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BACKGROUND OF THE INVENTION
This invention relates to a method of reclaiming rubber from vehicle tires so that the rubber can be recycled in various forms and for many purposes.
The increasing vehicle population of the world presents an increasing enviromental problem in relation to the disposal of used vehicle tires. Currently there are large stockpiles of used tires throughout the world as there was not as yet been developed a method of disposal of the tires which is considered both environmentally acceptable and economic.
Burying of tires in landfill has been used as a method of disposal, however, in view of the size, construction and flexibility of tires, they result in initially forming cavities in the landfill and are difficult to effectively compact during the landfill operation. Further, it has been found that in these situations the soil tends to settle more than the tires and the latter may subsequently resurface. Further the practice of burning of tires as a fuel also presents a problem in the nature of the resulting products of combustion and the relatively low thermal output. Also there is the problem of tires incorporating non combustible components such as steel reinforcing wires or mesh which present difficulties in the operation of combustion equipment.
There have been a number of proposals for stripping the rubber material from the metal or fabric reinforcement, however, most prior proposals have not proven to be economically viable. In order to maximise the financial return from the reclaiming of materials from vehicle tires, it is desirable to be able to separate substantially all of the rubber content of the tires from the metal reinforcement therein, and to further separate the relatively high quality rubber in the tread portion of the tire from the lower quality rubber in the sidewalls, bead area of the tire.
Various processes and machinery for the reclaiming of rubber from tires have been disclosed in the following U.S. Pat. Nos.
4,113,18--SMITH
4,216,916--TUPPER
4,726,530--MILLER
4,802,635--BARCLAY
4,840,316--BARCLAY
4,863,106--PERKEL:
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a method of reclaiming rubber from vehicle tires which enables the maximum rate of recovery of rubber to be achieved in an economic manner while also enabling the higher grade tread rubber to be separated from other rubbers recovered from the tire.
With this object in view, there is provided according to the present invention, a method of reclaiming rubber from vehicle tires, comprising:
separating the tread portion of the tire from the respective sidewalls to provide an elongate tread strip incorporating a tread reinforcement bell;
removing the tread rubber in a particulate form from the tread reinforcement belt;
independently removing the remaining rubber in a particulate form; from the tread reinforcement belt; and
reducing the sidewall to a particulate form.
Preferably the rubber of the sidewalls is also reduced to a particulate form and also the rubber incorporated in the tire beads. Where fabric reinforcement materials are used in the sidewalls and/or the beads, that non-metallic material is particulised with the rubber. Conveniently, if desired, the reinforcement material can be separated from the rubber subsequent to the breakdown thereto to the particulate form, conveniently by a process dependent on the differences in specific gravity of the respective materials.
The initial separation of the tread portion from the remainder of the tire is effected by making peripheral cuts through each sidewall in the area of the junction thereof with the tread portion. These cuts may be effected mechanically such as by rotary knives or saws or by high pressure liquid jets, commonly referred to as ultra high pressure liquid (UHPL) cutting. Preferably the separated tread portion has one or more cuts across the width of the tread portion, through the total thickness thereof to form one or more strips.
The tread strip is then fed in a flat state past a rotary cutter set to remove the tread rubber from the reinforcement belt. Preferably the rotary cutter cuts across the full width of the tread strip so that all of the tread rubber is removed in a single pass.
The remainder of the tread strip, after the removal of the tread rubber, is subject to UHPL cutting to remove the remaining rubber, including the rubber normally provided on the inner side of the tread reinforcement of the tire. This UHPL cutting is performed in a manner to remove the rubber in a particulate form, such as by using a plurality of jets moving in a predetermined cyclic path selected to produce particles in the required size range. Preferably the rubber is removed from the inner side of the tread reinforcement by applying the jets to the inner side in preference to form the tread side through the reinforcement
In tires having a metal reinforcement belt in the tread portion, it is possible to operate the UHPL cutting so that the metal reinforcement is not broken up and mixed with the rubber. However, when fabric reinforcement is used, it will normally be particulated with the rubber and when required can be subsequently separated. There are some uses for this rubber where the presence of the particulated reinforcement is not detrimental or can be advantageous.
The individual sidewalls, with the bead still attached as produced by the tread portion removal operation, can also be subjected to UHPL cutting to particulate the rubber and fabric reinforcement leaving the bare bead wires. The bead wires being of high tensile steel, can be recycled economically.
The above described process enables relatively high production rates to be achieved as each of the four stages of the breaking down on the tire can be carried out at the same time in a continuous process, namely:
(1) Separation of tread portion from side walls
(2) Particulating of the tread rubber of the tread strip
(3) Particulating of the remainder of the rubber in the tread strip
(4) Particulating of the sidewalls.
Following the separation of the tread portion from the sidewall and bead portions of the tire, the removal of the respective rubber components of the tread portion of the tire can be carried out at the same time as the removal of the rubber from the sidewalls is also in progress. Further, as the separation of the tread portion from the sidewalls is independent to the removal of the tread rubber from the tread portion of the tire, these operations can also be carried out at the same time on respective tires. Thus the throughput of tires is solely governed by the time required by the slower of the above four referred to steps and, by appropriate design of the respective elements of the machinery, high production rates can be achieved.
Also it is envisaged that step (1) the separation of the tread portion from the sidewalls and beads, can be carried out separately in both location and or time from the remaining steps. This substantially reduces the space occupied in storing the tire prior to further processing. The separation operation, step (1), can be carried out on a mobile unit that collects the used tires from service stations and other tire sales outlets where replacement tires are fitted.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail in respect of one practical arrangement thereof as illustrated in the accompanying drawings.
In the drawings:
FIG. 1 is a diagrammatic representation of a cross section of a typical vehicle tire.
FIGS. 2A and 2B together is a flow chart for the recovery of rubber and other materials from tires.
FIG. 3 is a side view of the mechanism for initially segmenting the tire.
FIG. 4 is a side view of the mechanism for recovery of rubber from the remaining portion of the tread.
FIG. 5 is a plan view of the mechanism for recovery of rubber from the sidewalls.
FIG. 6 is a side view of the mechanism shown in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 the vehicle tire 10 has a tread portion 12 sidewalls 11 and beads 13. Conventionally the bead 13 includes a rigid ring made of a number of coils of steel wire. The tread portion 12 comprises a reinforcement belt 15 normally composed of a woven fabric or metal fibres with a relatively thick outer layer of high quality tread rubber 14. The sidewalls and the inner part of the tread portion being formed of a lower quality rubber with a fabric reinforcement therein.
FIGS. 2A and 2B is a flow chart of the complete recycling process for vehicle tires in which the proposed removal separation and collection of different quality rubbers is incorporated.
Tires are collected from a range of sources at a central receival facility 100 and placed into a store 101. After receival the tires may be sorted in accordance with size, rubber quality, remaining tread thickness or other characteristics that can influence the extent and nature of subsequent processing.
The tires pass from the store 101 to the first processing operation 102 wherein the tread portion 12 of the tire is separated from the two sidewall 11 and integral beads 13. The tread portion and sidewall-bead portions are stored separately at store 103 for subsequent independent treatment. The respective portions of the tire may also be stored separately in accordance with quality and or size considerations. From the store 103 the tread portion and sidewall-bead portion travel separate paths 104, 105 respectively to the mechanical tread rubber shredder 106 and sidewall disintegrator 111.
The tread portion 12 is fed in strip form through the mechanical shredder 106, so the high quality tread rubber located outwardly of the reinforcement belt is removed. This can be effected by a rotary cutter or grinder, as hereinafter further described, which produces rubber particles of a selected size. As the tread rubber particles are removed independent of other components of the tire, such as reinforcement materials, and without addition of other materials such as water, the tread rubber particles can be immediately passed to storage bin 121.
