis 19 coincides again, the mechanism remains fully parallel to the axis of the spindle as shown in FIG. 3.
[0027] As explained herein above, the main feature of the present invention is that the mechanism for cutting and cleaning the reserve copies the accurate position of the spindle either by directly contacting the spindle or by contacting another part or element which has a concrete accurate position with respect to the spindle. The present invention is not limited to any of corresponding mechanisms, but instead deals with the idea of copying the position of the spindle by means of the mechanism or similar one. In connection with this, some modifications of the inventive mechanism within the spirit of the present invention are possible.
[0028] A triangle-shaped mechanism can be utilized, with the sides which are slightly curved to take the exact shape of the spindle or the element used for being positioned with respect to the spindle, so as to carry the same function as the above mentioned element with the roller or guiding bearing 4 . Together with the triangle-shaped element, a second element for protrusion of the triangle will carry out the same functions as the above mentioned element 1 . The triangle-shaped element will rotate in that case on a point located over the part and at the same time it will move forward along the continuous machine for cleaning the reserve of the spindle, as shown in FIGS. 6 and 7.
[0029] A mechanism for simultaneously cleaning several spindles can be provided in accordance with another embodiment. For each spindle to be simultaneously cleaned, an approximately half-arched-shaped part is made, which is formed of two parts. One part is used for cleaning the spindle and is equivalent to the element 1 and the other part is equivalent to the roller or guiding bearing 4 for copying the position of the spindle or the element which is equivalent to the element 12 to allow to position the mechanism with respect to the spindle taking the shape thereof.
[0030] Each of the half-arched part are attached to a common frame, and then the whole assembly can be moved toward the spindle for copying the position of the spindle, by matching different moves pressing elements if required. Also, the spindle can be taken apart from the spindle by a small move of a few millimeters, for escaping from the spindle, which allows to move a step forward and to clean the following group of spindles. This embodiment is illustrated in FIGS. 8 and 9.
[0031] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
[0032] While the invention has been illustrated and described as embodied in a mechanism for cutting a thread reserve of spindles in continuous spinning machines, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0033] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
|
A mechanism for cutting a reserve of thread of spindles of continuous spinning machines has a cutting blade, an element which is draggable and which is adjustable without contacting an area of a spindle where there exists a thread of a reserve to be cut and removed, and a device for regulating an adjustment of the element.
| 3
|
CROSS REFERENCE TO RELATED APPLICATION:
This application claims the benefit of U.S. Provisional Application No. 61/015,586 filed Dec. 20, 2007.
FIELD OF THE INVENTION
The present invention is directed in part to a lubricating oil composition containing an oil of lubricating viscosity, a N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine and a lubricating oil additive. Particularly effective is a combination of a N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine and a second antioxidant such as diarylamine which together provide superior oxidation inhibition.
BACKGROUND OF THE INVENTION
Diarylamine antioxidants are known and have been widely used to improve the thermal-oxidative stability and/or light induced degradation in numerous products used in engineering; for example, they can improve the performance properties in lubricants, hydraulic fluids, metal working fluids, fuels or polymers, just to name a few.
Commonly, these diarylamines have been alkylated, see for example, U.S. Pat. No. 2,943,112 which discloses an improved process for alkylating diphenylamine and U.S. Pat. No. 3,655,559 which discloses alkylated diphenylamines as stabilizers. Alkaryl substituted diphenylamines and phenylnapthylamines (such as α-methylstyryl-diphenylamine) are disclosed for example in U.S. Pat. Nos. 3,533,992; 3,452,056 and 3,660,290.
Synergist and antagonist combinations of antioxidants have been disclosed. Effective synergistic mixtures of antioxidants are typically compounds that intercept oxidation by two different mechanisms. For example, those in which one compounds functions as decomposer of peroxides and the other compound functions as an inhibitor of free radicals. Well known heterosynergism has been disclosed between sulfur and phosphorous containing compounds (such as sulfides, dithiocarbamates, phosphites and dithiophosphates) and aminic or phenolic antioxidants. U.S. Pat. No. 2,718,501 discloses a synergistic mixture of a sulfur-containing compound, such as a wax sulfide or dioctadecyl disulfide, and an aromatic amine compound having at least 2 aromatic rings, such as phenyl alpha-naphthyl amine, for use in preventing oxidation in lubricating oils. For example, U.S. Pat. No. 2,958,663 discloses an extreme pressure lubricant composition containing from 0.01 to 5 percent each of sulfurized oleic acid, C 18 -C 22 alkenyl succinic acid, chlorinated paraffin wax containing from 20 to 60 percent chlorine, diphenylamine and N,N-salicylal-1,2-propylenediamine. U.S. Pat. No. 3,345,292 discloses stabilized alkyl substituted diaryl sulfides for use as functional fluids where the stabilizer can be diaryl amine or alkylated phenol. U.S. Pat. No. 4,032,462 discloses lubricants having improved antioxidancy having an oil soluble antimony compound and an oil soluble antioxidant selected from sterically hindered phenols and thiophenols, and aromatic amines, and mixtures of these antioxidants. U.S. Pat. No. 4,089,792 discloses lubricants having a an antioxidant mixture of a primary amine and an antioxidant selected from aromatic or alkyl sulfides and polysulfides, sulfurized olefins, sulfurized carboxylic acid esters and sulfurized ester-olefins. U.S. Pat. No. 4,102,796 discloses lubricants having an antioxidant mixture of aromatic and alkyl sulfides and polysulfides, sulfurized olefins, sulfurized carboxylic acid esters and sulfurized ester-olefins and a secondary aliphatic amine. U.S. Pat. No. 6,306,802 discloses of an antioxidant mixture containing a combination of an oil soluble molybdenum compound and an aromatic amine.
Commonly, antioxidant compounds which were intended to decompose hydroperoxides or peroxides (including sulfurized olefins, metal dithiocarbamates, dithiophospates, phosphites, thioesters, etc.) are increasingly difficult to incorporate into the finished lubricant due to the undesirable amounts of sulfur, phosphorous and ash content they add to the lubricating oil composition. It is known that sulfur, phosphorous and ash content may negatively impact pollution control devices (such as poisoning catalysts, etc.) which are finding increasing application. Thus, there is a need for new antioxidants and antioxidant systems which do not negatively impact pollution control equipment yet provide improved antioxidancy performance to handle the typical higher operating temperatures and longer service life desired. Synergistic antioxidant systems are particularly important since they reduce the overall additive impact. For example, some antioxidants such as diphenylamines cannot be used at relatively high concentrations since this may result in sedimentation or deposits in hot engine areas such as the diesel ring areas in diesel engines. Thus, one aspect of the invention is directed to an improved antioxidant system comprising a free radical antioxidant and an effective peroxide decomposer selected from an tetraalkyl-naphthalene-1,8-diamine.
SUMMARY OF THE INVENTION
The present is directed in part to a lubricating oil composition which provides improved oxidation stability. Accordingly the compositions of the present invention have various uses such as lubricants for automotive and truck crankcase lubricants; as well as transmission lubricants, gear lubricants, hydraulic fluids, compressor oils, diesel and marine lubricants. The lubricating oil compositions of the present invention comprise at least one oil of lubricating viscosity, an oil soluble antioxidant according to formula I:
wherein R 1 , R 2 , R 3 and R 4 are each independently selected from alkyl groups each having from 1 to 20 carbon atoms, and at least one additive selected from antioxidants, dispersants, and detergents. The antioxidant according to formula I is effective by itself when employed in a lubricating composition. However, there is an improvement in antioxidancy performance when the compounds of formula I are employed with a free radical antioxidant. Thus another aspect is directed to a lubricating oil composition comprising an oil of lubricating viscosity and an antioxidant is a mixture comprising: a) from 0.1 to 10 weight percent of a first antioxidant according to formula I:
wherein R 1 , R 2 , R 3 and R 4 are each independently selected from alkyl groups each having from 1 to 20 carbon atoms; and
b) from 0.01 to 10 weight percent of a second antioxidant selected from the formula
wherein R a and R b are each independently aryl from 6 to 10 carbon atoms which may be unsubstituted or substituted with one or two alkyl groups each having from 1 to 20 carbon atoms.
Improvement of the combination of component a) and component b) is demonstrated at ratios of component a) to component b) from about 0.5:1 to about 10:1 and even more particularly from about 0.75:1 to about 5.1. Due to the demonstrated improvement in oxidative stability of the composition afforded by the mixture of components a) & b), the mixture of these components present in the total composition is less than 5 weight percent. More preferably the mixture of a) & b) is from 0.5 to 2.0 weight percent based on the total weight of the composition.
The composition defined above can contain other additives. Thus another aspect of the present invention further comprises an oil soluble molybdenum compound. A particularly preferred oil soluble molybdenum compound is an unsulfurized or sulfurized oxymolybdenum containing composition prepared by (i) reacting an acidic molybdenum compound and a basic nitrogen compound selected from the dispersant group consisting of succinimide, a carboxylic acid amide, a hydrocarbyl monoamine, a phosphoramide, a thiophosphoramide, a Mannich base, a dispersant viscosity index improver, or a mixture thereof in the presence of a polar promoter, to form an oxymolybdenum complex. More preferably the basic nitrogen compound is a succinimide.
The composition above can further comprise an oil-soluble, phosphorus-containing, anti-wear compound selected from the group consisting of metal dithiophosphates, phosphorus esters, amine phosphates and amine phosphinates, sulfur-containing phosphorus esters, phosphoramides and phosphonamides. Preferred said phosphorus esters are selected from the group consisting of phosphates, phosphonates, phosphinates, phosphine oxides, phosphites, phosphonites, phosphinites, and phosphines. Particularly preferred oil-soluble, phosphorus-containing, anti-wear compound is a metal dithiophosphate, such as zinc dialkyldithiophosphate.
Further provided is a method for lubricating an internal combustion engine comprising supplying the lubricant composition described herein above to the engine. As noted, the compounds of formula I are useful as antioxidants, thus one aspect is directed to the use of the compounds of formula I in a lubricating oil composition for oxidation retardation purposes.
DETAILED DESCRIPTION OF THE INVENTION
Inhibition of free radical-mediated oxidation is one of the most important reactions in organic substrates and is commonly used in rubbers, polymers and lubrication oils; namely, since these chemical products may undergo oxidative damage by the autoxidation process. Hydrocarbon oxidation is a three step process which comprises: initiation, propagation and termination. Oxidative degradation and the reaction mechanisms are dependent upon the specific hydrocarbons, temperatures, operating conditions, catalysts such as metals, etc., which more detail can be found in Chapter 4 of Mortier R. M. et al., 1992, “Chemistry and Technology of Lubricants Initiation”, VCH Publishers, Inc.; incorporated herein by reference in its entirety. Initiation involves the reaction of oxygen or nitrogen oxides (NO x ) on a hydrocarbon molecule. Typically, initiation starts by the abstraction of hydrocarbon proton. This may result in the formation of hydrogen peroxide (HOOH) and radicals such as alkyl radicals (R.) and peroxy radicals (ROO.). During the propagation stage, hydroperoxides may decompose, either on their own or in the presence of catalysts such as metal ions, to alkoxy radicals (RO.) and peroxy radicals. These radicals can react with the hydrocarbons to form a variety of additional radicals and reactive oxygen containing compounds such as alcohols, aldehydes, ketones and carboxylic acids; which again can further polymerize or continue chain propagation. Termination results from the self termination of radicals or by reacting with oxidation inhibitors.
The uncatalyzed oxidation of hydrocarbons at temperatures of up to about 120° C. primarily leads to alkyl-hydroperoxides, dialkylperoxides, alcohols, ketones; as well as the products which result from cleavage of dihydroperoxides such as diketones, keto-aldehydes hydroxyketones and so forth. At higher temperatures (above 120° C.) the reaction rates are increased and cleavage of the hydroperoxides plays a more important role. Additionally, at the higher temperatures, the viscosity of the bulk medium increases as a result of the polycondensation of the difunctional oxygenated products formed in the primary oxidation phase. Further polycondensation and polymerization reaction of these high molecular weight intermediates results in products which are no longer soluble in the hydrocarbon and form varnish like deposits and sludge.
Since autoxidation is a free-radical chain reaction, it therefore, can be inhibited at the initiation and/or propagation steps. Typical oxidation inhibition by diarylamines, such as dialkyldiphenylamine and N-phenyl-α-napthylamine, also involves radical scavenging. The transfer of hydrogen from the NH group of the amine to the peroxide radicals results in the formation of a diarylamino radical which is resonance stabilized, thus prevents new chains from forming. A secondary peroxy radical or hydroperoxide can react with the diarylamino radical to form the nitroxy radical, which is also a very potent inhibitor. Hydroperoxide decomposers convert the hydroperoxides into non-radical products and thus prevent the chain propagation reaction. Traditionally organosulfur and organophosphorous containing additives have been employed for this purpose typically eliminating hydroperoxides via acid catalyzed decomposition or oxygen transfer. However as mentioned previously, increased concerns regarding total sulfur and/or phosphorous content in finished lubricating oil has led to efforts to find new hydroperoxide decomposers perhaps those that even react by a different mechanism. Also, increased demands have been placed on many functional fluids which have in-turn placed emphasis on new inhibitors.
The present invention is directed in part to a lubricating oil composition having an suitable oil of lubricating viscosity and a first component a) is a N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine compound which can serve as a particularly useful as a stabilizer and thus is typically employed with at least on other additive. Particularly applicable is component a) in combination with another antioxidant and moreover with component b) a secondary aryl amine, the combination has improved oxidation stability. Synergism has been suggested for combinations of different types of antioxidants also called heterosynergism due to the different mechanism of stabilizer, for example a combination of radical scavengers and peroxide decomposers. Additionally, it has been suggested even within the same class, compounds which act by a different reaction mechanism/rate may lead to synergistic results, for example combinations of hindered phenolics and alkylated diphenylamines has been studied. Heretofore, antioxidancy in lubricating oil had not be demonstrated for N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine nor has synergism been demonstrated for a mixture of a) N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine and b) a secondary aryl amine.
N,N,N′,N′-Tetraalkyl-naphthalene-1,8-diamine—Component a)
Component a) is a N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine which alone is particularly useful as an antioxidant and thus suited for use an antioxidant in a lubricating oil composition typically combined with other additives such as antioxidants, detergents and dispersants. Disclosed are particularly suited sterically hindered amine compounds according to formula I:
wherein: R 1 and R 2 and R 3 and R 4 are each independently selected from the group consisting of alkyl from 1 to 20 carbon atoms, more preferably alkyl from 1 to 10 carbon atoms and even more preferably lower alkyl from 1 to six carbon atoms. The alkyl groups above, can have either a straight chain or a branched chain, which are fully saturated hydrocarbon chain; for example, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, and the like, and isomers and mixtures thereof An example of a suitable hindered amine that may be used in the present invention is N,N,N′,N′-tetramethyl-naphthalene-1,8-diamine and sold by Sigma-Aldrich as Proton-sponge™. The N,N,N′,N′-tetramethyl-naphthalene-1,8-diamine is a strained molecule due to the close proximity to the dimethylamine groups. The free base is destabilized by the steric inhibition of resonance, van der Walls repulsions, and lone pair interactions. These strains are typically relieved by monoprotonation and formation of an intramolecular hydrogen bond and thus can effectively alter the equilibrium constant of the hydroperoxide decomposition reaction. This imparts a high basicity relative to normal aliphatic amines or aromatic amines and which is necessary to deprotonate a hydroperoxide. Deprotonation of the peroxide would render the oxygen-oxygen bond more stable toward decomposition into radicals. The strong basicity of the N,N,N′,N′-tetramethyl-naphthalene-1,8-diamine can be ascribed to the operation of several factors, e.g. the steric inhibition of conjugation in the free base, relief of nonbonded repulsions, including a little lone pair/lone pair repulsion, stabilization of the cation by the hydrogen bonding, etc. Clearly the N,N,N′,N′-tetramethyl-naphthalene-1,8-diamine structure is compromise involving several factors including a twist in the naphthalene ring system, favorable lone pair/π overlap, lone pair/methyl nonbonded interactions, and lone pair/lone pair repulsion.
The compounds of formula I are selected with sufficient alkyl groups to be oil soluble in the lubricating composition and thus the compound of formula I are combined with an oil of lubricating viscosity. The concentration of the compound of formula I in the lubricating composition can vary depending upon the requirements, applications and effect or degree of synergy desired. In a preferred embodiment of the invention, a practical N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine use range in the lubricating composition is from about 1,000 parts per million to 20,000 parts per million (i.e. 0.1 to 2.0 wt %) based on the total weight of the lubricating oil composition, preferably the concentration is from 1,000 to 15,000 parts per million (ppm) and more preferably from about 3,000 to 10,000 ppm by weight.
The N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine compound of formula I can be used as a complete or partial replacement for commercially available antioxidants currently used in lubricant formulations and can be in combination with other additives typically found in motor oils and fuels. When used in combination with other types of antioxidants or additives used in oil formulations, synergistic and/or additive performance effects may also be obtained with respect to improved antioxidancy, antiwear, frictional and detergency and high temperature engine deposit properties. Such other additives can be any presently known or later-discovered additives used in formulating lubricating oil compositions. The lubricating oil additives typically found in lubricating oils are, for example, dispersants, detergents, corrosion/rust inhibitors, antioxidants, anti-wear agents, anti-foamants, friction modifiers, seal swell agents, emulsifiers, VI improvers, pour point depressants, and the like. Particularly preferred to a demonstrated synergy is the compounds of component a) with an additional antioxidant such as a free radical inhibitor antioxidant, even more preferably selected from diarylamines or hindered phenolic types and combinations thereof.
In general, the concentration of each of the additives in the lubricating oil composition, when used, may range from about 0.001 wt. % to about 10 wt. %, from about 0.01 wt. % to about 5 wt. %, or from about 0.1 wt. % to about 2.5 wt. %, based on the total weight of the lubricating oil composition. Further, the total amount of the additives in the lubricating oil composition may range from about 0.001 wt. % to about 40 wt. %, from about 0.01 wt. % to about 20 wt. %, or from about 0.1 wt. % to about 10 wt. %, based on the total weight of the lubricating oil composition.
Diarylamine—component b):
The secondary diarylamines are well known antioxidants. Preferably, the secondary diarylamine antioxidant is one of the formula R a —NH—R b , wherein R a and R b each independently represent a substituted or unsubstituted aryl group having from C 6 to C 30 carbon atoms, preferably R a and R b are each independently aryl from 6 to 10 carbon atoms which may be unsubstituted or substituted with one or two alkyl groups each having from 1 to 20 carbon atoms.
Illustrative of substituents for the aryl moieties are aliphatic hydrocarbon groups, such as alkyl or alkenyl of 1 to 20 carbon atoms. The aryl moieties are preferably substituted or unsubstituted phenyl or substituted or unsubstituted naphthyl, particularly where one or both of the aryl moieties are substituted with alkyl, such as one having 4 to 18 carbon atoms.
The aliphatic hydrocarbon moiety, which can be of 1 to 20 carbon atoms, can have either a straight chain or a branched chain for example, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, and the like, and isomers and mixtures thereof.
Preferably either R a and/or R b contain substituted aryl groups. These secondary diarylamines may be substituted at one or both rings with alkyl groups, preferably straight and branched alkyl groups from 4 to 12 carbon atoms, more preferably 8 to 9 carbon atoms. Commonly mixtures of alkylated diphenylamines are prepared such as that prepared by reacting diphenylamine with 2,4,4-trimethylpentyl; or employing other alkyl groups, preferably branched chain to prepare for example nonylated diphenylamine (bis(4-nonylphenyl)amine) or octylated-butylated diphenyl amine.
For exhibiting good solubility of their oxidized product in base oil, these aliphatic hydrocarbon moieties comprise C 20 or less alkyl groups, preferably C 8-16 branched alkyl groups, more preferably those C 8-16 branched alkyl groups derived from oligomers of C 3 or C 4 olefins. The C 3 or C 4 olefins referred to here include propylene, 1-butene, 2-butene and isobutylene, among which propylene and isobutylene are preferable for good solubility of their oxidized product in base oil. Specifically, a branched octyl group derived from an isobutylene dimer, a branched nonyl group derived from a propylene trimer, a branched dodecyl group derived from an isobutylene trimer, a branched dodecyl group derived from a propylene tetramer or a branched pentadecyl group derived from a propylene pentamer is particularly preferable. The substituted secondary diaryl amines and particularly p,p′-dialkyl diphenyl amines and N-p-alkylphenyl-α-naphthyl amines, may be a commercially available product, but can be easily produced by reacting the diaryl amine with a C 1-6 alkyl halide, a C 2-6 olefin, or a C 2-6 olefin oligomer with secondary diaryl amine by use of a Friedel-Crafts catalyst. Examples of the Friedel-Crafts catalyst are metal halides such as aluminum chloride, zinc chloride and iron chloride, and acidic catalysts such as sulfuric acid, phosphoric acid, phosphorus pentoxide, boron fluoride, acidic clay and active clay. Other alkylation methods are known in the art.
Examples of some of the secondary diarylamines that are useful in the practice of the present invention include: diphenylamine, monoalkylated diphenylamine, dialkylated diphenylamine, trialkylated diphenylamine, or mixtures thereof, mono- and/or di-butyldiphenylamine, mono- and/or di-octyldiphenylamine, mono- and/or di-nonyldiphenylamine, phenyl-alpha-naphthylamine, phenyl-beta-naphthylamine, diheptyldiphenylamine, t-octylated N-phenyl-1-naphthylamine, mixtures of mono- and dialkylated t-butyl-t-octyldiphenylamine.
Examples of commercial diarylamines include, for example, IRGANOX L06, IRGANOX L57 and IRGANOX L67 from Ciba Specialty Chemicals; NAUGALUBE AMS, NAUGALUBE 438, NAUGALUBE 438R, NAUGALUBE 438L, NAUGALUBE 500, NAUGALUBE 640, NAUGALUBE 680, and NAUGARD PANA from Crompton Corporation; GOODRITE 3123, GOODRITE 3190X36, GOODRITE 3127, GOODRITE 3128, GOODRITE 3185X1, GOODRITE 3190X29, GOODRITE 3190X40, GOODRITE 3191 and GOODRITE 3192 from BF Goodrich Specialty Chemicals; VANLUBE DND, VANLUBE NA, VANLUBE PNA, VANLUBE SL, VANLUBE SLHP, VANLUBE SS, VANLUBE 81, VANLUBE 848, and VANLUBE 849 from R. T. Vanderbilt Company Inc.
The concentration of the secondary diarylamine in the lubricating composition can vary depending upon the requirements, applications and degree of synergy desired. In a preferred embodiment of the invention, a practical secondary diarylamine use range in the lubricating composition is from about 1,000 parts per million to 20,000 parts per million (i.e. 0. 1 to 2.0 wt %) based on the total weight of the lubricating oil composition, preferably the concentration is from 1,000 to 15,000 parts per million (ppm) and more preferably from about 3,000 to 10,000 ppm by weight.
Typically, with regard to total antioxidant in the lubricating composition, quantities of less than 1,000 ppm have little or minimal effectiveness whereas quantities larger than 50,000 ppm are generally not economical. Preferably the total amount of component a) and component b) in the lubricating oil composition is from about 0. 1 to 2 wt % and more preferably from about 0.5 to about 2 wt % based upon the total weight of the lubricating oil composition.
Other oxidation inhibitors which can be used with the compounds of formula I include but are not limited to hindered phenols, sulfurized hindered phenols, hindered phenolic esters, alkylated phenothiazines, and ashless dialkylthiocarbamates. Tertiary alkylated monohydric phenols are widely employed typically with a tertiary alkyl group in the ortho (and optionally meta and/or para position) containing from 4 to 12 carbon atoms and are depicted for example in U.S. Pat. No. 2,831,898. Methylene-bridged tertiary alkyl polyphenols be utilized such as prepared in U.S. Pat. No. 3,211,652. Phenol type phenolic oxidation inhibitors: 4,4′-methylenebis(2,6-di-tert-butylphenol), 4,4′-bis(2,6-di-tert-butylphenol), 4,4′-bis(2-methyl-6-tert-butylphenol), 2,2′-(methylenebis(4-methyl-6-tert-butyl-phenol)), 4,4′-butylidenebis(3-methyl-6-tert-butylphenol), 4,4′-isopropylidenebis(2,6-di-tert-butylphenol), 2,2′-methylenebis(4-methyl-6-nonylphenol), 2,2′-isobutylidene-bis(4,6-dimethylphenol), 2,2′-methylenebis(4-methyl-6-cyclohexylphenol), 2,6-di-tert-butyl-4-methylphenol, 2,6-di-tert-butyl4-ethylphenol, 2,4-dimethyl-6-tert-butyl-phenol, 2,6-di-tert-alpha-dimethylamino-p-cresol, 2,6-di-tert-4(N,N′dimethylaminomethylphenol), 4,4′-thiobis(2-methyl-6-tert-butylphenol), 2,2′-thiobis(4-methyl-6-tert-butylphenol), bis(3-methyl-4-hydroxy-5-tert-butylbenzyl)-sulfide, and bis (3,5-di-tert-butyl4-hydroxybenzyl).
The lubricating oil composition disclosed herein can optionally comprise an anti-wear agent that can reduce friction and excessive wear. Any anti-wear agent known by a person of ordinary skill in the art may be used in the lubricating oil composition. Non-limiting examples of suitable anti-wear agents include zinc dithiophosphate, metal (e.g., Pb, Sb, Mo and the like) salts of dithiophosphate, metal (e.g. Zn, Pb, Sb, Mo and the like) salts of dithiocarbamate, metal (e.g., Zn, Pb, Sb and the like) salts of fatty acids, boron compounds, phosphate esters, phosphite esters, amine salts of phosphoric acid esters or thiophosphoric acid esters, reaction products of dicyclopentadiene and thiophosphoric acids and combinations thereof. The amount of the anti-wear agent may vary from about 0.01 wt. % to about 5 wt. %, from about 0.05 wt. % to about 3 wt. %, or from about 0.1 wt. % to about 1 wt. %, based on the total weight of the lubricating oil composition. Some suitable anti-wear agents have been described in Leslie R. Rudnick, “Lubricant Additives: Chemistry and Applications,” New York, Marcel Dekker, Chapter 8, pages 223-258 (2003), which is incorporated herein by reference.
In certain embodiments, the anti-wear agent is or comprises a dihydrocarbyl dithiophosphate metal salt, such as zinc dialkyl dithiophosphate compounds. The metal of the dihydrocarbyl dithiophosphate metal salt may be an alkali or alkaline earth metal, or aluminum, lead, tin, molybdenum, manganese, nickel or copper. In some embodiments, the metal is zinc. In other embodiments, the alkyl group of the dihydrocarbyl dithiophosphate metal salt has from about 3 to about 22 carbon atoms, from about 3 to about 18 carbon atoms, from about 3 to about 12 carbon atoms, or from about 3 to about 8 carbon atoms. In further embodiments, the alkyl group is linear or branched.
The amount of the dihydrocarbyl dithiophosphate metal salt including the zinc dialkyl dithiophosphate salts in the lubricating oil composition disclosed herein is measured by its phosphorus content. In some embodiments, the phosphorus content of the lubricating oil composition disclosed herein is from about 0.01 wt. % to about 0.12 wt. %, from about 0.01 wt. % to about 0.10 wt. %, or from about 0.02 wt. % to about 0.08 wt. %, based on the total weight of the lubricating oil composition.
In one embodiment, the phosphorous content of the lubricating oil composition herein is from about 0.01 to 0.08wt % based on the total weight of the lubricating oil composition. In another embodiment, the phosphorous content of the lubricating oil composition herein is from about 0.05 to 0. 12 wt % based on the total weight of the lubricating oil composition.
The dihydrocarbyl dithiophosphate metal salt may be prepared in accordance with known techniques by first forming a dihydrocarbyl dithiophosphoric acid (DDPA), usually by reacting one or more of alcohols and phenolic compounds with P 2 S 5 and then neutralizing the formed DDPA with a compound of the metal, such as an oxide, hydroxide or carbonate of the metal. In some embodiments, a DDPA may be made by reacting mixtures of primary and secondary alcohols with P 2 S 5 . In other embodiments, two or more dihydrocarbyl dithiophosphoric acids can be prepared where the hydrocarbyl groups on one are entirely secondary in character and the hydrocarbyl groups on the others are entirely primary in character. The zinc salts can be prepare from the dihydrocarbyl dithiophosphoric acids by reacting with a zinc compound. In some embodiments, a basic or a neutral zinc compound is used. In other embodiments, an oxide, hydroxide or carbonate of zinc is used.
In some embodiments, oil soluble zinc dialkyl dithiophosphates may be produced from dialkyl dithiophosphoric acids represented by formula (II):
wherein each of R 3 and R 4 is independently linear or branched alkyl or linear or branched substituted alkyl. In some embodiments, the alkyl group has from about 3 to about 30 carbon atoms or from about 3 to about 8 carbon atoms.
The dialkyldithiophosphoric acids of formula (II) can be prepared by reacting alcohols R 3 OH and R 4 OH with P 2 S 5 where R 3 and R 4 are as defined above. In some embodiments, R 3 and R 4 are the same. In other embodiments, R 3 and R 4 are different. In further embodiments, R 3 OH and R 4 OH react with P 2 S 5 simultaneously. In still further embodiments, R 3 OH and R 4 OH react with P 2 S 5 sequentially.
Mixtures of hydroxyl alkyl compounds may also be used. These hydroxyl alkyl compounds need not be monohydroxy alkyl compounds. In some embodiments, the dialkyldithiophosphoric acids is prepared from mono-, di-, tri-, tetra-, and other polyhydroxy alkyl compounds, or mixtures of two or more of the foregoing. In other embodiments, the zinc dialkyldithiophosphate derived from only primary alkyl alcohols is derived from a single primary alcohol. In further embodiments, that single primary alcohol is 2-ethylhexanol. In certain embodiments, the zinc dialkyldithiophosphate derived from only secondary alkyl alcohols. In further embodiments, that mixture of secondary alcohols is a mixture of 2-butanol and 4-methyl-2-pentanol.
The phosphorus pentasulfide reactant used in the dialkyldithiophosphoric acid formation step may contain certain amounts of one or more of P 2 S 3 , P 4 S 3 , P 4 S 7 , or P 4 S 9 . Compositions as such may also contain minor amounts of free sulfur. In certain embodiments, the phosphorus pentasulfide reactant is substantially free of any of P 2 S 3 , P 4 S 3 , P 4 S 7 , and P 4 S 9 . In certain embodiments, the phosphorus pentasulfide reactant is substantially free of free sulfur.
In the present invention, the sulfated ash content of the total lubricating oil composition is about 5 wt. %, about 4 wt. %, about 3 wt. %, about 2 wt. %, or about 1 wt. %, as measured according to ASTM D874.
In some embodiments, the lubricating oil composition comprises at least a detergent. Any compound or a mixture of compounds that can reduce or slow the build up of engine deposits can be used as a detergent. Some non-limiting examples of suitable detergents include polyolefin substituted succinimides or succinamides of polyamines, for instance polyisobutylene succinimides or polyisobutylene amine succinamides, aliphatic amines, Mannich bases or amines and polyolefin (e.g. polyisobutylene) maleic anhydrides. Some suitable succinimide detergents are described in GB960493, EP0147240, EP0482253, EP0613938, EP0557561 and WO 98/42808, all of which are incorporated herein by reference. In some embodiments, the detergent is a polyolefin substituted succinimide such as polyisobutylene succinimide. Some non-limiting examples of commercially available detergent additives include F7661 and F7685 (available from Infineum, Linden, N.J.) and OMA 4130D (available from Octel Corporation, Manchester, UK).