Subject to the nature of further use and sale of the reclaimed tread rubber it can conveniently be withdrawn from the bin in batch lots weighed at 122, packaged at 123 and stored at 124 for subsequent sale. As will be referred to hereinafter, other reclaimed tire materials can also be weighed, packaged and stored at 122, 123 and 124 by the latter being selectively operably coupled to storage bins 117 and 118.
After the high quality tread rubber has been removed by the shredder 106 the tread portion strip is passed through UHPL disintegrator 107 where it is subjected to ultra high pressure water jets that break the strip down to particulate form. The resulting particle mix of rubber and steel wire from the tread belt is subjected to a magnetic separator 108 to remove the steel wire from the rubber, the steel wire being passed to a steel scrap store 125 for subsequent sale.
The rubber particle material passes from UHP disintegrator 107 to a dewatering station 109 from which the water is recycled to the UHP disintegrator and the rubber particle material passed via a surge bin 110 to a dryer 115. After drying the rubber particle material is then passed through sizing screens 116 and rubber particles within selected size ranges are directed to respective storage bins 117 and 118. Subject to the extent of size variation in the rubber particle material produced, and market demands, the rubber particle material can be graded into more than two sizes. The graded rubber particles can be weighed packed and stored at 122, 123, and 124 as previously referred to.
The individual sidewall and bead sections are passed from the store 103 to the further UHPL disintegrator 111 wherein they are subjected to ultra high pressure water jets that breakup the sidewalls into particular material of rubber and fibre, and also removes the rubber and fibre material from the bead, also in particulate form. The mixture of rubber and fibre material passes from the UHP disintegrator 111 to the dewatering station 112 from which the separated water is passed through the filter 119 and then recycled to the UHPL water supply. The rubber and fibre particle material is passed to the separator 113 which can be of a flotation or cyclonic type, whereafter the fibre is passed to store 126, and the rubber particle material passes to the surge bin 114.
As the nature of the respective materials held in the surge bin 110 and surge bin 114 are substantially the same they are each processed together or sequenually through the same equipment down stream of the respective surge bin 110, 114. Thus material from surge bin 114 is dried by the dryer 115, graded by the screen 116, and subsequently weighed, packed and stored as previously described in relation to material from surge bin 110.
It will be seen from the above description of the proposed recycling process that there is recovered in a usuable form substantially the whole material content of the tire in an integated process. The high grade tread rubber is completely separated from the other materials of the tire, the lower grade rubber in the sidewalls and tread are each recovered separated from the respective reinforcement materials, and the fibre and steel of reinforcement materials are individually recovered.
As each of these components of a tire are usuable for differing purposes or in differing products, the maximum financial return is obtainable by processing used tires by the process above described.
Further details of one practical construction and arrangement of specific machines used in carrying out the proposed process will now be described.
Referring to FIG. 3 there is shown in basic form a mechanism for initially separating the tire into three sections, a tread portion and two sidewall-bead portions, comprising a tire chuck assembly 20 and a cutter assembly 21. The chuck assembly comprise a tire platform 23 mounted upon the base frame 24 to rotate about a vertical axis and driven by the motor 25 through the reduction gear train 26. Mounted on the tire platform 23 are four chuck fingers 27 equally spaced about the axis of the tire platform 23 to pass through a tire 10 positioned on the platform.
The four fingers 27 are each mounted to be radially slidable in unison with respect to the tire platform 23 in order to accommodate a range of tire sizes, and to permit a tire to be received freely over the fingers and then gripped thereby by moving the fingers radially outward in unison. The radial movement of the fingers 27 is effected by the hydraulic motor 28 to retract and expand the finger as required during loading, driving and unloading of the tires from the chuck assembly.
The cutter assembly 21 comprises a base frame 30 with a cutter column assembly 31 mounted thereon for linear movement relative thereto toward and away from the tyre chuck assembly 20. The vertical cutter drive shaft 32 is rotatable supported at the upper and lower ends by bearing arms 33 and 34 projecting from the column 31. The drive shaft 32 is coupled to the motor 35.
The lower saw blade 37 is mounted in a fixed location on the drive shaft 32. The position of the saw blade 37 is selected so the blade is at a level to cut a tire mounted on the tire platform 23 of the chuck assembly in the area of the junction between the tire tread portion and lower sidewall as indicated at 16 in FIG. 1. The upper saw blade 36 is mounted on the splined upper portion 38 of the drive shaft 32 so it can be adjusted to the level of the junction of the tire tread portion and the upper sidewall of the tire on the chuck platform 23. The arm 39 is vertically slidable in the track 42 provided on the column 31 under the control of the hydraulic cylinder 40. The arm 39 carries the support 41 for the upper saw blade 36 whereby by operation of the hydraulic cylinder 40 the upper saw blade 36 can be positioned relative to the lower saw blade 37 to suit different width tires.
The complete cutter column assembly 31 is slidably mounted on the base frame 30 and movable relative thereto under the control of the hydraulic cylinder 45 in order to move the saw blades 36 and 37 into and out of operational engagement with a tire mounted on the chuck platform 23. When the saw blades are so engaged with the tire, and the tire is rotating, the two sidewalls and beads will be each separated from the tread portion of the tire. Upon release of the fingers 27 of the chuck assembly 20 the three sections of tire, namely the tread portion and two sidewall and bead portions, can be removed from the chuck assembly for subsequent individual processing. The tread portion 12 of the tire as removed from the chuck platform 23 is in the form of an annulus and is subsequently guillotined or otherwise cut across the face of the tread portion so it may be either flattened or rolled for economic storage. If the tread portion is to be stored flat it is preferred to cut it into two or three sections.
It is to be understood that the above described separation of the tread portion from the sidewalls may be effected at a location remote from the area where the tread portion and sidewalls are further processed. This initial separation assists in the economic transportation of the tire to the processing plant, as the space occupied by separated components of the tire is substantially less than that occupied by the tire when in one piece.
Suitable equipment to separate the tread portion from the sidewalls may be mounted on a trailer or vehicle so that the initial sectioning of the tire is carried out as part of the collection operation and would enable the tread portion to be rolled or stacked flat and the sidewalls stacked flat for subsequent transportation and/or storage before further processing.
Referring again to FIG. 4, the tread rubber removal assembly 48 comprises conveyor 45 and feed rollers 49, which receive the previously separated tread portion 12, and withdrawal rollers 50 which feed the remainder of the tread portion, after the removal of the tread rubber, to the UHP treatment apparatus 53.
The tread rubber removal assembly 48 further includes back-up rollers 51 and a rotary cutting 52, the latter having an appropriate cutting tooth formation on the upper surface thereof, and is driven at a speed relative to the feed rate of the tread portion to remove the tread rubber in an appropriate particle size. The position of the cutter 52 with respect to the back-up roller 51 is adjusted in accordance with sensed measurements of the tread portion, particularly the thickness thereof, so that the cutter 52 only removes that portion of the tread rubber below the level of the reinforcement belt in the tread portion of the tire. This tread rubber being of a higher quality than the remainder of the tire and is required to be kept separate therefrom. The high grade tread rubber is collected in the hopper 55 and withdrawn therefrom by the screw conveyor 56 and delivered to bin 121 (FIG. 2B).
The remainder of the tread portion of the tire is then passed into the UHPL apparatus 53 by the conveyor 54 wherein two revolving heads 56, each with an array of high pressure nozzles impinge jets of water onto the remainder of the tread portion to cut the rubber therein into small particles and strip it from reinforcement belt, which is normally, of a metal filaments construction. In order to separate the metal filaments, released as the rubber is removed by the UHP apparatus 53, from the rubber a magnet structure 58 is provided adjacent the lower flight of the conveyor on the side thereof opposite the tread portion. The magnet structure is constructed to provide a magnetic field of sufficient strength to hold the metal filaments in contact with the conveyor and thereby separate the filaments from the rubber particles created by the UHPL jets. The influence of the magnetic field created by the magnet structure extends a short distance beyond the area where the tread rubber particles are collected in the hopper 59 so that beyond the magnetic influence the metal reinforcement belt fibres are discharged onto conveyor 54. The rubber removed by the UHPL apparatus in particle form is collected in the hopper 59 and removed therefrom by the screw conveyor 57 with the water from the UHP apparatus being separated from the rubber particles.