Some non-limiting examples of suitable metal detergent include sulfurized or unsulfurized alkyl or alkenyl phenates, alkyl or alkenyl aromatic sulfonates, borated sulfonates, sulfurized or unsulfurized metal salts of multi-hydroxy alkyl or alkenyl aromatic compounds, alkyl or alkenyl hydroxy aromatic sulfonates, sulfurized or unsulfurized alkyl or alkenyl naphthenates, metal salts of alkanoic acids, metal salts of an alkyl or alkenyl multiacid, and chemical and physical mixtures thereof. Other non-limiting examples of suitable metal detergents include metal sulfonates, phenates, salicylates, phosphonates, thiophosphonates and combinations thereof. The metal can be any metal suitable for making sulfonate, phenate, salicylate or phosphonate detergents. Non-limiting examples of suitable metals include alkali metals, alkaline metals and transition metals. In some embodiments, the metal is Ca, Mg, Ba, K, Na, Li or the like.
Generally, the amount of the detergent is from about 0.001 wt. % to about 5 wt. %, from about 0.05 wt. % to about 3 wt. %, or from about 0. 1 wt. % to about 1 wt. %, based on the total weight of the lubricating oil composition. Some suitable detergents have been described in Mortier et al., “ Chemistry and Technology of Lubricants,” 2nd Edition, London, Springer, Chapter 3, pages 75-85 (1996); and Leslie R. Rudnick, “ Lubricant Additives: Chemistry and Applications ,” New York, Marcel Dekker, Chapter 4, pages 113-136 (2003), both of which are incorporated herein by reference.
The lubricating oil composition disclosed herein can optionally comprise a dispersant that can prevent sludge, varnish, and other deposits by keeping particles suspended in a colloidal state. Any dispersant known by a person of ordinary skill in the art may be used in the lubricating oil composition. Non-limiting examples of suitable dispersants include alkenyl succinimides, alkenyl succinimides modified with other organic compounds, alkenyl succinimides modified by post-treatment with ethylene carbonate or boric acid, succiamides, succinate esters, succinate ester-amides, pentaerythritols, phenate-salicylates and their post-treated analogs, alkali metal or mixed alkali metal, alkaline earth metal borates, dispersions of hydrated alkali metal borates, dispersions of alkaline-earth metal borates, polyamide ashless dispersants, benzylamines, Mannich type dispersants, phosphorus-containing dispersants, and combinations thereof The amount of the dispersant may vary from about 0.01 wt. % to about 10 wt. %, from about 0.05 wt. % to about 7 wt. %, or from about 0.1 wt. % to about 4 wt. %, based on the total weight of the lubricating oil composition. Some suitable dispersants have been described in Mortier et al., “ Chemistry and Technology ofLubricants,” 2nd Edition, London, Springer, Chapter 3, pages 86-90 (1996); and Leslie R. Rudnick, “ Lubricant Additives: Chemistry and Applications ,” New York, Marcel Dekker, Chapter 5, pages 137-170 (2003), both of which are incorporated herein by reference.
The lubricating oil composition disclosed herein can optionally comprise a friction modifier that can lower the friction between moving parts. Any friction modifier known by a person of ordinary skill in the art may be used in the lubricating oil composition. Non-limiting examples of suitable friction modifiers include fatty carboxylic acids; derivatives (e.g., alcohol, esters, borated esters, amides, metal salts and the like) of fatty carboxylic acid; mono-, di- or tri-alkyl substituted phosphoric acids or phosphonic acids; derivatives (e.g., esters, amides, metal salts and the like) of mono-, di- or tri-alkyl substituted phosphoric acids or phosphonic acids; mono-, di- or tri-alkyl substituted amines; mono- or di-alkyl substituted amides and combinations thereof. In some embodiments, the friction modifier is selected from the group consisting of aliphatic amines, ethoxylated aliphatic amines, aliphatic carboxylic acid amides, ethoxylated aliphatic ether amines, aliphatic carboxylic acids, glycerol esters, aliphatic carboxylic ester-amides, fatty imidazolines, fatty tertiary amines, wherein the aliphatic or fatty group contains more than about eight carbon atoms so as to render the compound suitably oil soluble. In other embodiments, the friction modifier comprises an aliphatic substituted succinimide formed by reacting an aliphatic succinic acid or anhydride with ammonia or a primary amine. The amount of the friction modifier may vary from about 0.01 wt. % to about 10 wt. %, from about 0.05 wt. % to about 5 wt. %, or from about 0. 1 wt. % to about 3 wt. %, based on the total weight of the lubricating oil composition. Some suitable friction modifiers have been described in Mortier et al., “ Chemistry and Technology of Lubricants,” 2nd Edition, London, Springer, Chapter 6, pages 183-187 (1996); and Leslie R. Rudnick, “Lubricant Additives: Chemistry and Applications,” New York, Marcel Dekker, Chapters 6 and 7, pages 171-222 (2003), both of which are incorporated herein by reference.
The lubricating oil composition disclosed herein can optionally comprise a pour point depressant that can lower the pour point of the lubricating oil composition. Any pour point depressant known by a person of ordinary skill in the art may be used in the lubricating oil composition. Non-limiting examples of suitable pour point depressants include polymethacrylates, alkyl acrylate polymers, alkyl methacrylate polymers, di(tetra-paraffin phenol)phthalate, condensates of tetra-paraffin phenol, condensates of a chlorinated paraffin with naphthalene and combinations thereof. In some embodiments, the pour point depressant comprises an ethylene-vinyl acetate copolymer, a condensate of chlorinated paraffin and phenol, polyalkyl styrene or the like. The amount of the pour point depressant may vary from about 0.01 wt. % to about 10 wt. %, from about 0.05 wt. % to about 5 wt. %, or from about 0.1 wt. % to about 3 wt. %, based on the total weight of the lubricating oil composition. Some suitable pour point depressants have been described in Mortier et al., “Chemistry and Technology ofLubricants,” 2nd Edition, London, Springer, Chapter 6, pages 187-189 (1996); and Leslie R. Rudnick, “ Lubricant Additives: Chemistry and Applications ,” New York, Marcel Dekker, Chapter 11, pages 329-354 (2003), both of which are incorporated herein by reference.
The lubricating oil composition disclosed herein can optionally comprise a demulsifier that can promote oil-water separation in lubricating oil compositions that are exposed to water or steam. Any demulsifier known by a person of ordinary skill in the art may be used in the lubricating oil composition. Non-limiting examples of suitable demulsifiers include anionic surfactants (e.g., alkyl-naphthalene sulfonates, alkyl benzene sulfonates and the like), nonionic alkoxylated alkylphenol resins, polymers of alkylene oxides (e.g., polyethylene oxide, polypropylene oxide, block copolymers of ethylene oxide, propylene oxide and the like), esters of oil soluble acids, polyoxyethylene sorbitan ester and combinations thereof The amount of the demulsifier may vary from about 0.01 wt. % to about 10 wt. %, from about 0.05 wt. % to about 5 wt. %, or from about 0. 1 wt. % to about 3 wt. %, based on the total weight of the lubricating oil composition. Some suitable demulsifiers have been described in Mortier et al., “ Chemistry and Technology of Lubricants,” 2nd Edition, London, Springer, Chapter 6, pages 190-193 (1996), which is incorporated herein by reference.
The lubricating oil composition disclosed herein can optionally comprise a foam inhibitor or an anti-foam that can break up foams in oils. Any foam inhibitor or anti-foam known by a person of ordinary skill in the art may be used in the lubricating oil composition. Non-limiting examples of suitable anti-foams include silicone oils or polydimethylsiloxanes, fluorosilicones, alkoxylated aliphatic acids, polyethers (e.g., polyethylene glycols), branched polyvinyl ethers, alkyl acrylate polymers, alkyl methacrylate polymers, polyalkoxyamines and combinations thereof. In some embodiments, the anti-foam comprises glycerol monostearate, polyglycol palmitate, a trialkyl monothiophosphate, an ester of sulfonated ricinoleic acid, benzoylacetone, methyl salicylate, glycerol monooleate, or glycerol dioleate. The amount of the anti-foam may vary from about 0.01 wt. % to about 5 wt. %, from about 0.05 wt. % to about 3 wt. %, or from about 0. 1 wt. % to about 1 wt. %, based on the total weight of the lubricating oil composition. Some suitable anti-foams have been described in Mortier et al., “ Chemistry and Technology of Lubricants,” 2nd Edition, London, Springer, Chapter 6, pages 190-193 (1996), which is incorporated herein by reference.
The lubricating oil composition disclosed herein can optionally comprise a corrosion inhibitor that can reduce corrosion. Any corrosion inhibitor known by a person of ordinary skill in the art may be used in the lubricating oil composition. Non-limiting examples of suitable corrosion inhibitor include half esters or amides of dodecylsuccinic acid, phosphate esters, thiophosphates, alkyl imidazolines, sarcosines and combinations thereof. The amount of the corrosion inhibitor may vary from about 0.01 wt. % to about 5 wt. %, from about 0.05 wt. % to about 3 wt. %, or from about 0.1 wt. % to about 1 wt. %, based on the total weight of the lubricating oil composition. Some suitable corrosion inhibitors have been described in Mortier et al., “Chemistry and Technology of Lubricants,” 2nd Edition, London, Springer, Chapter 6, pages 193-196 (1996), which is incorporated herein by reference.
The lubricating oil composition disclosed herein can optionally comprise an extreme pressure (EP) agent that can prevent sliding metal surfaces from seizing under conditions of extreme pressure. Any extreme pressure agent known by a person of ordinary skill in the art may be used in the lubricating oil composition. Generally, the extreme pressure agent is a compound that can combine chemically with a metal to form a surface film that prevents the welding of asperities in opposing metal surfaces under high loads. Non-limiting examples of suitable extreme pressure agents include sulfurized animal or vegetable fats or oils, sulfurized animal or vegetable fatty acid esters, fully or partially esterified esters of trivalent or pentavalent acids of phosphorus, sulfurized olefins, dihydrocarbyl polysulfides, sulfurized Diels-Alder adducts, sulfurized dicyclopentadiene, sulfurized or co-sulfurized mixtures of fatty acid esters and monounsaturated olefins, co-sulfurized blends of fatty acid, fatty acid ester and alpha-olefin, functionally-substituted dihydrocarbyl polysulfides, thia-aldehydes, thia-ketones, epithio compounds, sulfur-containing acetal derivatives, co-sulfurized blends of terpene and acyclic olefins, and polysulfide olefin products, amine salts of phosphoric acid esters or thiophosphoric acid esters and combinations thereof. The amount of the extreme pressure agent may vary from about 0.01 wt. % to about 5 wt. %, from about 0.05 wt. % to about 3 wt. %, or from about 0.1 wt. % to about 1 wt. %, based on the total weight of the lubricating oil composition. Some suitable extreme pressure agents have been described in Leslie R. Rudnick, “ Lubricant Additives: Chemistry and Applications ,” New York, Marcel Dekker, Chapter 8, pages 223-258 (2003), which is incorporated herein by reference.
The lubricating oil composition disclosed herein can optionally comprise a rust inhibitor that can inhibit the corrosion of ferrous metal surfaces. Any rust inhibitor known by a person of ordinary skill in the art may be used in the lubricating oil composition. Non-limiting examples of suitable rust inhibitors include oil-soluble monocarboxylic acids (e.g., 2-ethylhexanoic acid, lauric acid, myristic acid, palmitic acid, oleic acid, linoleic acid, linolenic acid, behenic acid, cerotic acid and the like), oil-soluble polycarboxylic acids (e.g., those produced from tall oil fatty acids, oleic acid, linoleic acid and the like), alkenylsuccinic acids in which the alkenyl group contains 10 or more carbon atoms (e.g., tetrapropenylsuccinic acid, tetradecenylsuccinic acid, hexadecenylsuccinic acid, and the like); long-chain alpha,omega-dicarboxylic acids having a molecular weight in the range of 600 to 3000 daltons and combinations thereof. The amount of the rust inhibitor may vary from about 0.01 wt. % to about 10 wt. %, from about 0.05 wt. % to about 5 wt. %, or from about 0. 1 wt. % to about 3 wt. %, based on the total weight of the lubricating oil composition.
Other non-limiting examples of suitable rust inhibitors include nonionic polyoxyethylene surface active agents such as polyoxyethylene lauryl ether, polyoxyethylene higher alcohol ether, polyoxyethylene nonyl phenyl ether, polyoxyethylene octyl phenyl ether, polyoxyethylene octyl stearyl ether, polyoxyethylene oleyl ether, polyoxyethylene sorbitol monostearate, polyoxyethylene sorbitol mono-oleate, and polyethylene glycol mono-oleate. Further non-limiting examples of suitable rust inhibitor include stearic acid and other fatty acids, dicarboxylic acids, metal soaps, fatty acid amine salts, metal salts of heavy sulfonic acid, partial carboxylic acid ester of polyhydric alcohol, and phosphoric ester.
In some embodiments, the lubricating oil composition comprises at least a multifunctional additive. Some non-limiting examples of suitable multifunctional additives include sulfurized oxymolybdenum dithiocarbamate, sulfurized oxymolybdenum organophosphorodithioate, oxymolybdenum monoglyceride, oxymolybdenum diethylate amide, amine-molybdenum complex compound, and sulfur-containing molybdenum complex compound.
In certain embodiments, the lubricating oil composition comprises at least a viscosity index improver. Some non-limiting examples of suitable viscosity index improvers include polymethacrylate type polymers, ethylene-propylene copolymers, styrene-isoprene copolymers, hydrated styrene-isoprene copolymers, polyisobutylene, and dispersant type viscosity index improvers.
In some embodiments, the lubricating oil composition comprises at least a metal deactivator. Some non-limiting examples of suitable metal deactivators include disalicylidene propylenediamine, triazole derivatives, thiadiazole derivatives, and mercaptobenzimidazoles.
The additives disclosed herein may be in the form of an additive concentrate having more than one additive. The additive concentrate may comprise a suitable diluent, such as a hydrocarbon oil of suitable viscosity. Such diluent can be selected from the group consisting of natural oils (e.g., mineral oils), synthetic oils and combinations thereof Some non-limiting examples of the mineral oils include paraffin-based oils, naphthenic-based oils, asphaltic-based oils and combinations thereof Some non-limiting examples of the synthetic base oils include polyolefin oils (especially hydrogenated alpha-olefin oligomers), alkylated aromatic, polyalkylene oxides, aromatic ethers, and carboxylate esters (especially diester oils) and combinations thereof In some embodiments, the diluent is a light hydrocarbon oil, both natural or synthetic. Generally, the diluent oil can have a viscosity from about 13 centistokes to about 35 centistokes at 40 ° C.
Oil of Lubricating Viscosity
The lubricant compositions of this invention include a major amount of base oil of lubricating viscosity. Base Oil as used herein is defined as a base stock or blend of base stocks which is a lubricant component that is produced by a single manufacturer to the same specifications (independent of feed source or manufacturer's location): that meets the same manufacturer's specification; and that is identified by a unique formula, product identification number, or both. Base stocks may be manufactured using a variety of different processes including but not limited to distillation, solvent refining, hydrogen processing, oligomerization, esterification, and rerefining. Rerefined stock shall be substantially free from materials introduced through manufacturing, contamination, or previous use. The base oil of this invention may be any natural or synthetic lubricating base oil fraction particularly those having a kinematic viscosity at 100 degrees Centigrade (C) and about 5 centistokes (cSt) to about 20 cSt, preferably about 7 cSt to about 16 cSt, more preferably about 9 cSt to about 15 cSt. Hydrocarbon synthetic oils may include, for example, oils prepared from the polymerization of ethylene, i.e., polyalphaolefin or PAO, or from hydrocarbon synthesis procedures using carbon monoxide and hydrogen gases such as in a Fisher-Tropsch process. A preferred base oil is one that comprises little, if any, heavy fraction; e.g., little, if any, lube oil fraction of viscosity 20 cSt or higher at 100 degrees C.
The base oil may be derived from natural lubricating oils, synthetic lubricating oils or mixtures thereof Suitable base oil includes base stocks obtained by isomerization of synthetic wax and slack wax, as well as hydrocrackate base stocks produced by hydrocracking (rather than solvent extracting) the aromatic and polar components of the crude. Suitable base oils include those in all API categories I, II, III, IV and V as defined in API Publication 1509, 14th Edition, Addendum I, December 1998. Saturates levels and viscosity indices for Group I, II and III base oils are listed in Table 1. Group IV base oils are polyalphaolefins (PAO). Group V base oils include all other base oils not included in Group I, II, III, or IV. Although Group II, III and IV base oils are preferred for use in this invention, these preferred base oils may be prepared by combining one or more of Group I, II, III, IV and V base stocks or base oils.
TABLE 1
Saturates, Sulfur and Viscosity Index of Group I, II and III Base Stocks
Saturates
Viscosity Index
(As determined by ASTM D 2007)
(As determined by
Sulfur
ASTM D 4294, ASTM D
Group
(As determined by ASTM D 2270)
4297 or ASTM D 3120)
I
Less than 90% saturates and/or
Greater than or equal to
Greater than to 0.03% sulfur
80 and less than 120
II
Greater than or equal to 90%
Greater than or equal to
saturates and less than or equal to
80 and less than 120
0.03% sulfur
III
Greater than or equal to 90%
Greater than or equal to
saturates and less than or equal to
120
0.03% sulfur
Natural lubricating oils may include animal oils, vegetable oils (e.g., rapeseed oils, castor oils and lard oil), petroleum oils, mineral oils, and oils derived from coal or shale.
Synthetic oils may include hydrocarbon oils and halo-substituted hydrocarbon oils such as polymerized and inter-polymerized olefins, alkylbenzenes, polyphenyls, alkylated diphenyl ethers, alkylated diphenyl sulfides, as well as their derivatives, analogues and homologues thereof, and the like. Synthetic lubricating oils also include alkylene oxide polymers, interpolymers, copolymers and derivatives thereof wherein the terminal hydroxyl groups have been modified by esterification, etherification, etc. Another suitable class of synthetic lubricating oils comprises the esters of dicarboxylic acids with a variety of alcohols. Esters useful as synthetic oils also include those made from C 5 to C 12 monocarboxylic acids and polyols and polyol ethers. Tri-alkyl phosphate ester oils such as those exemplified by tri-n-butyl phosphate and tri-iso-butyl phosphate are also suitable for use as base oils.
Silicon-based oils (such as the polyakyl-, polyaryl-, polyalkoxy-, or polyaryloxy-siloxane oils and silicate oils) comprise another useful class of synthetic lubricating oils. Other synthetic lubricating oils include liquid esters of phosphorus-containing acids, polymeric tetrahydrofurans, polyalphaolefins, and the like.
The base oil may be derived from unrefined, refined, rerefined oils, or mixtures thereof. Unrefined oils are obtained directly from a natural source or synthetic source (e.g., coal, shale, or tar sand bitumen) without further purification or treatment. Examples of unrefined oils include a shale oil obtained directly from a retorting operation, a petroleum oil obtained directly from distillation, or an ester oil obtained directly from an esterification process, each of which may then be used without further treatment. Refined oils are similar to the unrefined oils except that refined oils have been treated in one or more purification steps to improve one or more properties. Suitable purification techniques include distillation, hydrocracking, hydrotreating, dewaxing, solvent extraction, acid or base extraction, filtration, and percolation, all of which are known to those skilled in the art. Rerefined oils are obtained by treating used oils in processes similar to those used to obtain the refined oils. These rerefined oils are also known as reclaimed or reprocessed oils and often are additionally processed by techniques for removal of spent additives and oil breakdown products.
Base oil derived from the hydroisomerization of wax may also be used, either alone or in combination with the aforesaid natural and/or synthetic base oil. Such wax isomerate oil is produced by the hydroisomerization of natural or synthetic waxes or mixtures thereof over a hydroisomerization catalyst.
It is preferred to use a major amount of base oil in the lubricating oil of this invention. A major amount of base oil as defined herein comprises greater than about 50 wt. % to about 97 wt. % of at least one of Group II, III and IV base oil or more preferably about 60 wt. % to about 97 wt. % of at least one of Group II, III and IV base oil. (When wt. % is used herein, it is referring to wt. % of the lubricating oil unless otherwise specified.) A more preferred embodiment of this invention may comprise an amount of base oil that comprises about 85 wt. % to about 95 wt. % of the lubricating oil.
Oil Soluble Molybdenum Compound
Oil soluble molybdenum compounds and molybdenum/sulfur complexes are known in the art and are described, for example, in U.S. Pat. No. 4,263,152 to King et al., and U.S. Pat. No. 6,962,896 to Ruhe, the disclosures of which is hereby incorporated by reference and which are particularly preferred. Other representative of the molybdenum compounds which can be used in this invention include: glycol molybdate complexes as described by Price et al. in U.S. Pat. No. 3,285,942; overbased alkali metal and alkaline earth metal sulfonates, phenates and salicylate compositions containing molybdenum such as those disclosed and claimed by Hunt et al in U.S. Pat. No. 4,832,857; molybdenum complexes prepared by reacting a fatty oil, a diethanolamine and a molybdenum source as described by Rowan et al in U.S. Pat. No. 4,889,647; a sulfur and phosphorus-free organomolybdenum complex of organic amide, such as molybdenum containing compounds prepared from fatty acids and 2-(2-aminoethyl)aminoethanol as described by Karol in U.S. Pat. No. 5,137,647 and molybdenum containing compounds prepared from 1-(2-hydroxyethyl)-2-imidazoline substituted by a fatty residue derived from fatty oil or a fatty acid; overbased molybdenum complexes prepared from amines, diamines, alkoxylated amines, glycols and polyols as described by Gallo et al in U.S. Pat. No. 5,143,633; 2,4-heteroatom substituted-molybdena-3,3-dioxacycloalkanes as described by Karol in U.S. Pat. No. 5,412,130; and mixtures thereof Representative molybdenum compounds of the above are commercially available and include but, are not limited to: Sakura-Lube® 700 supplied by the Asahi Denka Kogyo K.K. of Tokyo, Japan, a molybdenum amine complex; molybdenum HEX-CEM®. supplied by the OM Group, Inc., of Cleveland, Ohio, a molybdenum 2-ethylhexanoate; molybdenum octoate supplied by The Shepherd Chemical Company of Cincinnati, Ohio, a molybdenum 2-ethylhexanoate; Molyvan®855 supplied by the R.T. Vanderbilt Company, Inc., of Norwalk, Conn., a sulfur and phosphorus-free organomolybdenum complex of organic amide; Molyvan®856-B also from R.T. Vanderbilt, an organomolybdenum complex.
Particularly preferred oil soluble molybdenum complexes are unsulfurized or sulfurized oxymolybdenum containing compositions which can be prepared by (i) reacting an acidic molybdenum compound and a basic nitrogen compound selected from the dispersant group consisting of succinimide, a carboxylic acid amide, a hydrocarbyl monoamine, a phosphoramide, a thiophosphoramide, a Mannich base, a dispersant viscosity index improver, or a mixture thereof in the presence of a polar promoter, to form an oxymolybdenum complex. This oxymolybdenum complex can be reacted with a sulfur containing compound, to thereby form a sulfurized oxymolybdenum containing composition, useful within the context of this invention. Preferably the dispersant is a polyisobutenyl succinimide. The oxymolybdenum or sulfurized oxymolybdenum containing compositions may be generally characterized as a sulfur/molybdenum complex of a basic nitrogen dispersant compound preferably with a sulfur to molybdenum weight ratio of about (0.01 to 1.0) to 1 and more preferably from about (0.05 to 0.5) to 1 and a nitrogen to molybdenum weight ratio of about (1 to 10) to 1 and more preferably from (2 to 5) to 1. The precise molecular formula of these oxymolybdenum compositions are not known with certainty. However, they are believed to be compounds in which molybdenum, whose valences are satisfied with atoms of oxygen or sulfur, is either complexed by, or the salt of one or more nitrogen atoms of the basic nitrogen atoms of the basic nitrogen containing compound used in the preparation of these compositions. In one aspect, the oxymolybdenum complex is prepared at a reaction temperature at or below 120 degrees centigrade and if optionally sulfurized, it is also reacted at or below 120 degrees centigrade. Such a process yields a lighter color product when compared to higher temperature reaction conditions at equivalent pressure.
The molybdenum compounds used to prepare the oxymolybdenum and oxymolybdenum/sulfur complexes employed in this invention are acidic molybdenum compounds. By acidic is meant that the molybdenum compounds will react with a basic nitrogen compound as measured by ASTM test D-664 or D-2896 titration procedure. Typically these molybdenum compounds are hexavalent and are represented by the following compositions: molybdic acid, ammonium molybdate, sodium molybdate, potassium molybdate and other alkaline metal molybdates and other molybdenum salts such as hydrogen salts, e.g., hydrogen sodium molybdate, MoOCl 4 , MoO 2 Br 2 , Mo 2 O 3 Cl 6 , molybdenum trioxide, bis(acetylacetonato)-dioxomolybdenum (VI) or similar acidic molybdenum compounds. Preferred acidic molybdenum compounds are molybdic acid, ammonium molybdate, and alkali metal molybdates. Particularly preferred are molybdic acid and ammonium molybdate.
The basic nitrogen compound used to prepare the oxymolybdenum complexes have at least one basic nitrogen and are preferably oil-soluble. Typical examples of such compositions are succinimides, carboxylic acid amides, hydrocarbyl monoamines, hydrocarbon polyamines, Mannich bases, phosphoramides, thiophosphoramides, phosphonamides, dispersant viscosity index improvers, and mixtures thereof. Any of the nitrogen-containing compositions may be after-treated with, e.g., boron, using procedures well known in the art so long as the compositions continue to contain basic nitrogen. These after-treatments are particularly applicable to succinimides and Mannich base compositions.
The mono and polysuccinimides that can be used to prepare the molybdenum complexes described herein are disclosed in numerous references and are well known in the art. Certain fundamental types of succinimides and the related materials encompassed by the term of art “succinimide” are taught in U.S. Pat. Nos. 3,219,666; 3,172,892; and 3,272,746, the disclosures of which are hereby incorporated by reference. The term “succinimide” is understood in the art to include many of the amide, imide, and amidine species which may also be formed. The predominant product however is a succinimide and this term has been generally accepted as meaning the product of a reaction of an alkenyl substituted succinic acid or anhydride with a nitrogen-containing compound. Preferred succinimides, because of their commercial availability, are those succinimides prepared from a hydrocarbyl succinic anhydride, wherein the hydrocarbyl group contains from about 24 to about 350 carbon atoms, and an ethylene amine, said ethylene amines being especially characterized by ethylene diamine, diethylene triamine, triethylene tetramine, and tetraethylene pentamine. Particularly preferred are those succinimides prepared from polyisobutenyl succinic anhydride of 70 to 128 carbon atoms and tetraethylene pentamine or triethylene tetramine or mixtures thereof.
Also included within the term “succinimide” are the cooligomers of a hydrocarbyl succinic acid or anhydride and a poly secondary amine containing at least one tertiary amino nitrogen in addition to two or more secondary amino groups. Ordinarily this composition has between 1,500 and 50,000 average molecular weight. A typical compound would be that prepared by reacting polyisobutenyl succinic anhydride and ethylene dipiperazine.
Carboxylic acid amide compositions are also suitable starting materials for preparing the oxymolybdenum complexes employed in this invention. Typical of such compounds are those disclosed in U.S. Pat. No. 3,405,064, the disclosure of which is hereby incorporated by reference. These compositions are ordinarily prepared by reacting a carboxylic acid or anhydride or ester thereof, having at least 12 to about 350 aliphatic carbon atoms in the principal aliphatic chain and, if desired, having sufficient pendant aliphatic groups to render the molecule oil soluble with an amine or a hydrocarbyl polyamine, such as an ethylene amine, to give a mono or polycarboxylic acid amide. Preferred are those amides prepared from (1) a carboxylic acid of the formula R′COOH, where R′ is C 12-20 alkyl or a mixture of this acid with a polyisobutenyl carboxylic acid in which the polyisobutenyl group contains from 72 to 128 carbon atoms and (2) an ethylene amine, especially triethylene tetramine or tetraethylene pentamine or mixtures thereof
Another class of compounds which are useful in this invention are hydrocarbyl monoamines and hydrocarbyl polyamines, preferably of the type disclosed in U.S. Pat. No. 3,574,576, the disclosure of which is hereby incorporated by reference. The hydrocarbyl group, which is preferably alkyl, or olefinic having one or two sites of unsaturation, usually contains from 9 to 350, preferably from 20 to 200 carbon atoms. Particularly preferred hydrocarbyl polyamines are those which are derived, e.g., by reacting polyisobutenyl chloride and a polyalkylene polyamine, such as an ethylene amine, e.g., ethylene diamine, diethylene triamine, tetraethylene pentamine, 2-aminoethylpiperazine, 1,3-propylene diamine, 1,2-propylenediamine, and the like.
Another class of compounds useful for supplying basic nitrogen are the Mannich base compositions. These compositions are prepared from a phenol or C 9-200 alkylphenol, an aldehyde, such as formaldehyde or formaldehyde precursor such as paraformaldehyde, and an amine compound. The amine may be a mono or polyamine and typical compositions are prepared from an alkylamine, such as methylamine or an ethylene amine, such as, diethylene triamine, or tetraethylene pentamine, and the like. The phenolic material may be sulfurized and preferably is dodecylphenol or a C 80-100 alkylphenol. Typical Mannich bases which can be used in this invention are disclosed in U.S. Pat. Nos. 4,157,309 and 3,649,229; 3,368,972; and 3,539,663, the disclosures of which are hereby incorporated by reference. The last referenced patent discloses Mannich bases prepared by reacting an alkylphenol having at least 50 carbon atoms, preferably 50 to 200 carbon atoms with formaldehyde and an alkylene polyamine HN(ANH) n H where A is a saturated divalent alkyl hydrocarbon of 2 to 6 carbon atoms and n is 1-10 and where the condensation product of said alkylene polyamine may be further reacted with urea or thiourea. The utility of these Mannich bases as starting materials for preparing lubricating oil additives can often be significantly improved by treating the Mannich base using conventional techniques to introduce boron into the composition.
Another class of composition useful for preparing the oxymolybdenum complexes employed in this invention are the phosphoramides and phosphonamides such as those disclosed in U.S. Pat. Nos. 3,909,430 and 3,968,157, the disclosures of which are hereby incorporated by reference. These compositions may be prepared by forming a phosphorus compound having at least one P-N bond. They can be prepared, for example, by reacting phosphorus oxychloride with a hydrocarbyl diol in the presence of a monoamine or by reacting phosphorus oxychloride with a difunctional secondary amine and a mono-functional amine. Thiophosphoramides can be prepared by reacting an unsaturated hydrocarbon compound containing from 2 to 450 or more carbon atoms, such as polyethylene, polyisobutylene, polypropylene, ethylene, 1-hexene, 1,3-hexadiene, isobutylene, 4-methyl-1-pentene, and the like, with phosphorus pentasulfide and a nitrogen-containing compound as defined above, particularly an alkylamine, alkyldiamine, alkylpolyamine, or an alkyleneamine, such as ethylene diamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, and the like.
Another class of nitrogen-containing compositions useful in preparing the molybdenum complexes employed in this invention includes the so-called dispersant viscosity index improvers (VI improvers). These VI improvers are commonly prepared by functionalizing a hydrocarbon polymer, especially a polymer derived from ethylene and/or propylene, optionally containing additional units derived from one or more co-monomers such as alicyclic or aliphatic olefins or diolefins. The functionalization may be carried out by a variety of processes which introduce a reactive site or sites which usually has at least one oxygen atom on the polymer. The polymer is then contacted with a nitrogen-containing source to introduce nitrogen-containing functional groups on the polymer backbone. Commonly used nitrogen sources include any basic nitrogen compound especially those nitrogen-containing compounds and compositions described herein. Preferred nitrogen sources are alkylene amines, such as ethylene amines, alkyl amines, and Mannich bases.