It will be appreciated that provision is made for the appropriate collection of the tread rubber removed by the cutter 52 independently of the rubber removed by the UHPL device, so the higher value tread rubber can be recycled separately. Also the metal belt fibres can be recycled.
The sidewalls with the beads integral therewith are processed independently as indicated in FIG. 2A by equipment as will now be described with reference to FIGS. 5 and 6 of the accompanying drawings.
The sidewall and bead sections 11 are deposited on the conveyer 60 and passed sequentially beneath a series of three UHPL devices 61 positioned and operated to break up the rubber and fibre reinforcement of the sidewall and to remove rubber from the bead portion 13.
The sidewall and bead portion 11 of the tire as removed from the tread portion, is loaded onto the conveyor 60 in a row formation and are advanced through the treatment area 66, wherein three UHPL devices 61 are arranged to operate simultaneously in breaking up the wall portion of the tire passing therethrough, and release the rubber attached to the bead wires.
The three UPHL devices are arranged so the full width of the side wall and bead portion is subjected to the action of the jets of the UPH devices in a single pass. If desired the relative location of the UHPL devices may be adjusted for accommodating sidewall portions of differing diameters. It has been found that a small number, up to about four, of individual sidewall and bead portions can be stacked one on the other and subjected to the UHPL treatment in that stacked arrangement.
It is to be appreciated that although the UHPL jets have a highly effective cutting action, they apply only minimum forces to the sidewall and bead portions and thus it is not required to hold down or otherwise secure the sidewall portions to the conveyor 60.
The rubber and fabric particle created in the breaking up of the sidewalls is collected in the hopper 62 from which it is passed by screw conveyor 67 to the dewater treaatment and then separation of the rubber from the fabric as referred to with respect to FIGS. 2A and 2B. The steel wire of the bead is passed directly to storage or may be chopped to small lengths, or baked prior to storage.
The equipment above described herin with reference to FIGS. 3 to 6 is intended to be only the currently best known equipment for carrying out the method claimed in this Application. It is to be understood that other equipment may be used in the practice of the invention. Also the individual processing of the respective sections of the tire are not necessarily carried out at the same time or at the same location.
The UHPL cutting equipment as rererred in the description of the practical implementation of the present invention is not described herein in detail as the basic principles of operation of such equipment is well known and can be readily applied to provide cutting equipment suitable for use in carrying out the present invention. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application, pursuant to 35 U.S.C. § 119(e), claims priority to U.S. Provisional Application Ser. No. 60/820,861, filed Jul. 31, 2006. That application is incorporated by reference in its entirety.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to pipes and tubing used in the oilfield. Specifically, the invention relates to an improved method for removing mineral scale from pipes and tubing.
[0004] 2. Background Art
[0005] Hydrocarbons (e.g., oil, natural gas, etc.) are obtained from a subterranean geologic formation (i.e., a “reservoir”) by drilling a wellbore that penetrates the hydrocarbon-bearing formation. In order for the hydrocarbons to be produced, that is, travel from the formation to the wellbore, and ultimately to the surface, at rates of flow sufficient to justify their recovery, a sufficiently unimpeded flowpath from the subterranean formation to the wellbore, and then to the surface, must exist or be provided.
[0006] Subterranean oil recovery operations may involve the injection of an aqueous solution into the oil formation to help move the oil through the formation and to maintain the pressure in the reservoir as fluids are being removed. The injected aqueous solution, usually surface water (lake or river) or seawater (for operations offshore), generally contains soluble salts such as sulfates and carbonates. These salts may be incompatible with the ions already contained in the oil-containing reservoir. The reservoir fluids may contain high concentrations of certain ions that are encountered at much lower levels in normal surface water, such as strontium, barium, zinc and calcium. Partially soluble inorganic salts, such as barium sulfate (or barite) and calcium carbonate, often precipitate from the production water as conditions affecting solubility, such as temperature and pressure, change within the producing well bores and topsides.
[0007] A common reason for a decline in hydrocarbon production is the formation of scale in or on the wellbore, in the near-wellbore area or region of the hydrocarbon-bearing formation matrix, and in other pipes or tubing. Oilfield operations often result in the production of fluid containing saline-waters as well as hydrocarbons. The fluid is transported from the reservoir via pipes and tubing to a separation facility, where the saline-waters are separated from the valuable hydrocarbon liquids and gasses. The saline-waters are then processed and discharged as waste water or re-injected into the reservoir to help maintain reservoir pressure. The saline-waters are often rich in mineral ions such as calcium, barium, strontium and iron anions and bicarbonate, carbonate and sulphate cations. Generally, scale formation occurs from the precipitation of minerals, such as barium sulfate, calcium sulfate, and calcium carbonate, which become affixed to or lodged in the pipe or tubing. When the water (and hence the dissolved minerals) contacts the pipe or tubing wall, the dissolved minerals may begin to precipitate, forming scale. These mineral scales may adhere to pipe walls as layers that reduce the inner bore of the pipe, thereby causing flow restrictions. Not uncommonly, scale may form to such an extent that it may completely choke off a pipe. Oilfield production operations may be compromised by such mineral scale. Therefore, pipes and tubing may be cleaned or replaced to restore production efficiency.
[0008] Some mineral scales, such as barium sulphate, are very difficult to remove chemically, from tubing and, as such, the tubing is simply replaced with new tubing. The scaled tubing may be removed for disposal, but the mineral scale that forms presents an environmental hazard. For example, some mineral scales may have the potential to contain naturally occurring radioactive material (NORM). The scale has an associated radioactivity because the radioactive decay daughters of Uranium and Thorium are naturally present in reservoir waters and co-precipitate with barium ions to form a barium sulphate scale that, for example, contains Radium-226 Sulphate. The primary radionuclides contaminating oilfield equipment include Radium-226 ( 226 Ra) and Radium-228 ( 228 Ra), which are formed from the radioactive decay of Uranium-238 ( 233 U) and Thorium-232 ( 232 Th). While 238 U and 232 Th are found in many underground formations, they are not very soluble in the reservoir fluid. However, the daughter products, 226 Ra and 228 Ra, are soluble and can migrate as ions into the reservoir fluids to eventually contact the injected water. While these radionuclides do not precipitate directly, they are generally co-precipitated in barium sulfate scale, causing the scale to be mildly radioactive. This NORM poses a hazard to people coming into contact with it through irradiation and through breathing or ingestion of NORM particles. As a result, the NORM scaled tubing has to be handled, transported, and disposed of under carefully controlled conditions, as outlined in legislation, to protect the welfare of employees, the public at large, and the environment.
[0009] Common operations used for removing scale from tubing may be slow and inefficient because each tube has to be individually treated if they are radioactive and access to the scaled internal surface of the tubing may be restricted.
[0010] When pipes and equipment used in oilfield operations become layered with scale, the encrustation must be removed in a time- and cost-efficient manner. Occasionally, contaminated tubing and equipment is simply removed and replaced with new equipment. When the old equipment is contaminated with NORM, this scale encrusted equipment may not be disposed of easily because of the radioactive nature of the waste. The dissolution of NORM scale and its disposal may be costly and hazardous. In addition, a considerable amount of oilfield tubular goods and other equipment awaiting decontamination is presently sitting in storage facilities. Some equipment, once cleaned, may be reused, while other equipment must be disposed of as scrap. Once removed from the equipment, several options for the disposal of NORM exist, including deep well injection, landfill disposal, and salt cavern injection.
[0011] Typical equipment decontamination processes have included both chemical and mechanical efforts, such as milling, high pressure water jetting, sand blasting, cryogenic immersion, and chemical chelants and solvents. Water jetting using pressures in excess of 140 MPa (with and without abrasives) has been the predominant technique used for NORM removal. However, use of high pressure water jetting is generally time consuming, expensive, and may fail to thoroughly treat the contaminated area.