Preferred basic nitrogen compounds for use in this invention are succinimides, carboxylic acid amides, and Mannich bases. More preferred are succinimides having an average molecular weight of 1000 or 1300 or 2300 and mixtures thereof. Such succinimides can be post treated with boron or ethylene carbonate as known in the art.
The oxymolybdenum complexes of this invention can also be sulfurized. Representative sulfur sources for preparing the oxymolybdenum/sulfur complexes used in this invention are sulfur, hydrogen sulfide, sulfur monochloride, sulfur dichloride, phosphorus pentasulfide, R″ 2 S x where R″ is hydrocarbyl, preferably C 1-40 alkyl, and x is at least 2, inorganic sulfides and polysulfides such as (NH 4 ) 2 S y , where y is at least 1, thioacetamide, thiourea, and mercaptans of the formula R″SH where R″ is as defined above. Also useful as sulfurizing agents are traditional sulfur-containing antioxidants such as wax sulfides and polysulfides, sulfurized olefins, sulfurized carboxylic and esters and sulfurized ester-olefins, and sulfurized alkylphenols and the metal salts thereof.
The sulfurized fatty acid esters are prepared by reacting sulfur, sulfur monochloride, and/or sulfur dichloride with an unsaturated fatty ester under elevated temperatures. Typical esters include C 1 -C 20 alkyl esters of C 8 -C 24 unsaturated fatty acids, such as palmitoleic, oleic, ricinoleic, petroselinic, vaccenic, linoleic, linolenic, oleostearic, licanic, paranaric, tariric, gadoleic, arachidonic, cetoleic, etc. Particularly good results have been obtained with mixed unsaturated fatty acid esters, such as are obtained from animal fats and vegetable oils, such as tall oil, linseed oil, olive oil, caster oil, peanut oil, rape oil, fish oil, sperm oil, and so forth. Exemplary fatty esters include lauryl tallate, methyl oleate, ethyl oleate, lauryl oleate, cetyl oleate, cetyl linoleate, lauryl ricinoleate, oleyl linoleate, oleyl stearate, and alkyl glycerides.
Cross-sulfurized ester olefins, such as a sulfurized mixture of C 10 -C 25 olefins with fatty acid esters of C 10 -C 25 fatty acids and C 10 -C 25 alkyl or alkenyl alcohols, wherein the fatty acid and/or the alcohol is unsaturated may also be used.
Sulfurized olefins are prepared by the reaction of the C 3 -C 6 olefin or a low-molecular-weight polyolefin derived therefrom with a sulfur-containing compound such as sulfur, sulfur monochloride, and/or sulfur dichloride.
Also useful are the aromatic and alkyl sulfides, such as dibenzyl sulfide, dixylyl sulfide, dicetyl sulfide, diparaffin wax sulfide and polysulfide, cracked wax-olefin sulfides and so forth. They can be prepared by treating the starting material, e.g., olefinically unsaturated compounds, with sulfur, sulfur monochloride, and sulfur dichloride. Particularly preferred are the paraffin wax thiomers described in U.S. Pat. No. 2,346,156.
Sulfurized alkyl phenols and the metal salts thereof include compositions such as sulfurized dodecylphenol and the calcium salts thereof. The alkyl group ordinarily contains from 9-300 carbon atoms. The metal salt may be preferably, a Group I or Group II salt, especially sodium, calcium, magnesium, or barium.
Preferred sulfur sources are sulfur, hydrogen sulfide, phosphorus pentasulfide, R′″ 2 S z where R′″is hydrocarbyl, preferably C 1 -C 10 alkyl, and z is at least 3, mercaptans wherein R′″is C 1 -C 10 alkyl, inorganic sulfides and polysulfides, thioacetamide, and thiourea. Most preferred sulfur sources are sulfur, hydrogen sulfide, phosphorus pentasulfide, and inorganic sulfides and polysulfides.
The polar promoter used in the preparation of the molybdenum complexes employed in this invention is one which facilitates the interaction between the acidic molybdenum compound and the basic nitrogen compound. A wide variety of such promoters are well known to those skilled in the art. Typical promoters are 1,3-propanediol, 1,4-butane-diol, diethylene glycol, butyl cellosolve, propylene glycol, 1,4-butyleneglycol, methyl carbitol, ethanolamine, diethanolamine, N-methyl-diethanol-amine, dimethyl formamide, N-methyl acetamide, dimethyl acetamide, methanol, ethylene glycol, dimethyl sulfoxide, hexamethyl phosphoramide, tetrahydrofuran and water. Preferred are water and ethylene glycol. Particularly preferred is water. While ordinarily the polar promoter is separately added to the reaction mixture, it may also be present, particularly in the case of water, as a component of non-anhydrous starting materials or as waters of hydration in the acidic molybdenum compound, such as (NH 4 ) 6 Mo 7 O 24 .H 2 O. Water may also be added as ammonium hydroxide.
A method for preparing the oxymolybdenum complexes used in this invention is to prepare a solution of the acidic molybdenum precursor and a polar promoter with a basic nitrogen-containing compound with or without diluent. The diluent is used, if necessary, to provide a suitable viscosity for easy stirring. Typical diluents are lubricating oil and liquid compounds containing only carbon and hydrogen. If desired, ammonium hydroxide may also be added to the reaction mixture to provide a solution of ammonium molybdate. This reaction is carried out at a variety of temperatures, typically at or below the melting point of the mixture to reflux temperature. It is ordinarily carried out at atmospheric pressure although higher or lower pressures may be used if desired. This reaction mixture may optionally be treated with a sulfur source as defined above at a suitable pressure and temperature for the sulfur source to react with the acidic molybdenum and basic nitrogen compounds. In some cases, removal of water from the reaction mixture may be desirable prior to completion of reaction with the sulfur source. In a preferred and improved method for preparing the oxymolybdenum complexes, the reactor is agitated and heated at a temperature less than or equal to about 120 degrees Celsius, preferably from about 70 degrees Celsius to about 90 degrees Celsius. Molybdic oxide or other suitable molybdenum source is then charged to the reactor and the temperature is maintained at a temperature less than or equal to about 120 degrees Celsius, preferably at about 70 degrees Celsius to about 90 degrees Celsius, until the molybdenum is sufficiently reacted. Excess water is removed from the reaction mixture. Removal methods include but are not limited to vacuum distillation or nitrogen stripping while maintaining the temperature of the reactor at a temperature less than or equal to about 120 degrees Celsius, preferably between about 70 degrees Celsius to about 90 degrees Celsius. The temperature during the stripping process is held at a temperature less than or equal to about 120 degrees Celsius to maintain the low color intensity of the molybdenum-containing composition. It is ordinarily carried out at atmospheric pressure although higher or lower pressures may be used. The stripping step is typically carried out for a period of about 0.5 to about 5 hours.
If desired, this product can be sulfurized by treating this reaction mixture with a sulfur source as defined above at a suitable pressure and temperature, not to exceed about 120 degrees Celsius for the sulfur source to react with the acidic molybdenum and basic nitrogen compounds. The sulfurization step is typically carried out for a period of from about 0.5 to about 5 hours and preferably from about 0.5 to about 2 hours. In some cases, removal of the polar promoter (water) from the reaction mixture may be desirable prior to completion of reaction with the sulfur source.
In the reaction mixture, the ratio of molybdenum compound to basic nitrogen compound is not critical; however, as the amount of molybdenum with respect to basic nitrogen increases, the filtration of the product becomes more difficult. Since the molybdenum component probably oligomerizes, it is advantageous to add as much molybdenum as can easily be maintained in the composition. Usually, the reaction mixture will have charged to it from 0.01 to 2.00 atoms of molybdenum per basic nitrogen atom. Preferably from 0.3 to 1.0, and most preferably from 0.4 to 0.7, atoms of molybdenum per atom of basic nitrogen is added to the reaction mixture.
When optionally sulfurized, the sulfurized oxymolybdenum containing compositions may be generally characterized as a sulfur/molybdenum complex of a basic nitrogen dispersant compound preferably with a sulfur to molybdenum weight ratio of about (0.01 to 1.0) to 1 and more preferably from about (0.05 to 0.5) to 1 and a nitrogen to molybdenum weight ratio of about (1 to 10) to 1 and more preferably from (2 to 5) to 1. For extremely low sulfur incorporation the sulfur to molybdenum weight ratio can be from (0.01 to 0.08) to 1.
The sulfurized and unsulfurized oxymolybdenum complexes of this invention are typically employed in a lubricating oil in an amount of 0.01 to 10 %, more preferably from 0.04 to 1 wt %.
Additional components may be added to the synergist combination of component a) and component b) to further the resistance to oxidation of the organic substrate and which may add to the synergism. Particularly preferred is a component which operates as a peroxy radical scavenger. These hydroperoxide decomposers convert hydroperoxides into non-radical products thus preventing chain propagation reactions. Commonly organosulfur and organophophorous compounds have severed this purpose, and many suitable compounds have identified herein above with regard the oxymolybdenum component and need not be repeated again. Particularly preferred organophosphorous compounds are the oil-soluble, phosphorus-containing, anti-wear compounds selected from the group consisting of metal dithiophosphates, phosphorus esters (including phosphates, phosphonates, phosphinates, phosphine oxides, phosphites, phosphonites, phosphinites, phosphines and the like), amine phosphates and amine phosphinates, sulfur-containing phosphorus esters including phosphoro monothionate and phosphoro dithionates, phosphoramides, phosphonamides and the like. More preferably, the phosphorus-containing compound is a metal dithiophosphate and, even more preferably, a zinc dithiophosphate. Suitable phosphorous compounds are disclosed in U.S. Pat. No. 6,696,393, incorporated herein by reference.
The following additive components are examples of components that can be favorably employed in combination with the lubricating additive of the present invention. These examples of additives are provided to illustrate the present invention, but they are not intended to limit it.
(A) Ashless dispersants: alkenyl succinimides, alkenyl succinimides modified with other organic compounds such as ethylene carbonate, polysuccinimides, and alkenyl succinimides modified with boric acid, alkenyl succinic ester.
(B) Oxidation inhibitors:
1) Phenol type phenolic) oxidation inhibitors: 4,4′-methylenebis (2,6-di-tert-butylphenol),4,4′-bis(2,6-di-tert-butylphenol), 4,4′-bis(2-methyl-6-tert-butylphenol), 2,2′-(methylenebis(4-methyl-6-tert-butyl-phenol), 4,4′-butylidenebis(3-methyl-6-tert-butylphenol), 4,4′-isopropylidenebis(2,6-di-tert-butylphenol), 2,2′-methylenebis(4-methyl-6-nonylphenol), 2,2′-isobutylidene-bis(4,6-dimethylphenol), 2,2′-methylenebis(4-methyl-6-cyclohexylphenol), 2,6-di-tert-butyl4-methylphenol, 2,6-di-tert-butyl4-ethylphenol, 2,4-dimethyl-6-tert-butyl-phenol, 2,6-di-tert-α-dimethylamino-p-cresol, 2,6-di-tert-4(N.N′dimethylaminomethylphenol),4,4′-thiobis(2-methyl-6-tert-butylphenol), 2,2′-thiobis(4-methyl-6-tert-butylphenol), bis(3-methyl-4-hydroxy-5-tert-butylbenzyl)-sulfide, and bis (3,5-di-tert-butyl4-hydroxybenzyl).
2) Diphenylamine type oxidation inhibitor: alkylated diphenylamine, phenyl-α-naphthylamine, and alkylated α-naphthylamine.
3) Other types: metal dithiocarbamate (e.g., zinc dithiocarbamate), and methylenebis (dibutyldithiocarbamate).
(C) Rust inhibitors (Anti-rust agents):
1) Nonionic polyoxyethylene surface active agents: polyoxyethylene lauryl ether, polyoxyethylene higher alcohol ether, polyoxyethylene nonylphenyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene octyl stearyl ether, polyoxyethylene oleyl ether, polyoxyethylene sorbitol monostearate, polyoxyethylene sorbitol mono-oleate, and polyethylene glycol monooleate.
2) Other compounds: stearic acid and other fatty acids, dicarboxylic acids, metal soaps, fatty acid amine salts, metal salts of heavy sulfonic acid, partial carboxylic acid ester of polyhydric alcohol, and phosphoric ester.
(D) Demulsifiers: addition product of alkylphenol and ethyleneoxide, polyoxyethylene alkyl ether, and polyoxyethylene sorbitane ester.
(E) Extreme pressure agents (EP agents):, sulfurized oils, diphenyl sulfide, methyl trichlorostearate, chlorinated naphthalene, benzyl iodide, fluoroalkylpolysiloxane, and lead naphthenate.
(F) Friction modifiers: fatty alcohol, fatty acid, amine, borated ester, and other esters
(G) Multifunctional additives: sulfurized oxymolybdenum dithiocarbamate, sulfurized oxymolybdenum organo phosphorodithioate, oxymolybdenum monoglyceride, oxymolybdenum diethylate amide, amine-molybdenum complex compound, and sulfur-containing molybdenum complex compound
(H) Viscosity Index improvers: polymethacrylate type polymers, ethylene-propylene copolymers, styrene-isoprene copolymers, hydrated styrene-isoprene copolymers, polyisobutylene, and dispersant type viscosity index improvers.
(I) Pour point depressants: polymethyl methacrylate.
(K) Foam Inhibitors: alkyl methacrylate polymers and dimethyl silicone polymers.
(L) Wear inhibitors: zinc dialkyldithiophosphate (Zn-DTP, primary alkyl type & secondary alkyl type).
EXAMPLES
The invention is further illustrated by the following examples, which are not to be considered as limitative of its scope. A further understanding of the invention can be had in the following nonlimiting Preparations and Examples. Wherein unless expressly stated in the contrary, all temperatures and temperatures ranges refer to the Centigrade system and the term “ambient” or “room temperature” refers to about 20 to 25° C. The term “percent or %” refers to weight percent, and the term “mole” or “moles” refers to gram moles. The term “equivalent” refers to a quantity of reagent equal in moles, to the moles of the preceding or succeeding reactant recited in that example in terms of finite moles or finite weight or volume.
The lubricating oil compositions disclosed herein can be prepared by any method known to a person of ordinary skill in the art for making lubricating oils. In some embodiments, the base oil can be blended or mixed with N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine compound neat or in combination with the other additive component(s). The N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine compound and the optional additives may be added to the base oil individually or simultaneously and the one or more additions may be in any order. In some embodiments, the solubilizing of the N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine compound or any solid additives in the base oil may be assisted by heating the mixture to a temperature from about 25° C. to about 200 ° C., from about 50 ° C. to about 150 ° C. or from about 75° C. to about 125 ° C.
Any mixing or dispersing equipment known to a person of ordinary skill in the art may be used for blending, mixing or solubilizing the ingredients. The blending, mixing or solubilizing may be carried out with a blender, an agitator, a disperser, a mixer (e.g., planetary mixers and double planetary mixers), a homogenizer (e.g., Gaulin homogenizers and Rannie homogenizers), a mill (e.g., colloid mill, ball mill and sand mill) or any other mixing or dispersing equipment known in the art.
Performance Examples
Oxidation studies of the products of selected Examples were carried out in a bulk oil oxidation bench test as described by E. S. Yamaguchi et al. in Tribology Transactions, Vol. 42(4), 895-901 (1999). In this test the rate of oxygen uptake at constant pressure by a given weight of oil was monitored. The time required (induction time) for rapid oxygen uptake per 25 grams of sample was measured at 171° C. under 1.0 atmosphere of oxygen pressure. The sample was stirred at 1000 revolutions per minute. The results are reported, however, as time for rapid oxygen uptake per 100 grams of sample. The oil contained a catalyst added as oil soluble naphthenates to provide 26 ppm iron, 45 ppm copper, 512 ppm lead, 2.3 ppm manganese, and 24 ppm tin.
Performance Examples 1-13
A base line formulation was prepared which to assess the performance of the mixture of: component A) N,N,N′,N′-tetramethyl-naphthalene-1,8-diamine and sold by Sigma-Aldrich as Proton-sponge™, and component B1) a commercially available alkylated diphenylamine (mixture t-butyl and t-octyl—prepared by alkylating diphenylamine with 2,4,4-trimethylpentene) and sold by Ciba-Geigy as Irganox® L-57 or B2) a commercially available bis(nonylphenylamine)amine and sold by Chemtura as Naugalube® 438L; in the oxidator bench test. The base line formulation—Formulation A, contained in a Group 2+ base oil, 12.5 mmoles/kg dialkyl zinc dithiophosphate, 5.0% polyisobutenyl succinimide, 35.0 mmoles/kg overbased calcium sulfonate detergent, 15.0 mmole/kg calcium phenate detergent and 0.3% V.I. improver. The Formulation A baseline was tested in the bulk oil oxidation bench test above and resulted in a value of 7.0 hours to rapid O 2 uptake. To this baseline (Formulation A) were varying amounts of component A with varying amounts of added component B1) or B2). The results are depicted in Table 1 and Table 2 below:
TABLE 1
Synergistic Mixture Top Treated to
Formulation A
Component A)
Component B1)
N,N,N′,N′-tetramethyl-
Alkylated
Results
naphthalene-1,8-
diphenylamine 1
Hr to
Performance
diamine concentration
concentration
rapid O 2
Example
(weight percent)
(weight percent)
uptake
0
0
7.0
1
0
0.5
15.0
2
0.5
0
15.0
3
0.5
0.5
42.0
4
1.0
0.5
66.0
1 Irganox ® L57 is available commercially from Ciba-Geigy
TABLE 2
Synergistic Mixture Top Treated to
Formulation A
Component A)
Component B2)
N,N,N′,N′-tetramethyl-
Alkylated
Results
naphthalene-1,8-
diphenylamine 1
Hr to
Performance
diamine concentration
concentration
rapid O 2
Example
(weight percent)
(weight percent)
uptake
0
0
7.0
5
0
0.5
12.0
6
0.5
0
15.0
7
0.25
0.5
16.0
8
0.5
0.5
19.0
9
0.75
0.5
33.0
10
1.0
0.5
43.0
11
1.25
0.5
49.0
12
1.5
0.5
67.0
13
2.0
0.5
116.0
1 Naugalube ® 438L is available commercially from Chemtura
The excellent oxidation performance of N,N,N′,N′-tetramethyl-naphthalene-1,8-diamine is shown in Example 2. The excellent oxidation performance of N,N,N′,N′-tetramethyl-naphthalene-1,8-diamine in combination with diphenylamines is shown Examples 3,4 and 7-13.
|
Disclosed is a lubricating oil composition containing an oil of lubricating viscosity and a N,N,N′,N′-tetraalkyl-naphthalene-1,8-diamine and at least one additive selected from antioxidants, dispersants, and detergents which together provide superior oxidation inhibition and are suitable lubricants for automotive and truck crankcase lubricants; as well as transmission lubricants, gear lubricants, hydraulic fluids, compressor oils, diesel and marine lubricants.
| 2
|
BACKGROUND OF THE INVENTION
This invention relates to method and apparatus for the control of a ball lift mechanism used in bowling alleys.
In a typical bowling alley, returning balls are lifted up to be placed in a position which is within convenient reach of the players. This is generally accomplished by providing a continuously moving belt driven by an electric motor at each alley. In most bowling alleys, the belt is continually driven as long as the bowling alley is open for business, while in some situations the belt may be driven when the particular alley is in use.
In either type of situation, since the average time required to lift a ball is no more that four seconds, it can readily be seen that a large amount of electrical power is being used to keep the belts driven when not even needed. In addition to costs in terms of power usage, the motor, the drives, the belts, etc. are continuously in use with the result that maintenance and repair costs with consequent down time is an important cost consideration in the operation of a bowling alley.
A variety of systems have been developed for accelerating returning bowling balls, detecting fouls by players, and similarly related control systems. Examples of these are shown in British Pat. No. 1,396,117 and U.S. Pat. Nos. 2,417,092, 2,664,290, 2,852,765, 4,140,220, and 4,378,114. None of the preceding patents teach any system which can be useful in controlling the operation of the ball lifting mechanism in accordance with the principles of this invention.
SUMMARY OF THE INVENTION
The present invention provides a system for controlling the operation of the ball lifting belt drive mechanism in which the drive is energized only when its operation is required by an approaching ball and utilizes a solid state timer to control the start winding of the motor driving the belt instead of the usual centrifugal clutch switch that normally controls the winding.
In accordance with a preferred embodiment of this invention, there is provided a control system in a ball lift mechanism for the ball return chute of a bowling alley having a continuous belt interconnecting a pair of pulleys for lifting each returning ball and an induction motor with a capacitor start having a run winding and a start winding for driving said pulleys. The control system includes a light sensitive device for detecting the approach of a returning ball and producing a trigger signal, and a pair of running timers or clocks to activate the run winding of the motor. This causes an opto-isolator to produce a first activation signal, for a first triac which energizes the run winding. A starting timer or clock is provided for the start winding, utilizing a second opto-isolator and triac to energize the start winding of the motor. An inhibit signal is employed to prevent retriggering of the starting timer while the motor is running. Provision is included to restart the running timers when a successive ball approaches while a preceding ball is being lifed.
It is thus a principal object of this invention to provide a control system for a bowling ball lift mechanism which is operable only when required.
Other objects and advantages of this invention will become obvious from the following detailed description of preferred embodiments of this invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a partially schematic view of a typical returning bowling ball lift mechanism to which this invention relates.
FIG. 2 is a schematic of a preferred embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there is illustrated a typical lift assembly 10 for returning bowling balls now in use in bowling alleys. Assembly 10 consists of a ball rack 12 on which balls 14 collect after being raised, a pair of spaced returning rails 16 on which balls 14 ride while returning, and a lift mechanism 18 to raise balls 14 for assembling on rack 12. Mechanism 18 consists of a continuous belt 22 wrapped around a pair of pulleys 24 and 26 driven by a belt drive 28 from motor 32 to pulley 26. A stationary strap 48 is provided for braking purposes.
In the operation of the assembly 10 just described, when ball 14 on parallel, spaced rails 16 returning by gravity makes contact with moving belt 18 it is raised by the latter and deposited on rack 12. As previously described, mechanism 18 is normally in continuous operation even though only during a small percentage of time is mechanism 18 actually performing its function of raising a ball 14.
For a description of the preferred embodiment of this invention, reference is also made to FIG. 2. Operating system 30 comprises a photocell 33 consisting of a light source 34 centrally located between and below rails 16 and a photo receptor 36 directly above so that returning ball 14 will interrupt the passage of light as it passes between source 34 and receptor 36. Photocell 33 would be located as seen in FIG. 1 just before ball 14 reaches continuous belt 22.
The output of photocell 33 goes to a transistor Tp whose output signal is fed to timers or clocks T1, T2 and T3. The outputs of timers T1 and T2 are connected to the input of timer T3 through a delay line DL and also to opto-isolator 38. Typically timer T1 will produce a signal upon actuation for 0.5 sec., while timer T2 will produce a signal for 3.5 secs. beginning when the signal from timer T1 terminates as conveyed through capacitor C1 as the result of the manner by which timers T1 and T2 are connected to each other. Timer T3 will produce a signal for about 0.2 sec. The signal to timer T3 coming from delay line DL acts as an inhibit signal. The purpose of these periods of time will be described below. Delay line DL includes a capacitor C2 and a bleeding resistor R1.
The outputs of timers T1 and T2 are also ORed through a pair of diodes D1 and D2, respectively, to opto-isolator 38 which passes its output through a triac 42 to RUN winding I1 in induction motor 32. Diodes D3, D4, D5 as well as diodes D1 and D2 prevent any reverse current flow.
The output of timer T3 goes to opto-isolator 44 which energizes triac 46 which activates START winding I2 in motor 32 through a capacitor C3. Motor 32 is powered from the A.C. source illustrated when triacs 42 and/or 46 are energized, as shown. The purpose of opto-isolators 38 and 44 is to isolate the low voltage and high voltage sides of the system.
From the arrangement just described, it is seen that RUN winding I1 is energized for a total of four seconds (the total sequential time of timers T1 and T2). Four seconds is the time determined to insure that a ball passing through photocell 33 has enough time to reach rack 12. Timer T3 fires for 0.2 sec., the time required to energize START winding I2.
It is understood that each of the timers which have been described are clocks which deliver signals for preselected periods of time, as is understood in the art.
In the operation of system 30, in its quiescent state (belt 22 inoperative), light from source 34 strikes photo acceptor 36 unimpeded. All timers T1, T2, and T3 are not active and this holds opto-isolators 38 and 44 off which in turn holds the triacs 42 and 46 off. The motor RUN and START windings, I1 and I2, respectively receive no current.
When a ball 14 comes down the chute it interrupts the light path from source 34 to photo receptor 36 causing transistor Tp to start conducting.
This results in a voltage drop at the collector of transistor Tp causing timer T1 to start running which will energize the run winding I1 and start to load up delay line DL, that is, charge up capacitor C2. At the same time, the firing of transistor Tp will initiate the operation of timer T3 which will energize the START winding I2 of motor 32. Timer T3 operates only for the length of time it takes to get motor 32 running and the period of time selected for timer T3 would depend on the characteristics of motor 32. A typical period of time, as already noted, would be 0.2 sec.
When timer T1 terminates, this causes by way of capacitor C1 timer T2 to begin running resulting in the RUN winding I2 of motor 32 to remain energized and keep the latter going. The signal being received and passed through by delay line DL to timer T3 acts as an inhibit signal and keeps timer T3 from being initiated. The purpose of the delay is not to interfere with the initiation of timer T3 by the signal directly from transistor Tp when starting from a quiescent state.
In the event no ball passes through photo cell 32 within four seconds after the first ball, timer T2 will stop running after 3.5 secs, delay line DL will bleed off the charge on its capacitor C2, and motor 32 will stop running.
However, should a second ball pass through photo cell 32 while timer T2 is still running, activation of transistor TP will cause timer T1 to refire (ie. start running) and timer T2 to be reset (that is, stop it from running and have it ready to start all over again when timer T1 terminates).
It should be noted that the mechanics of the ball handling system shown in FIG. 1 are such that no ball can follow closer than 1 sec. behind the preceding ball so that it is not possible for a successive ball to pass through photo cell 32 while timer T1 is running.
The outputs of timers T1 and T2 keep RUN winding I1 activated for a minimum of four seconds. If an additional ball arrives before the end of the four second period then timer T1 and timer T3 are retriggered in succession as previously described. This extends motor run time to four seconds after the last ball has arrived, at which time system 30 returns to its quiescent state provided no new ball arrives within the four seconds.
In the arangement which has been described it is understood that timer T3 delivers a timing signal of sufficient duration to effect the start of motor 32. The duration of the timing signals delivered by timers T1 and T2 in sucession is sufficient to cover the period of time for ball lift assembly 10 to carry a ball 14 arriving at lift mechanism 18 to its resting place on ball rack 12. The duration of the timing signal delivered by timer T1 is less than the spacing capabilities of lift mechanism 18, that is, less than the minimun period of time between balls that the apparatus is capable of handling. Typically, such apparatus could not lift balls at the rate of more than one a second. The shorter duration of the signal from timer T1 insures that any successive ball which arrives at photo detector 33 will occur while timer T2, rather than timer T1 is running, causing timer T1 to restart and timer T2 to be reset, that is, turned off and ready to be restarted when the signal from timer T1 terminates.
The advantages of the arrangement just described include the sharp reduction in power consumption. A system according to the preferred embodiment was installed and it was found that motor 32 ran only about one-third of the time with consequent sharp reduction in the amount of electric power consumed.
In addition, intermittent operation reduces motor and lift mechanism wear so that reduced repair and maintenance costs are to be expected with the use of this invention.
A further advantage of this invention is that the operation of the START winding I1 using a timer replaces the usual centrifugal clutch switch that normally controls it. Replacement of a mechanical part with a solid state timer increases its reliability.
While only certain preferred embodiments of this invention have been described it is understood that many variations are possible without departing from the principles of this invention as defined in the claims which follows.
|
Method and apparatus for controlling and operating the return ball lift mechanism in a bowling alley. In a preferred embodiment the motor which drives the lifting belt is normally inoperative and it is actuated when a ball arrives to be lifted into the storage rack. A photo detector is utilized to detect the presence of the returning ball and provision is made to actuate the motor for a total of four seconds. In the event a second ball arrives before the end of four seconds, timing begins all over again. A feature of the invention is the elimination of a centrifugally operated switch to control the START winding of the motor as a solid state timer controls the operation of both windings of the motor.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to safes. More particularly, the present invention relates to an adjustable jamb device for securing door bolts in an open jamb-type safe.
2. Related Art
High security metal safes typically have a heavy steel door that, when closed, is secured by a series of hardened steel bolts that extend from the door into the frame of the safe surrounding the door. A recess or pocket is provided in the door frame for each of the door bolts. The door bolts are aligned with the pockets, and slide thereinto when the safe is locked. While these types of safes are very secure, they tend to be very expensive and very heavy, and are not generally suitable for a typical consumer.
Most consumers with the need for a safe are more likely to purchase a lower cost open-jamb type safe. These safes are typically fabricated of thinner steel than high security safes (i.e. sheet steel, rather than steel plates), and are intended to provide moderate security with high fire protection. The interior of the safe may include gun racks, shelves, file drawers, and other storage systems for holding various types of valuables such as cash, coins, jewels, stocks, bonds, important documents, records, electronic storage media (e.g. videotapes, floppy disks, compact disks, etc.) guns, and so forth. Gun safes of this type have become particularly popular in recent years, particularly in view of some widely publicized incidents related to unsecure storage of firearms.
Like their high security counterparts, lower cost open jamb-type safes comprise a steel case with a door that is secured closed by a series of hardened steel door bolts. However, unlike a high security safe, an open-jamb type safe simply has an inside door jamb against which all the bolts press, rather than having individual sleeves or pockets into which each bolt slides. When the bolts are extended, the door cannot open because the bolts press against the inside of the door frame.
Unfortunately, with this type of locking mechanism, open jamb-type safes present some common problems. One problem is that when the door is closed and bolted, there tends to be some flexure of the door relative to the door frame. One can actually pull on a bolted door and watch the edge of the door move outward next to the frame. This condition does not necessarily represent a functional flaw of the safe, but it is objectionable to consumers, and gives the impression of low quality goods.
This condition has several causes. Because they are not intended as high-priced, high security safes, manufacturing tolerances for low cost open jamb-type safes are generally lower than for high security safes. Consequently, the alignment of the door locking bolts may vary slightly, such that when the bolts are extended, they may not uniformly contact the inside of the door jamb. This problem is compounded by the presence of a resilient door seal strip, which allows some uniform give between the door and the door frame. To provide better and more uniform bearing, several approaches have been attempted. Some manufacturers provide a flexible steel flange along the length of the door jamb. When the bolts extend, they deflect the flange, thus providing more positive bearing for the bolts, regardless of any slight misalignment. However, a common flange for a number of bolts does not necessarily solve the problem of non-uniform bearing, because one single flange contacts all bolts, regardless of their actual alignment. Thus, the position of one bolt may deflect the flange away from contact with an adjacent bolt. Additionally, because the flange is flexible, the door flex problem remains.
Furthermore, the presence of a relatively large steel part (the common door flange) within a safe and directly connected to an inner portion of the safe cabinet presents fire resistance problems. Since metals are thermal conductors, it is important to limit the amount of exposed metal within a safe in order to promote fire and heat resistant properties. A large metal flange inside the safe will tend to aggravate this situation.