[0012] While chemical chelants, such as EDTA (ethylenediaminetctraacetic acid) or DTPA (diethylenetriaminepentaacetic acid), have long been used to remove scale from oilfield equipment, once EDTA becomes saturated with scale metal cations, the spent solvent is generally disposed of, such as by re-injection into the subsurface formation. Further, chemical chelants such as EDTA and DTPA are expensive and require prolonged contact at elevated temperatures to dissolve the scale.
[0013] Accordingly, there exists a need for an economically efficient means for removing scale from pipes and tubing with a low risk of exposure to radioactive materials.
SUMMARY OF INVENTION
[0014] In one aspect, embodiments disclosed herein relate to a method for removing mineral scale from tubing, the method including making a first longitudinal cut along a length of the tubing, making a second longitudinal cut along a length of tubing, removing a plurality of sections of tubing, wherein the sections of tubing are defined by the first and second longitudinal cuts.
[0015] In another aspect, embodiments disclosed herein relate to a method for removing mineral scale from tubing, the method including making a first longitudinal cut tangential to an inside diameter of the tubing, making a second longitudinal cut tangential to the inside diameter of the tubing, and removing a plurality of sections of tubing, wherein the sections of tubing are defined by the first and second longitudinal cuts.
[0016] In another aspect, embodiments disclosed herein relate to a method for removing mineral scale from tubing, the method including making at least one cut longitudinally along the tubing and separating cut tubing from the mineral scale.
[0017] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a cross-sectional view of a pipe encrusted with mineral scale, in accordance with embodiments disclosed herein.
[0019] FIG. 2 is a cross-sectional view of a pipe encrusted with mineral scale, in accordance with embodiments disclosed herein.
[0020] FIG. 3 is a cross-sectional view of a pipe and mineral scale, in accordance with embodiments disclosed herein.
[0021] FIG. 4 is a cross-sectional view of a pipe encrusted with mineral scale, in accordance with embodiments disclosed herein.
[0022] FIG. 5 is a cross-sectional view of a pipe encrusted with mineral scale, in accordance with embodiments disclosed herein.
[0023] FIG. 6 is a cross-sectional view of a pipe encrusted with mineral scale, in accordance with embodiments disclosed herein.
DETAILED DESCRIPTION
[0024] In one aspect, embodiments of disclosed herein relate to a method of removing mineral scale from oilfield pipes and tubing. In particular, embodiments disclosed herein relate to a method of mechanically separating mineral scale from oilfield pipes and tubing. Further, as used herein, “pipes,” “tubing,” and “tubes” may be used interchangeably to describe embodiments without limiting the scope of the claims.
[0025] Mineral scale that may be removed from oilfield equipment in embodiments disclosed herein includes oilfield scales, such as, for example, salts of alkaline earth metals or other divalent metals, including sulfates of barium, strontium, radium, and calcium, carbonates of calcium, magnesium, and iron, metal sulfides, iron oxide, and magnesium hydroxide.
[0026] A method of removing or separating mineral scale from a tubular or pipe according to an embodiment disclose herein is shown in FIGS. 1-4 . As shown in FIG. 1 , a pipe 202 is encrusted with a layer of mineral scale 204 . In this embodiment, mineral scale layer 204 is a uniform layer formed on an inside diameter of pipe 202 . However, one of ordinary skill in the art will appreciate that the layer of mineral scale may or may not be uniform along a length and/or circumference of the pipe. In one embodiment, at least one longitudinal cut is made along the pipe 202 . As used herein, “longitudinal” describes a direction along the length of the pipe 202 . In another embodiment, two longitudinal cuts are made along the pipe. One of ordinary skill in the art will appreciate that any number of longitudinal cuts may be made without departing from the scope of the invention.
[0027] In the embodiment shown in FIG. 1 , two longitudinal cuts 206 are made in pipe 202 . Longitudinal cuts 206 may be made so that each longitudinal cut 206 is substantially tangential to an inside diameter of pipe 202 . Accordingly, longitudinal cuts 206 are tangential to an interface 210 between mineral scale layer 204 and pipe 202 . In one embodiment, two longitudinal cuts 206 are substantially parallel.
[0028] Referring now to FIG. 2 , after longitudinal cuts 206 are made, a first cut portion 212 and a second cut portion 214 of pipe 202 may be moved away, as indicated at A, from mineral scale layer 204 . As shown in FIG. 3 , after removal of first and second cut portions 212 , 214 , a first side 222 and a second side 224 of pipe 202 may be removed, as indicated at B, from mineral scale layer 204 . Accordingly, as shown in FIGS. 1-3 , longitudinal cuts 206 made substantially tangential to interface 210 between pipe 202 and mineral scale layer 204 allow removal of pipe 202 from mineral scale layer 204 .
[0029] FIG. 4 shows another embodiment of a method for separating scale from a pipe or tubular. In this embodiment, two longitudinal cuts 407 , 408 are made in pipe 402 . Longitudinal cuts 407 , 408 may be made so that each longitudinal cut 407 , 408 is substantially tangential to an inside diameter of pipe 402 . Accordingly, the longitudinal cuts 407 , 408 are tangential to an interface 410 between mineral scale layer 404 and pipe 402 . In this embodiment, first longitudinal cut 407 is substantially perpendicular to second longitudinal cut 408 . In this embodiment, after the two longitudinal cuts 407 , 408 are made, a first cut portion 432 and a second cut portion 434 of pipe 402 may be removed. A small section 438 and a large section 436 of pipe 402 may then be removed from mineral scale layer 404 .
[0030] FIGS. 5 and 6 show another embodiment of a method for separating scale from a pipe or tubular. In this embodiment, two longitudinal cuts 511 , 513 are made in a pipe 502 . Longitudinal cuts 511 , 513 may be made so that each longitudinal cut 511 , 513 is substantially perpendicular to an outside surface of pipe 502 . The depth of each longitudinal cut 511 , 513 is limited to about a thickness T of pipe 502 , thereby not substantially cutting into mineral scale layer 504 . In this embodiment, after the two longitudinal cuts 511 , 513 are made, a first half 530 and a second half 532 of pipe 502 may be removed from mineral scale layer 504 .
[0031] Longitudinal cuts 206 ( FIG. 1 ), 407 , 408 ( FIG. 4 ) through a pipe may be made by any method known in the art. For example, pipe may be cut by milling, plasma cutting, laser cutting, ultra high pressure water cutting, and oxy-acetylene cutting. In addition, one of ordinary skill in the art will appreciate that other methods may be used to make longitudinal cuts through a pipe. In one embodiment, the cutting method may be automated, thereby reducing the risks associated with personnel in contact with radioactive mineral scale. In another embodiment, a cutting tool, for example, a multi-headed tool, may be used to cut several pipes or tubes simultaneously. In another embodiment, the process of cutting pipes and removing pipes from mineral scale may be performed under water, thereby providing greater levels of Health, Safety, and Environmental (HSE) standards.
[0032] In one embodiment, mineral scale layer 204 , 404 , 504 is substantially solid, forming a mineral scale cylinder. Thus, with reference, for example, to FIGS. 1-3 , when longitudinal cuts 206 are made through pipe 202 , the first and second cut portions 212 , 214 , and the first and second sides 222 , 224 of pipe 202 may be removed from a cylinder of mineral scale. Mineral scale may then be collected, processed disposed of in a safe manner. However, in another embodiment, mineral scale layer 204 may not be substantially solid. In this embodiment, the mineral scale may remain on the inside diameter of pipe 202 . Mineral scale may then be removed from pipe 202 after the pipe 202 is cut in the longitudinal direction by other mechanical or chemical means, as described below with reference to residual mineral scale.