Another approach to the problem is to provide an individual flexible flange corresponding to each bolt. These can be individually bent to the correct position for contact with each bolt. While this approach addresses the misalignment problem, it does not prevent door flexure because each flange is flexible. Pulling on the door simply deflects all flanges.
SUMMARY OF THE INVENTION
It has been recognized that it would be advantageous to develop a door bolt bearing system for an open jamb-type safe that substantially prevents door flexure.
It would also be desirable to develop a door bolt bearing system for an open jamb-type safe that allows individual adjustment for the alignment of each door bolt.
The invention advantageously provides a door bolt adjustment system for an open-jamb safe having a door jamb and a door bolt configured to extend behind the door jamb with a gap therebetween. The door bolt adjustment system generally comprises a substantially rigid door bolt adjuster, configured to be attached to the inside of the door jamb, and a displacement mechanism, configured to allow adjustment of the position of the door bolt adjuster so as to occupy the gap. The door bolt adjuster includes a flange for contacting a side of the extended safe door bolt, and when the adjuster occupies the gap places the flange in position for secure contact with the extended door bolt, so as to accommodate the alignment of the door bolt.
In accordance with a more detailed aspect of the present invention, the displacement track comprises at least one elongate slot, extending through the attachment side of the door bolt adjuster, the slot configured to mate with at least one fastener disposed on the door jamb, whereby the position of the door bolt adjuster plate may be selectively adjusted along the door jamb.
Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the exterior of a typical low cost open-jamb type safe.
FIG. 2 is a cross-sectional view showing the safe door, door frame, and bolt bearing mechanism incorporating a door bolt adjuster according to the present invention.
FIG. 3 is a cross-sectional view of the door jamb and adjuster shown in FIG. 2 .
FIG. 4 is a perspective view of the door bolt adjuster shown in FIGS. 12 and 3 .
FIG. 5 is a perspective view of an alternative door bolt adjuster configured for use in accordance with the present invention.
FIG. 6 is a perspective view of yet another alternative door bolt adjuster configured for use in accordance with the present invention.
DETAILED DESCRIPTION
Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein; which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
The present invention relates to metal safes, particularly lower cost open-jamb type safes, such as the safe 10 depicted in FIG. 1 . Like their high security counterparts, lower cost open jamb-type safes typically comprise a steel case 12 with a door 14 that is secured closed by a series of door bolts 16 . The interior of the safe may include gun racks, shelves, file drawers, and other storage systems for holding various types of items.
With reference to FIG. 2 , unlike a high security safe, an open-jamb type safe is one which, rather than having individual sleeves or pockets into which each bolt slides, simply has an inside door jamb 18 (i.e. a vertical edge of the inside of the case) against which all the bolts 16 press. When the bolts are extended, the door cannot open because the bolts press against the inside of the door frame.
Unfortunately, with this type of locking mechanism, open jamb-type safes present some common problems. One problem is that when the door is closed and bolted, there tends to be some flexure of the door 14 relative to the door frame, primarily due to slight misalignment of the door bolts 16 . This misalignment produces a gap 20 , between the inside edge 18 of the door jamb and the position of the extended bolt when the door is closed and properly aligned with its frame. One can actually pull on a bolted door and watch the edge of the door move outward next to the frame. This condition does not necessarily represent a functional flaw of the safe, but it is objectionable to consumers, and gives the impression of low quality goods.
This condition has several causes. Because they are not intended as high-priced, high security safes, manufacturing tolerances for low cost open jamb-type safes are generally lower than for high security safes. Consequently, the alignment of the door locking bolts may vary slightly, such that when the bolts are extended, they do not uniformly contact the inside of the door jamb. This problem is compounded by the presence of a resilient door seal strip 22 , which allows some uniform give between the door and the door frame. While it is possible to tighten manufacturing tolerances to eliminate much of this misalignment, the degree of accuracy required would greatly increase the cost of these safes.
To provide better and more uniform bearing, several approaches have been attempted. Some manufacturers provide a continuous flexible steel flange along the length of the inside of the door jamb. When the door bolts extend, they deflect the flange, thus providing more positive bearing for the bolts, regardless of slight misalignment. However, a common flange for a number of bolts does not necessarily solve the problem of non-uniform bearing, because one single flange contacts all bolts, regardless of their actual alignment. Thus, the position of one bolt may deflect the flange away from contact with an adjacent bolt. Additionally, because the flange is flexible, the door flex problem remains.
Furthermore, the presence of a relatively large steel part (the common door flange) within a safe and directly connected to an inner portion of the safe cabinet presents fire resistance problems. Since metals are thermal conductors, it is important to limit the amount of exposed metal within a safe in order to promote fire and heat resistant properties. A large metal flange inside the safe will tend to aggravate this situation.
Another approach to the problem is to provide an individual flexible flange corresponding to each bolt. These can be individually bent to the correct position for contact with each bolt. While this approach addresses the misalignment problem, it does not prevent door flexure because each flange is flexible. Pulling on the door simply deflects all flanges.
The present invention helps overcome the problems of the prior art by providing a door bolt bearing system for an open jamb-type safe that substantially prevents door flexure and allows individual adjustment for the alignment of each door bolt. Viewing FIGS. 2-4 , in one embodiment the invention comprises a substantially rigid door bolt adjuster plate 24 that attaches to the inside of the door jamb 18 adjacent to each bolt 16 . The adjuster plate comprises a bent metal plate having an attachment side 26 for attaching to the door jamb, and a flange side 28 configured for contacting a door bolt. Viewing FIG. 4 , the bend angle θ between the attachment side and the flange side is preferably slightly more than about 90°. It can be within about 10° of perpendicular, but an angle of about 95° is most preferred. This angle provides slight spring-like resistance against an extended door bolt. The flange is also oriented at an angle, as will be described in more detail below. The adjuster plate may be made of grade 301 stainless steel of about 0.0359″ thickness to provide adequate stiffness and rigidity. This configuration provides secure bearing against an extended door bolt, yet also flexes slightly when the door bolt presses into the bend angle. However, other materials of differing thicknesses may also be used. For example, other grades of steel, including nonstainless steel, plastic, and other durable materials may also be used.
The adjuster plate 24 and door jamb 18 comprise a displacement track, whereby the position of the flange 28 relative to the door jamb may be adjusted by moving the adjuster plate relative to the door jamb before tightening it on the door jamb. In the embodiment of FIGS. 3 and 4 , the displacement track comprises two elongate slots 30 , disposed in end-to-end relationship along a common axis on the attachment (or vertical) side 26 of the adjuster plate. The elongate slots are configured to mate with fasteners 34 , such as bolts, screws, etc., associated with the door jamb.
The displacement track is preferably configured with a maximum displacement length L at least as great as the width W of the gap 20 between the door bolt 16 and the door jamb 18 . The extreme positions of the adjuster plate 24 relative to a single door bolt are shown in dashed lines in FIG. 3 . The flange 28 is oriented at an angle α relative to the displacement track (also the common axis of the elongate slots 30 ), so as to provide a slanted face 36 . This angle may vary, but is preferably from about 5° to about 20°. The benefit of this configuration is that when the adjuster plate is moved linearly (i.e. vertically) along the displacement track (the common axis of the slots) before tightening the fasteners, the slanted face 36 of the flange 26 translates laterally to fill the gap 20 between the door bolt 16 and the door jamb 18 . Once tightened in place, the adjuster plate provides a secure bearing surface for the extended door bolt. In other words, by sliding the adjuster vertically, up or down, the point of contact of the flange with the bolt moves laterally. The result is that the bearing of each bolt can be individually adjusted, and when the door is bolted, there is little or no flex because of the rigidity of the adjuster plate.
The adjuster plate 24 may be configured in a variety of ways. It will be apparent that, rather than two aligned linear slots ( 28 in FIG. 4 ), the adjuster plate may comprise just one elongate slot through which one or more fasteners may extend. Alternatively, as shown in FIG. 5 , the adjuster plate may comprise a mounting hole 38 and an arcuate slot 40 disposed in the attachment side 26 of the adjuster plate. The mounting hole is configured to mount over a first fastener 34 , while the arcuate slot fits over a second fastener 34 . The arcuate slot defines a circular arc with the mounting hole defining the center point of the arc. This arrangement allows the adjuster plate to pivot on the first fastener, while sliding the second fastener along the arcuate slot, so as to adjust the position and angle of the flange 26 and its slanted face 36 relative to the displacement track. Once the flange is in the desired position, so as to provide positive bearing against the associated door bolt, the first and second fasteners can then be tightened.
As yet another alternative, the adjuster plate 24 may be configured without a slanting face, and instead comprise a pair of parallel elongate slots 42 slantingly disposed on its attachment side 26 . These slots are configured to mate with two fasteners 34 disposed on the door jamb, such that the position of the slanted face 36 of the flange 26 relative to the door jamb 18 may be linearly adjusted along a slanted path relative to an edge of the door jamb by sliding the adjuster along the two fasteners. This will translate the position of the flange either toward or away from the door jamb, without rotating it. Once the flange is in the desired position, so as to provide positive bearing against the associated door bolt 16 , the fasteners in each slot can then be tightened.
It will be apparent that other variations in the design of the door bolt adjustment system are possible. For example, rather than providing slots in the adjuster plates and attaching the fasteners to the door jamb, the configuration may be reversed, with the fasteners attached to the adjuster plate, and slots disposed in the door jamb. Alternatively, slots could be provided in both the adjuster plate and the door jamb, with separate fasteners extending through both.
It is to be understood that the above-referenced arrangements are illustrative of the application for the principles of the present invention. Numerous modifications and alternative arrangements can be devised without departing from the spirit and scope of the present invention while the present invention has been shown in the drawings and described above in connection with the exemplary embodiments(s) of the invention. It will be apparent to those of ordinary skill in the art that numerous modifications can be made without departing from the principles and concepts of the invention as set forth in the claims.
|
A door bolt adjustment system for an open-jamb safe having a door jamb and a door bolt configured to extend behind the door jamb with a gap therebetween. The door bolt adjustment system generally comprises a substantially rigid door bolt adjuster, configured to be attached to the inside of the door jamb, and a displacement mechanism, configured to allow adjustment of the position of the door bolt adjuster so as to occupy the gap. The door bolt adjuster includes a flange for contacting a side of the extended safe door bolt, and when the adjuster occupies the gap, the flange is placed in position for secure contact with the extended door bolt, so as to accommodate the alignment of the door bolt.
| 4
|
FIELD OF THE INVENTION
The present invention relates to a base for a camera; particularly, it relates to a clamping base capable of flexibly adjusting a holding position so that a camera can be easily installed on the clamping base.
BACKGROUND OF THE INVENTION
The base for holding the conventional web cams to an electronic device, such as a notebook, an LCD, and so on, is as follows: One means is to adapt the clamping force of a damper so as to clamp the web cam on the electronic device. Although the damper can be adjusted according to the thickness of the various electronic devices, large clamping force can easily cause the electronic device to break. Furthermore, the main drawback of the damper is that for those electronic devices with a greater thickness, the length of the two clamping arms of the damper must be increased. Another means is to adapt a base in a slight n-shape so as to utilize the fixed size of the opening of the base; the two opposite sidewalls of the opening press against the two sides of the electronic device respectively. The main drawback of the n-shape base is that because the size of the opening of the n-shape base is fixed, it is only useful for the electronic device having the same thickness as the size of the opening.
Due to the two conventional means being limited to the thickness of the electronic device, the inventor of the present invention provides an improved easily adjustable clamping base so that the web cam can be more easily installed on the base in accordance with the thickness of a variety of electronic devices.
SUMMARY OF THE INVENTION
An objective of the present invention is to provide a clamping base capable of being detached from or engaged with a camera.
Another objective of the invention is to provide a clamping base for a camera which can flexibly adjust the holding position in accordance with various thicknesses of electronic devices.
In order to accomplish the above objectives, the present invention provides a clamping base of a camera, including a body capable of engaging with and holding a camera, and a second wall portion capable of being detached from and engaged with the body. The body includes a pressing plate, wherein the pressing plate is used to allow the camera to be inserted therein, and thus to press against and hold the camera. The clamping base further includes a moving portion; the moving portion includes a sliding rod and a first wall portion set at one end of the sliding rod; wherein the sliding rod can perform a push-pull movement on the body, and the other end of the sliding rod is set inside the body.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and advantages of the present invention will become more apparent with reference to the appended drawings wherein:
FIG. 1 shows a perspective view illustrating the clamping base of the present invention and the camera before engagement;
FIG. 2 shows a perspective view illustrating the clamping base of the present invention and the camera after engagement;
FIG. 3 shows a perspective view illustrating the clamping base of the present invention in which the first wall portion is detached from the body;
FIG. 4A shows a side elevational view of the clamping base with the camera illustrating the wallboard of the first wall portion being moved closed to the first wall portion of the moving portion;
FIG. 4B shows a side elevational view similar to FIG. 4A illustrating the wallboard of the first wall portion being moved far from the second wall portion of the moving portion;
FIG. 5 shows a perspective view illustrating the moving portion being pulled away the body;
FIG. 6 shows a side elevational view of the clamping base of the invention with the camera illustrating the clamping base holding an electronic device;
FIG. 7A shows a sectional view of the body and the moving portion of the present invention illustrating the moving portion being not pulled away the body; and
FIG. 7B shows a sectional view of the body and the moving portion of the present invention illustrating the moving portion being pulled away the body.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , FIG. 2 and FIG. 3 , the elastic plate 21 of the camera 20 is inserted under the pressing plate 11 a (as shown in FIG. 3 ) of the clamping base 10 , that is, the elastic plate 21 is pressed against and held by the elasticity of the pressing plate 11 a so that the camera 20 can be stably disposed on the clamping base 10 . The material of the pressing plate 11 a of the present invention can be made of a malleable plate, such as a plastic plate, or a metallic plate, etc.
Referring to FIG. 3 again, the clamping base 10 of the present invention includes a body 11 , a moving portion 13 , and a first wall portion 15 . The body 11 can be in a slightly rectangular shape. The top of the body 11 is attached with the pressing plate 11 a , and the bottom thereof is detachably engaged with the first wall portion 15 . Further, it can be seen that the pressing plate 11 a at an end thereof joined to a lateral side of the body and the moving portion 13 is disposed at another lateral side of the body opposite to the lateral side joining the pressing plate 11 a . The body 11 has a semicircular recess and an L shaped groove (not shown) at another two opposite lateral sides thereof respectively. The first wall portion 15 further provides a horizontal plate section with a long lateral side thereof extending downward a wallboard 15 a and a semicircular upper plate section with an L shaped fitting piece at the inner side thereof extends upward from two short sides of the first wall portion 15 respectively corresponding to the semicircular recess and the L shaped groove. In addition, a split type engaging bar is disposed at the center of the horizontal plate section for engaging with the bottom of the body with the semicircular plate section and the L shaped fitting piece fitting with the semicircular recess and the L shaped groove respectively. Referring to FIG. 4A and FIG. 4B , the first wall portion 15 can be engaged with the body 11 in two ways. In FIG. 4 a , the wallboard 15 a of the first wall portion 15 is engaged to the body 11 in a way of being close to the second wall portion 13 a . In FIG. 4B , the wallboard 15 a of the first wall portion 15 is engaged to the body 11 in a way of being far from the second wall portion 13 a . That is, the position of the first wall portion 15 shown in FIG. 4A is opposite to the position of the first wall portion 15 shown in FIG. 4B .
Referring to FIG. 5 , the moving portion 13 further includes two parallel sliding rods 13 b , and the second wall portion 13 a set at one end of each of the sliding rods 13 b . The other end of the respective sliding rod 13 b is set inside the body 11 so that the sliding rods 13 b are movable inward and outward the body 11 . In other words, the sliding rods 13 b are capable of being pushed into and pulled out the body. In this way, the distance between the second wall portion 13 a and the wallboard 15 a can be changed while the clamping base of the invention being in use. Referring to FIG. 6 , when the clamping base 10 of the present invention is in use, the moving portion 13 is pulled away the body 11 with the slide rods 13 b and the wallboard 15 a is engaged to the body at a selected position such that the second wall portion 13 a and the wallboard 15 a are capable of pressing against the two sides of the electronic device 30 . The electronic device 30 can be a notebook or an LCD. The distance between the second wall portion 13 a and the wallboard 15 a can be flexibly varied depending on the lengths of the sliding rod 13 b being pulled outward the body 11 and the position of engagement between the first wall portion 15 and the body 11 in accordance with different electronic devices.