[0033] In one embodiment, when sections, for example first and second cut portions 212 , 214 of FIG. 2 , of the cut pipe 202 are removed from mineral scale layer 204 , the sections of cut pipe 202 may be uncontaminated. That is, the sections of cut pipe 202 removed from mineral scale layer 204 do not contain any residual mineral scale on the surface of pipe 202 . In another embodiment, when sections, for example first and second cut portions 212 , 214 of FIG. 2 , of cut pipe 202 are removed from mineral scale layer 204 , the sections of cut pipe 202 may contain some residual amount of mineral scale on the surface of sections of pipe 202 . In this case, the residual amounts of mineral scale may be more easily removed from sections of pipe 202 because of the accessibility to the inside surfaces of each section of pipe 202 . Residual mineral scale on the surface of sections of pipe 202 may be removed by physical or chemical means, or a combination of both, known in the art. For example, residual mineral scale may be removed from a section of pipe 202 by milling, high pressure water jetting, sand blasting, cryogenic immersion, and/or chemical chelants and solvents. Once sections of pipe 202 have been inspected to ensure each section is uncontaminated, the sections of pipe 202 may be disposed of.
[0034] Advantageously, embodiments disclosed herein may provide a method for removing mineral scale from a pipe or tube in a quick and safe manner. Embodiments disclosed herein may advantageously provide a method for automated removal of mineral scale from pipe that may reduce the health risk of associated personnel. Embodiments disclosed herein may advantageously provide a method for separating mineral scale from multiple pipes or tubes simultaneously. Embodiments disclosed herein may advantageously provide a method for more easily accessing the layer of mineral scale built up on the inside diameter of a pipe. Embodiments disclosed herein may advantageously retain mineral scale intact, thereby reducing radioactive dust or spray during the de-scaling operation.
[0035] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | 4y
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BACKGROUND
[0001] Wireless mobile communication networks continue to evolve given the increased traffic demands on the networks, the expanded coverage areas for service and the new systems being deployed. Cellular (“wireless”) communications networks rely on a network of base station antennas for connecting cellular devices, such as cellular telephones, to the wireless network. Many base station antennas include a plurality of radiating elements in a linear array. Various attributes of the antenna array, such as beam elevation angle, beam azimuth angle, and half power beam width may be adjusted by electrical-mechanical controllers. See, for example, U.S. Pat. Nos. 6,573,875 and 6,603,436, both of which are incorporated by reference. For example, with respect to U.S. Pat. No. 6,573,875, a plurality of radiating elements may be provided in an approximately vertical alignment. A feed network may be provided to supply each of the radiating elements with a signal. The phase angle of the signals provided to the radiating elements may be adjusted to cause a radiated beam angle produced by the antenna array to tilt up or down from a nominal or default beam angle.
[0002] Phase angles may be adjusted by mechanical phase shifters. In the example of the '875 patent, phase shifters are coupled by a common mechanical linkage. An expected phase angle may be ascertained from markings on a linearly-reciprocal linkage rod or by a sensor in a linear motion electro-mechanical actuator located off the antenna panel extending beyond a bottom edge of the panel. However, known linear pushrod actuators, while having certain advantages, are not always well adapted to actuating variable elements such as phase shifters. Many antenna variable elements require rotational actuation, so a mechanism must be included to translate linear motion to rotational motion. Rotational stepper motors are also known, however, when selected to produce sufficient torque to drive the variable elements such motors may be undesirably large. Smaller motors may be used with gear reduction arrangements to multiply torque, however, known gear reduction arrangements may occupy undesirably large amounts of space.
SUMMARY
[0003] An actuator providing improved torque, control, and reduced motor and actuator size is provided. An actuator according to one example of the present invention may include a base plate, a stationary ring gear on the base plate, the ring gear having an arc of substantially less than a conventional full circle ring gear, a pivot assembly and a drive shaft. In one example, the ring gear is approximately half a circle. The pivot assembly may be pivotally mounted on the base plate. The pivot assembly may also have a control board, a stepper motor and a drive gear coupled to an output shaft of the stepper motor, the drive gear mounted on the pivot assembly such that the drive gear engages the stationary ring gear. In one example, the stepper motor is coupled to the drive gear via a worm gear, spur gear, and a shaft. In another example, the drive gear is mounted directly on the output shaft of the stepper motor. The actuator also includes a drive shaft having an axis parallel to a pivot of the pivot assembly.
[0004] The drive shaft may be formed as part of the pivot assembly. For example, the pivot assembly may further include a pivot bracket, wherein the control board is mounted on the pivot bracket, and the pivot bracket is pivotally mounted on the base plate at a point comprising a center of a circle defined by the stationary ring gear. The drive shaft may be formed as part of the pivot bracket.
[0005] In various examples, the controller board may include several components, including a controller, a motor driver, and an accelerometer. The controller may be responsive to commands that conform with industry standards, such as AISG. The controller may be coupled to the accelerometer and coupled to ASIG connectors, and the motor driver may be coupled to the controller and to the stepper motor.
[0006] In another example, the actuator of the present invention is incorporated on a panel antenna. The panel antenna may include a plurality of radiating elements, an input, a first feed network coupling the input to a first set of dipoles of the plurality of radiating elements, the first feed network comprising a plurality of transmission lines and at least a first variable element, the first variable element including a rotatable component; and an actuator according to one or more examples of the present invention, where the drive shaft of the actuator physically engages the rotatable component of the variable element. The panel antenna may also include a second feed network, where one or more variable elements of the second feed network are also driven by the actuator, typically by a cross link.
[0007] In another example, an actuator may include a base plate, a stationary ring gear, on the base plate, and a pivot assembly. The ring gear having an arc of approximately 180°. The pivot assembly is pivotally mounted on the base plate. The pivot assembly may include a pivot bracket, a control board, and a stepper motor and drive gear. The pivot bracket comprises a drive shaft having an axis parallel to a pivot of the pivot assembly. The control board is mounted on the pivot bracket. The control board also includes an accelerometer, a controller coupled to the accelerometer, and a motor driver coupled to the controller. The drive gear is mounted on an output shaft of the stepper motor, and the stepper motor is coupled to the motor driver and mounted on the pivot bracket such that the drive gear engages the stationary ring gear. The controller is configured to obtain information from the accelerometer indicative of a physical angle of the pivot assembly, and the controller is further configured to operate the stepper motor until the pivot assembly reaches a desired physical angle with respect to vertical.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic diagram of a panel antenna.
[0009] FIG. 2 is an illustration of a pair of phase shifters.
[0010] FIG. 3 is a perspective drawing of a portion of a panel antenna having an actuator according to the present invention.
[0011] FIG. 4 is a perspective view of an actuator according to the present invention with the cover removed for clarity.
[0012] FIG. 5 is a bottom view of an actuator according to the present invention.
[0013] FIG. 6 is a top view of a first example pivot assembly according to the present invention.
[0014] FIG. 7 is a bottom view of the first example of a pivot assembly according to the present invention.
[0015] FIG. 8 is a top view of a second example of a pivot assembly according to the present invention.
[0016] FIG. 9 is a bottom view of the second example of a pivot assembly according to the present invention.
DETAILED DESCRIPTION
[0017] Referring to FIG. 1 , a typical antenna array 10 may include an input 11 , a plurality of radiating elements 12 and a feed network 14 coupling the input 11 to the radiating elements 12 . A schematic diagram of a typical feed network 14 for an antenna array 10 is provided in FIG. 1 . The feed network 14 may include a plurality of transmission lines 16 and one or more variable elements 18 . The transmission lines 16 have a nominal impedance which may be selected to match an impedance of a RF line that couples the antenna array 10 to a Low Noise Amplifier (not shown). Transmission lines 16 may be implemented as microstrip transmission lines, coaxial cables, or other impedance-controlled transmission media. The variable elements 18 may comprise one or more phase shifters, power dividers, a combination of the two, or another type of variable element. The variable elements 18 may comprise differential variable elements. In one example, first and second feed networks 14 are provided, with a first feed network 14 driving a first set of dipoles on radiating elements 12 , and a second feed network 14 driving a second set of dipoles on radiating elements 12 .
[0018] In one example of the invention, the variable elements 18 comprise rotating-wiper type phase shifters 20 . Referring to FIG. 2 , phase shifter 20 , in one example, may be implemented with first and second printed circuit boards (PCBs). In one illustrated example, the first PCB may comprise a stationary PCB 22 , and the second PCB may comprise a rotatable wiper PCB 24 .
[0019] The stationary PCB 22 includes a plurality of transmission line traces 26 , 28 . The transmission line traces 26 , 28 are generally arcuate. The transmission line traces 26 , 28 may be disposed in a serpentine pattern to achieve a longer effective length. In an illustrated example, there are two transmission line traces 26 , 28 on the stationary PCB 22 , one transmission line trace 26 being disposed along an outer circumference of a PCB 22 , and one transmission line trace 28 being disposed on a shorter radius concentrically within the outer transmission line trace 26 .
[0020] In the illustrated example, the stationary PCB 22 may include one or more input traces 40 leading from an input pad 42 near an edge of the stationary PCB 22 to where the pivot of the wiper PCB 24 is located. (The use of “input” and “output” herein refers to the radio frequency signal path as the panel antenna transmits. Radio frequency signals received by the panel antenna flow in the reverse direction.) Electrical signals on an input trace 40 are coupled to the wiper PCB 24 . The wiper PCB 24 couples the electrical signals to the transmission line traces 26 , 28 . Transmission line traces 26 , 28 may be coupled to output pads to which a coaxial cable may be connected. Alternatively, the stationary PCB 22 may be coupled to stripline transmission lines on a panel without additional coaxial cabling. As the wiper PCB 24 moves, an electrical length from the wiper PCB 24 to each output pad 44 , and therefore each radiating element served by the transmission lines 26 , 28 changes. For example, as the wiper PCB 24 moves to shorten the electrical length from the input transmission line trace 40 to a first radiating element, the electrical length from the input transmission line trace end to a second radiating element increases by a corresponding amount. In the example illustrated in FIG. 2 , an additional transmission line trace 29 is included on stationary PCB 22 . Transmission line trace 29 carries an unshifted signal.
[0021] In one example illustrated in FIG. 2 , two phase shifters 20 are illustrated. The wiper PCBs 24 are mechanically coupled by wiper link 30 such that the wiper arm PCBs move in unison.
[0022] Referring to FIG. 3 , in one embodiment of the present invention, an actuator 110 is directly coupled to one of the phase shifters 20 . The actuator 110 is mounted on an actuator mount 108 , which is mounted to a radome back panel (not shown for clarity). The phase shifters 20 are mounted on a reflector 106 . Referring to FIG. 4 and FIG. 5 , the actuator 110 comprises a baseplate 112 , a connector bracket 114 , a top cover 120 , a drive shaft 122 and a pivot assembly 124 . The connector bracket 114 may comprise a molded AISG connector bracket. Male AISG connector 116 and female AISG connector 118 may be installed on the connector bracket 114 . A ring gear 126 may be attached to the baseplate 112 . In the illustrated example, the baseplate 112 is semi-circular and the ring gear 126 comprises a half ring gear, with gear teeth on an inner circumference of the gear. In this regard the ring gear 126 comprises only a portion of a conventional circular ring gear. The ring gear 126 may also include additional supporting structure which connects ends of the ring gear 126 to provide additional mechanical strength and facilitate mounting of the ring gear 126 on the baseplate 112 in an appropriate orientation. The baseplate 112 may be thermo molded plastic, metal, or any other suitable material. The ring gear 126 may be formed integrally with the baseplate 112 , for example, the ring gear 126 may be molded as a single unit with the baseplate 112 . Alternatively, the ring gear 126 may be separately formed and fixedly attached to the baseplate 112 .
[0023] Referring to FIGS. 4 , 6 and 7 , the pivot assembly 124 includes a pivot bracket 132 , a control board 134 , drive gear 136 , and a stepper motor 138 . Operation of the stepper motor 138 is controlled by the control board 134 , and the stepper motor 138 and control board 134 are mounted on the pivot bracket 132 . The pivot bracket 132 engages the drive shaft 122 . In one example, the drive shaft 122 may be molded as a unitary piece with pivot bracket 132 . In a preferred example, an output shaft of stepper motor 138 drives worm gear 140 . Worm gear 140 meshes with and drives spur gear 142 . A shaft couples spur gear 142 to drive gear 136 . This arrangement reduces the likelihood that the variable elements will be able to back-drive the stepper motor 138 .
[0024] In an alternate example, referring to pivot assembly 224 on FIGS. 8 and 9 , stepper motor 238 and control board 234 are on one side of the pivot bracket 232 , and the drive gear 236 is on the other side of the pivot bracket 232 . This alternate example has fewer moving parts and allows good transfer of rotational force, because a rotor shaft of the stepper motor 238 passes through the pivot bracket 232 . The stepper motor 238 may include additional securing brackets and fasteners. Additional alternate physical relationships between the stepper motor and the drive gear may be implemented without departing from the scope of the invention.
[0025] The ring gear 126 is located such that a circle defined by the radius of the ring gear 126 is concentric with the drive shaft 122 . Additionally, the length of the pivot bracket 132 and the location of the drive gear 136 are dimensioned such that the drive gear 136 engages the ring gear 126 , and, as the stepper motor 138 is operated, the drive gear 136 moves the pivot board through an arc defined by the ring gear 126 and the radius of the pivot bracket 132 . In the illustrated example, the rotation of the pivot board is approximately 180 degrees. Other amounts of rotation may be implemented without departing from the invention.
[0026] The male AISG connector 116 and the female AISG connector 118 are coupled to the control board 134 . The control board 134 includes a controller 144 , which may be a microprocessor or microcontroller, and a motor driver 146 . These devices are configured to operate the stepper motor 138 . The controller may also be configured to receive and transmit commands and information according to AISG protocols.
[0027] In one example, the control board 134 includes an accelerometer 150 , such as a 3-axis MEMS accelerometer 150 . The controller 144 on the control board 134 may be configured to read register information from the accelerometer, thereby determining the orientation of the pivot assembly 124 , and therefore drive shaft 122 position. From this, phase adjuster position may be determined.
[0028] Preferably, the accelerometer 150 comprises a multiple-axis digital accelerometer, such as Digital Accelerometer ADXL345, from Analog Devices, Inc. In this example, the accelerometer 150 is a digital 3-axis accelerometer. However, other accelerometers may be acceptable in alternate embodiments. The accelerometer provides angle information for the three axes of rotation as serial data. In one example, the serial data conforms to the I 2 C digital interface. X-axis data, y-axis data, and z-axis data may be obtained by reading appropriate registers in the accelerometer 150 . The controller 144 interfaces with the accelerometer 150 and reads the data registers.
[0029] The accelerometer 150 is mounted on the wiper control board 134 such that it may detect a physical angle of the control board 134 with respect to vertical. Control board 134 physical angle 0 may be determined by a first axis of the accelerometer 150 . If control board 134 angle with respect to vertical is the only angle to be determined, the solution may be had with a single axis of the accelerometer 150 and the following trigonometry relationship:
[0000] V OUTX =V OFF +S sin θ
[0000] Where V OUTX is the voltage output from the X-axis of the accelerometer, V OFF is the an offset voltage and S is the sensitivity of the accelerometer. The acceleration on the x-axis due to gravity is:
[0000] A X =(V OUTX −V OFF )÷ S
[0000] In this case, the solution for control board 134 angle is:
[0000] θ=sin −1 ( A x)
[0000] In another example, the actuator is mounted such that the axis of rotation of the default angle of the panel antenna is on a different axis (e.g., the y-axis) from an axis of rotation of the control board 134 .
[0030] In an alternative embodiment, a rotary potentiometer may be attached to the drive shaft 122 and coupled to the controller. In another alternate embodiment, pivot assembly 124 position sensing may be accomplished with pressure sensitive potentiometer tape extending the length of the ring gear 126 .