Referring to FIG. 7A and FIG., an elastic element 13 c , such as a spring, is provided to coil around the respective sliding rod 13 b of the moving portion 13 in the body 11 . An end of the elastic element 13 c is fixedly joined to the free end of the respective sliding rod 13 b and another end of the elastic element 13 c presses against a lateral side of the body 11 next to the moving portion 13 . Thus, the second wall portion 13 a can be tightly pressed against the electronic device 30 by the elasticity of the spring.
The clamping base 10 of the present invention allows the camera 20 to be easily held and detached at the same time. Furthermore, the clamping base 10 provides an extensible moving portion 13 . Together with the various combinations of the second wall portion 15 and the body 11 , the clamping base 10 of the present invention can hold the camera 20 on the electronic device 30 with any thickness. The clamping base 10 of the present invention can be adapted to any type of camera 20 , such as a web cam, a digital camera, etc.
Those skilled in the art are to be noted that the present invention can be modified without leaving the scope and spirit of the present invention. The scope of the present invention is covered by the appended claims and all the substantial equivalents of variation and arrangement.
|
The present invention is a clamping base, including a body capable of engaging with and holding a camera, and a second wall portion capable of being detached from and engaged with the body. The clamping base further includes a moving portion. The moving portion includes a sliding rod and a first wall portion set at one end of the sliding rod. The sliding rod can perform a push-pull movement on the body and the other end of the sliding rod is set inside the body.
| 8
|
The present applicant claims priority to U.S. 60/777,360, which is hereby incorporated by reference.
FIELD OF THE INVENTION
The invention relates to anchoring device for securing an object to the ground. More particularly, the invention relates to an anchoring device that may be set, removed and reused with few or no tools.
BACKGROUND OF THE INVENTION
Posts, such as sign posts, fence posts, mailbox posts, etc., are typically set into the ground by digging a hole, placing the post in the hole, and filling the hole with concrete or compacted soil. The process is tedious and time-consuming, and below ground placement of a post can lead to rot or corrosion. Further, removal or repositioning of the post requires digging the post from the hole. The removal process can be even more difficult than initial placement.
Prior art includes a number of devices that facilitate placement or removal of a post. U.S. Pat. No. 5,400,997 describes a pre-fabricated anchoring base that may be set into the ground. A post may be securely yet removably set into the base. Disadvantageously, a hole must still be dug in the ground, the insert placed into the hole, and the hole backfilled with a suitable material. Digging scars the landscape, disrupts the land, requires replanting or reseeding, and dirt must be hauled away. Further, the post is still anchored below grade, so rot and corrosion could be problematic.
U.S. Pat. No. 6,308,468 teaches an anchor stake that is driven into the ground and over which a pole may be fitted. Digging of a hole is unnecessary, but a sledgehammer or other driver is needed to insert the stake. Variations on the anchor stake include U.S. Pat. Nos. 5,076,032, 6,745,990, 6,461,084 and 6,343,446, which include stakes having a plurality of fins for improved stability. The stakes are driven into the ground and provide a supporting platform for a post. The platform permits the post to rest above grade.
Another type of anchor includes a helical member that screws into the ground. U.S. Pat. No. 5,135,192 teaches a single helical rod fixedly secured, such as by welding, to a flat plate. The rod may be twisted into the ground until the flat plate rests on the ground. The plate may include means to attach a post to the plate. The single helical rod lacks lateral stability and can be lifted from the ground by sideways movement. Larger helical rods may be used to reduce this defect, but a large helical rod is more difficult to screw into the ground and may require a tool, such as a large wrench or pipe. Also, because the helical rod is fixedly secured to the plate, the plat would not be level and any post fixed to the plate would be out of plumb if the helical rod is screwed into the ground off perpendicular.
U.S. Pat. Nos. 6,202,368, 4,858,876, and 5,011,107 substitute a screw or auger for a helical rod. The screw or auger is fixedly attached a post mounting means. The larger cross-sections of the screw and auger demand greater power to drive the devices into the ground. A tool would probably be needed. Again, the fixed screw or auger could be inadvertently set so that the mounting means is out of plumb.
U.S. Pat. No. 5,113,627 teaches a sign and anchor apparatus. The sign includes a plurality of legs that penetrate the ground. The sign is set separately from the anchor, thereby facilitating vertical placement of the sign even if the anchor is out of plumb. The anchor includes an auger on a terminal end that is screwed into the ground. The other end of the anchor locks to the sign so that the sign cannot be easily pulled from the ground.
The above-described prior art, including the digging of holes or use of stakes, screws or augers, utilize rigid and often sharp points or edges forced into the ground. This requires the marking of utility services before placement. Failure to mark such services can result damage to the service line. Helical rods of the prior art do not necessarily have sharp points or edges, but only a large diameter rod provides sufficient holding power to secure a post to the ground. Such a large rod even lacking points or edges can damage a utility line.
A need exists for an anchoring device that securely yet removably fixes an object, such as a post, pole, or cable, to the ground, and does not pose a risk of damaging utility lines. The object could be plumbed regardless of the orientation of the anchors used to secure it to the ground. Advantageously, the anchoring device could be installed or removed without tools.
SUMMARY OF THE INVENTION
The present invention describes an anchor for removably fixing objects to the ground. Objects include, for example, posts, mailboxes, poles, and tie-outs. The anchor is especially useful for securely fixing, either temporarily or permanently, objects to the ground, such as signs, mailboxes, clothesline poles, tent supports, and sports nets. Placement of the anchor requires no digging and no special tools. Advantageously, subterranean obstructions can be detected and avoided while securing the anchor to the ground, thereby protecting utility lines from damage and causing no visible damage to the ground surface. Typically, the torque is needed to secure the anchor to the ground can be achieved using merely hands, a bar or wrench. A driving device, such as a sledgehammer, is unnecessary.
In a broad aspect, the anchor includes a base defining a plurality of holes. The base is set on the ground at the desired inclination. Fasteners pass through the holes and screw into the ground. The plurality of fasteners prevents the base from moving. The base prevents lateral movement of the fasteners that could weaken the holding power of the individual fasteners.
The base includes a central portion surrounded at least in part by a skirt. The central portion accepts and is shaped to receive the object. The central portion also comprises a retainer for the object. The retainer may be a flange, tenon or other mechanical connector. The skirt stabilizes the base and resists tipping. The size and shape of the skirt depends on the object to be secured. The skirt may include, for example, at least a portion of a disc or frusto-conical member surrounding the central portion. Alternatively, the skirt may include a plurality of legs. The skirt defines a plurality of holes through which the fasteners secure the base to the ground.
A fastener comprises a helical structure. The fastener may include a central shaft, such as a screw, or simply a helical coil. In one embodiment, the fastener should be flexible enough not to penetrate or sever utility lines. The flexibility of the fastener permits detection of subterranean obstacles, such as utility lines. In another embodiment, the fasteners may be screwed into the ground without tools. In still another embodiment, the fastener includes head. The head may be flattened or may define an eyelet. A wrench may be applied to the flattened head and the fastener screwed into the ground. An elongated object, such as a pipe, bar or screwdriver, may be inserted into the eyelet and the fastener screwed to the ground.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an anchor of the present invention.
FIG. 2 is a side view of a helical coil.
FIG. 3 is side perspective view of one embodiment of the invention.
FIG. 4 is side perspective view of a second embodiment of the invention.
FIG. 5 is a cut-away side view of an anchor of the present invention.
FIG. 6 is a top view of an anchor of the present invention.
FIG. 7 is side view an anchor of the present invention having a cover.
FIG. 8 is a washer for use in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the anchor 1 of the present invention. The anchor 1 includes a base 2 and a plurality of fasteners 5 . The base 2 includes a central portion 4 surrounded at least in part by a skirt 3 . The central portion 4 is adapted to receive an object (not shown). The skirt 3 defines holes 6 through which fasteners 5 imbed in the ground 7 , thereby securing the anchor 1 . The base 2 reduces relative movement of the fasteners 5 , thereby reducing lateral displacement that could lead to weakening of the fastener/ground contact.
The base 2 preferably has a flat bottom 7 so that the base 2 may be set on the ground to assure vertical positioning of the object. The base 2 may even include an integrated level. Unlike prior art, plumb may be set before the fasteners 5 secure the base 2 to the ground. The base 2 should comprise a rigid material, such as metal, wood or plastic. Plastic is resistant to corrosion and can be molded into a variety of shapes.
The skirt 3 at least partially surrounds the central portion 4 and may comprise at least a part of a disc, a plate, a frusto-conical element, or separate legs. The skirt 3 defines a plurality of holes 6 . The holes 6 should be located for stability. For example, two holes may be placed on either side of the central portion 4 or three holes may be positioned equally surrounding the central portion 4 . The holes 6 must be of sufficient size to permit the fasteners 5 to pass through. Each fastener 5 includes a head 8 . When the fastener 5 is fully imbedded in the ground, the head 8 presses the skirt 3 against the ground 7 . The fasteners 5 prevent the base 2 from moving while the fasteners 5 are set into the ground. The size of the skirt 3 will depend on its intended use. For example, when used as a post anchor for a mailbox, the skirt 3 should have a diameter at least about three times the width of the post. A larger diameter skirt 3 reduces tipping. A larger skirt would be necessary for larger or taller objects or for objects more prone to tipping.
The central portion 4 fixes the object to the base 2 . The shape and size of the central portion 4 will vary depending of the object. For example, the central portion 4 may include at least one vertical flange to which the object may be fixed. The flange may have a hole adapted to receive a mechanical interlock. A solid post may be fitted into box formed by a plurality of vertical flanges. Alternatively, a mortise-tenon arrangement is suitable for hollow objects. The central portion 4 may have an interlock that prevents the object from lifting off the central portion. The interlock may be any mechanical structure or chemical that fixes the object the central portion. Interlocks include, for example, flanges, screws, bolts, rivets, glues, snaps, springs, etc. Preferably, the interlock permits the object to be removed. In one example, the central portion includes a flange defining a hole. A screw is placed through the hole and into the object.
As shown in FIG. 2 , a fastener 5 comprises a helical portion 22 and a handle 21 . The fastener 5 should consist essentially of a corrosion-resistant material. Preferred materials include stainless steel, galvanized steel, or engineering plastics. The helical portion 22 screws into the ground, and may include a central shaft, surrounded by a screw, coil or auger. The handle 21 exerts a vertical pressure on the base when the fasteners are secured to the ground, thereby fixing the base in place. To this end, the handle 21 will often have a larger diameter than the helical portion 22 .
In order to produce greater torque when screwing the fastener 5 into the ground, the handle 21 may include a flattened portion, an extension or an eyelet. The flattened portion is adapted to receive a wrench. The extension may be, for example, T-shaped or L-shaped. A pipe may even be slipped over the extension for greater torque. An elongated object, such as a bar, may be passed through the eyelet. The helical portion 22 must be strong enough to be screwed into the ground, but preferably, the helical portion 22 may be sufficiently flexible that underground obstructions, such as utility lines, may be detected without harm to the obstruction and the fastener 5 easily repositioned so as to avoid such obstructions. A flexible fastener that is inserted with low torque is less likely to puncture an underground obstruction, such as a gas line, water pipe or electrical line. Because a plurality of fasteners is used, the fasteners need not penetrate into the ground as deeply as a single fastener of the prior art. Preferably, the fasteners will penetrate into the ground no more than about nine inches. In contrast, conventional post anchors often exceed two or more feet and may even require concrete reinforcement.
FIG. 3 shows a first embodiment of the anchor 1 . The anchor 1 comprises a base 2 including a central portion 4 surrounded by a disc-shaped skirt 3 . The skirt includes three holes 6 , two of which are visible in the figure. The fasteners 5 include helical coils 22 having a pointed end 13 and a handle 21 . The handle 21 is shaped so that its rotation about the longitudinal axis 15 of the fastener 5 defines a frusto-conical shape. At least a section of the holes 6 have a recess 16 with a complimentary profile matching the shape defined by rotation of the handle 21 . Engagement of the handle 21 with the recess 16 secures the base 2 to the ground. Optionally, a cap 111 may be placed over the handle 21 and hole 6 . In this embodiment, the central portion 4 is rectangular in cross-section and includes an abutment 17 on which would rest the object to be secured. The abutment 17 should be on at least two sides of the central portion 4 . The central portion 4 accepts a hollow, rectangular post. At least one interlock 12 secures the object to the central portion 4 .
FIG. 4 shows a second embodiment of the anchor 1 . The anchor 1 includes a base 2 having a central portion 4 surrounded by a plurality of legs 3 . Each leg 3 defines a hole 6 through which a fastener 5 passes and secures the base 2 to the ground. The interlock 12 comprises a bolt and wing-nut. The use of a bolt and wing-nut permits securing the object to the anchor 1 without tools.
A third embodiment of the invention is shown in FIGS. 5 and 6 . The base 2 includes central portion 4 and a skirt 3 and has a flat bottom 7 . The central portion comprises a tenon adapted to receive an object 52 having an end with a complimentary mortise 53 . The skirt 3 defines two holes 6 . Above the holes 6 , the skirt has a flattened mounting area 54 . In use, a fastener presses against the mounting area 54 to secure the base 2 to the ground. The fastener typically will include a washer. The skirt also includes a step 55 . A cover 51 may cover at least a part of the skirt 3 . As shown, the cover rests on the step 55 . The cover 51 can be aesthetic and functional. For example, the cover 51 will channel water away from skirt and fasteners, thereby reducing corrosion. The cover 51 may conform to the shape of the skirt 3 and fasteners 5 . Alternatively, the cover 51 may be of any desired color or shape.
FIG. 7 shows an anchor 1 having a central portion 4 surrounded by a skirt 3 . A fastener 5 passes through each hole 6 in the skirt 3 . Washers 71 rest on the mounting area 54 . The washers 71 are configured so that the handle 21 of the fastener 5 cannot pass therethrough. Preferably, as shown in FIG. 8 , the washer 71 defines a slot 81 into which a bottom portion of the handle 21 will fit, thereby locking the fastener 5 in place. Advantageously, the handle 21 of the each fastener 5 includes an eyelet 72 . An elongated object, such as a pipe or bar, may be slipped into the eyelet 72 so that greater torque can be applied to the fastener 5 . A cover 51 fits over the skirt 3 and fasteners 5 . The cover may comprise one or more pieces. A single piece cover 51 defines an opening large enough so that the cover 51 can be slipped over the central portion 4 . A two-piece cover could be assembled around the central post 4 . The outer perimeter of the cover 51 rests on a step 55 . The inner perimeter of the cover 51 rests on an abutment 73 around the central portion 4 . A mortised object 52 fits over the central portion 4 and holds the cover 51 against the abutment 73 .
Obviously, numerous modifications and variations of the present invention are possible. It is, therefore, to be understood that within the scope of the following claims, the invention may be practiced otherwise than as specifically described. While this invention has been described with respect to certain preferred embodiments, different variations, modifications, and additions to the invention will become evident to persons of ordinary skill in the art. All such modifications, variations, and additions are intended to be encompassed within the scope of this patent, which is limited only by the claims appended hereto.
|
The present invention describes an anchor for securing an object the ground. The anchor is especially useful for securing, either temporarily or permanently, fixing objects to the ground, such as signs, poles, mailbox posts, tent or net supports. Placement of the device requires no digging and few or no tools, and visible damage to the landscape is reduced. Advantageously, subterranean obstructions can be detected and avoided while securing the device to the ground, thereby protecting utility lines from damage. Typically, little strength and low torque is needed to secure the anchor to the ground.
| 4
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.