[0031] In one example, the actuator 110 is directly coupled to a first phase shifter. The first phase shifter may be mechanically linked to additional phase shifters such that, by driving the first phase shifter, all phase shifters are driven simultaneously.
[0032] The pivot bracket 132 may be rotationally fixed to the drive shaft 122 . The pivot bracket 132 and drive shaft 122 may be arranged such that they fit together in only one orientation, so that a risk of misalignment of the drive shaft 122 and pivot assembly 124 is minimized. In one example, the drive shaft 122 may have a D-shaped output side 123 , so that, once again, a risk of misalignment is minimized when the drive shaft 122 is connected to a phase shifter or linkage to operate one or more phase shifters.
[0033] In operation, commands indicating a desired antenna beam downtilt angle are received via the AISG connector. The controller determines an appropriate actuator 110 position (for example, a position of the pivot assembly 124 ) that corresponds to the desired beam downtilt angle. The controller may determine the appropriate actuator position by retrieving from a look-up table a physical actuator 110 position that corresponds to a desired beam downtilt angle. The relationship between downtilt angle and pivot assembly 124 angle actuator 110 position may have been previously determined empirically and stored in the look-up table in the firmware for the controller. The controller then operates the stepper motor 138 until the pivot assembly 124 reaches the appropriate orientation. In the case of position being determined by an accelerometer, registers providing x-axis, y-axis, and z-axis information may be read periodically while the motor is moving the pivot assembly 124 . The registers may also be read when the motor is not in operation to determine actuator 110 position, true mechanical tilt of the panel antenna, or for other reasons.
[0034] Various examples of the actuator 110 described herein benefit from improve torque. The torque of the stepper motor 138 is multiplied by the lever arm of the pivot bracket 132 . Thus, for a desired torque to operate a series of phase shifters, a proportionately smaller motor may be used. Additionally, the present invention requires only half a ring gear 126 , and that half ring gear 126 is stationary while the motor moves. This difference from conventional reduction gearing means that the actuator 110 takes up less space than a conventional reduction gear setup. If, for example, the motor were fixed and the ring gear 126 rotated, it would require 360 degrees of clearance to achieve 180 degrees of rotation. | 4y
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This application claims the benefit under 35 U.S.C. §119(e) of the co-pending provisional application of Ser. No. 60/307,745 entitled “Ladder Carrying Device” filed on Jul. 25, 2001, which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to carrying devices, and more specifically to a device that provides for user comfort and protection from injury when carrying a ladder.
BACKGROUND OF THE INVENTION
A ladder is generally carried by a worker to and from a storage location or vehicle and the place where it is used. A ladder generally is constructed to have a pair of side rails connected by at least one rung. A ladder can be cumbersome and can be difficult to control when it is carried because it can swing, or rise and fall in a variety of directions. If uncontrolled, this movement can injure the worker carrying the ladder. Uncontrolled, unpredictable movement of the ladder can also be dangerous to other people or property in the field of movement of the ladder.
A ladder may be carried either above or below the shoulder. If the ladder is carried above the shoulder, one of the side rails is placed on a carrier's or worker's shoulder with the remainder of the ladder, i.e., the rungs and the opposing side rail, above the carrier's or worker's shoulder. If the ladder is carried below the shoulder, one of the side rails is placed on a carrier's or worker's shoulder with the rungs and the opposing side rail located below the person's shoulder.
In either of the above-described carrying positions, the entire weight of the ladder is borne by the carrier's or worker's shoulder muscles and collarbone, which may cause substantial strain on that area of the body. Also, as the ladder side rail may assume a variety of configurations such as U-shaped or C-shaped, there may be increased discomfort due to uneven contacting of the rail with the carrier's or worker's shoulder area. For example, with U-shaped and C-shaped side rails the edges of the side rail contacts the body but the flat, center area of the side rail does not contact the body. That results in the weight and pressure of the ladder being supported by two narrow places on the carrier's shoulder.
The wrist may also experience strain as the carrier or worker attempts to control the ladder to prevent uncontrolled movements. Ladders can be difficult to balance when carried. If more of the ladder is carried behind the carrier or worker, he may try to compensate by pulling the ladder down in front of him, which can create a strain on his body. A comparable balancing problem can occur if more of the ladder is in front of the carrier or worker.
It can sometimes be difficult to determine the best or optimum support point for carrying a ladder, as it is dependent on the carrier or worker carrying the ladder and the terrain. Some carriers or workers contend the best support point for a ladder is at its center of balance or slightly ahead of its center of balance. At the center of balance, the carrier or worker can determine whether or not the ends of a ladder are moved up or down. If the support point is in front of the center of balance of the ladder, the front of the ladder will not fall and dig into the ground, which can injure the carrier or worker carrying the ladder. However, using this support position causes the back end of the ladder to touch the ground and scrape along as the carrier or worker moves forward, which can cause more uncontrolled movement of the ladder. Generally, the carrier or worker carrying the ladder does other physical work after putting the ladder in place, so that it is prudent to conserve his energy and strength. Various attempts have been made to alleviate the above-mentioned problems encountered in carrying ladders.
U.S. Pat. No. 5,058,789 describes a device consisting of a base plate with flanges for attachment around a ladder rail. The base plate has cushions attached to each side to protect the carrier's shoulder from injury. This device interposes another piece of metal with flanges between the person and the ladder. Those flanges can painfully contact the worker's shoulder in a manner described above with regard to the U-shaped and C-shaped rails.
U.S. Pat. No. 5,511,285 describes another ladder carrying device that provides a handle for the side rail of the ladder. This device has the disadvantage that considerable strain can be exerted on arm and back muscles. Further, if the ladder has to be raised over rough terrain or obstacles present in the path of movement, the ends of the ladder can contact the terrain or obstacles. Further exertion can be required by the person carrying ladder to raise the ladder.
U.S. Pat. No. 6,189,752 describes a ladder carrying device that consists of a rigid frame and a cushion pad. Part of the rigid frame contacts the ladder rail and the part of the frame that contacts the person's shoulder has a cushion to provide user comfort. This device has the disadvantage of requiring a rigid frame, which may, through repeated use, break through the cushion and painfully contact the carrier's shoulder.
Therefore, a need exists in the art for a ladder carrying device that will overcome the disadvantages listed above and permits a person to carry a ladder supported on his shoulder in comfort and which will distribute the weight of the ladder over the shoulder area.
SUMMARY OF THE INVENTION
The present invention provides for such a ladder carrying device that can be used to carry a ladder on a carrier's or worker's shoulder positioned either over or under his shoulder. The ladder carrying device of the present invention can be mounted in a variety of different positions on the side rails and/or rungs of a ladder, thereby allowing the ladder carrying device to be positioned according to the carrier's preference.
One embodiment of the present invention is directed to a ladder carrying device for carrying a ladder with two side rails and rungs therebetween over or under a shoulder of a carrier in which the ladder carrying device has at least one block and an adhesive strip to attach the block to the ladder such that the block is positioned between the ladder and the carrier's shoulder.
Another embodiment of the present invention is directed to a ladder carrying device for carrying a ladder having a first side rail and a second side rail, wherein the first and second side rails each have an inner surface and an outer surface and wherein the first and second side rails are connected by a plurality of rungs located therebetween and attached to the inner surfaces of the first and second side rails. The ladder carrying device has a first block having an adhesive strip to position the first block on the inner surface of the ladder's first side rail between an upper rung and a lower rung. The ladder carrying device also has a second block having an adhesive strip to position said second block opposite the first block on the inner surface of the ladder's second side rail between the upper rung and the lower rung. Finally, the ladder carrying device has a third block having an adhesive strip to position the third block on the bottom side of the upper rung adjacent to both the first block and the second block.
These and other advantages and benefits of the present invention will be apparent from the Detailed Description of the Invention herein below.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described for the purpose of illustration and not limitation in conjunction with the following figures wherein:
FIG. 1 is a perspective view of one embodiment of the ladder carrying device of the present invention;
FIG. 2 illustrates one embodiment of the ladder carrying device of the present invention attached to a ladder;
FIG. 3 is a cross-sectional view of a section of a C-shaped side rail having one embodiment of the ladder carrying device of the present invention attached to the inner surface of the side rail; and
FIG. 4 illustrates one embodiment of the ladder carrying device of the present invention attached to the outer surface of a side rail.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, one embodiment of the ladder carrying device 10 of the present invention comprises a rounded, rectangular block. Preferably, this block may be fashioned from a variety of plastic foams such as polyurethane, rubber, or any other material, which has sufficient resiliency to support the weight of the ladder 15 , but which also can conform to the contour of the carrier's shoulder. Plastic foams allow the ladder carrying device 10 to act as a cushion against the carrier's shoulder. As shown in FIG. 3, a cushioning ladder carrying device 10 serves two purposes, particularly when used with ladders 15 having C-shaped and U-shaped side rails 20 and/or rungs 25 : (1) the block creates a broader surface that contacts with the carrier's shoulder resulting in a more even distribution of weight and pressure across the carrier's shoulder and eliminating the narrow pressure points created by the C-shaped and U-shaped side rails and/or rungs; and (2) the plastic foam provides a cushioned surface that increases the carrier's comfort when carrying and maneuvering the ladder 15 .
The present invention 10 also encompasses a block comprised of a non-cushioning material such as a hard plastic or fiberglass. Such a material would not offer the cushioning effect of the softer plastic or plastic foam, but would serve the remaining purpose of creating a broader, flat surface in contact with the carrier's shoulder. Again, the creation of a broader contact area decreases the discomfort caused by C-shaped and U-shaped side rails 20 (see FIG. 3) and rungs 25 by more evenly distributing the weight and pressure of the ladder 15 across the carrier's shoulder.
Most ladders 15 are constructed so as to have similar dimensions. Generally, rungs 25 are spaced approximately twelve inches apart from one another. Most ladders 15 have side rails 20 that are three to four inches wide. For most C-shaped and U-shaped side rails 20 the depth of the C-shape or U-shape (or the depth of the edges of the C-shape or U-shape) is approximately one and a quarter inches to one and a half inches. Generally, the block of the present invention 10 will be eight to thirteen inches in length, one and a half to three inches in thickness, and two to five inches in width. In the preferred embodiment, the block would be produced from high-density foam rubber or plastic foam and would measure approximately ten to twelve inches in length, approximately two inches in thickness, and approximately three to four inches in width. It will be obvious to one skilled in the art though, that the present invention can be dimensioned and shaped to fit the specific dimensions of any ladder 15 , side rail 20 , or rung 25 , regardless of the size and shape of the ladder 15 , side rail 20 , and rung 25 .
The ladder carrying device 10 of the present invention comprises a front face 30 , a top face 32 , and a side face 34 . Rear, bottom and opposite side faces are not shown in FIG. 1 . Top face 32 preferably has adhesive strip 36 affixed thereto. Adhesive strip 36 can be used to attach the ladder carrying device 10 of the present invention to the ladder 15 as illustrated in FIG. 2 . Although depicted herein as a rounded, rectangular block, it will be apparent to those skilled in the art that the ladder carrying device 10 of the present invention can be sized and shaped to fit a wide variety of ladders 15 and may therefore assume other shapes than illustrated, such as squares or ovals.
In the preferred embodiment, the present invention will be attached to the ladder 15 near its center of gravity, but one skilled in the art will realize that the blocks can be placed in any one location or multiple locations depending on the user's preference, such as on the inner surface of a side rail 20 (see FIG. 2 ), on the outer surface of a side rail 20 (see FIG. 4 ), and/or on the bottom surface of a rung 25 (see FIG. 2 ). FIG. 2 illustrates one possible configuration of the ladder carrying device 10 of the present invention. This configuration can be attached to a ladder 15 to provide user comfort and protection against injury from the ladder's 15 side rail 20 coming into direct contact with the carrier's shoulder. As depicted in FIG. 2, ladder 15 is composed of side rails 20 connected by rungs 25 . Three ladder carrying devices 10 of the present invention are attached by adhesive strips 36 to the inner portion of the side rails 20 and the bottom portion of one rung 25 . This method of placement allows the carrier to carry the ladder 15 in the below the shoulder position described above. Placing a ladder carrying device 10 of the present invention on the lower portion of the rung 25 permits the worker to comfortably move the ladder 15 in a vertical orientation, such as when the ladder 15 is leaning against a building.
In another embodiment, the ladder carrying device 10 of the present invention can be attached to the outer surface of a ladder side rail 20 (as shown in FIG. 4) thereby enabling the carrier to utilize the over the shoulder carrying method described above.
The ladder carrying device 10 of the present invention can be quickly and easily applied by the user at the particular location on the ladder 15 that he prefers and can be used on a wide variety of ladders 15 to allow for safe, comfortable carrying. Because the user is protected from pain and strain from carrying the ladder 15 , he may also be able to exert greater control over the ladder 15 thereby becoming less hazardous to himself and the people and property around him.
As will be apparent to those skilled in the art, the ladder carrying device 10 of the present invention can be used with ladders 15 having side rails 20 of a variety of configurations including, but not limited to, flat, C-shaped, and U-shaped. Similarly, it will be apparent to those skilled in the art that the ladder carrying device 10 of the present invention can be used with ladders 15 having rungs 25 of a variety of configurations, including but not limited to flat, rounded, C-shaped, and U-shaped. Other embodiments using different numbers of ladder carrying devices 10 of the present invention in various configurations are also contemplated by the inventor. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of U.S. Provisional Patent Application No. 61/273,333 entitled “MULTI-PROCESS ELECTRONIC CONTROL VALVE SYSTEM,” filed Aug. 3, 2009, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This disclosure relates to control valves in general and, more specifically, to control valve systems for fluid wells.
BACKGROUND OF THE INVENTION
In some areas of the world, access to ground water supplies must be carefully monitored. Existing wells should not be drawn down below a certain level, while at the same time farmers and rancher need reliable access to the well water that is available. In situations where water is plentiful, it is often the case that the amount of water being drawn from a well will need to be within a certain flow rate or pressure range to be suitable to the water system utilizing the well (for example, an irrigation system).
In some cases, access to well water may only be needed on a seasonal or sporadic basis. For example, in times of heavy rain, little or no water may be needed for irrigation. In times like these, it is important for
What is needed is a system and method for addressing the above and related concerns.
SUMMARY OF THE INVENTION
The invention of the present disclosure, in on aspect thereof, comprises a valve system. The system has a main valve that is adjustable for output flow and pressure. The system also includes an output flow transducer, an output pressure transducer, and a fluid depth transducer. A microcontroller is operatively coupled to the valve, the output flow transducer, the output pressure transducer, and the fluid depth transducer. The microcontroller operates the valve to selectively control the output flow, the output pressure, and the fluid depth according to inputs received from a user.
In some embodiments, the main valve is hydraulically operated and may be diaphragm actuated and pilot controlled. The system may include one ore more electrically actuated solenoid pilot valves attached to the main valve and controlling the main valve in response to a signal from the microcontroller. One pilot valve may be normally open, and when de-energized by the microcontroller act to close the main valve. A needle valve may be operatively connected to the main valve to control the opening speed of the main valve. Another may be connected to the main valve to control the closing speed of the main valve. A check valve may be provided to prevent fluid flow in a reverse direction through the main valve.
In some embodiments, a control panel is operatively coupled to the microcontroller for receiving user inputs. A rain holdoff control may be provided for signaling the microcontroller to close the main valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a control valve system installed on a well according to aspects of the present disclosure.
FIG. 2 is a diagram of a valve assembly according to aspects of the present disclosure.
FIG. 3 is schematic diagram of a valve control unit according to aspects of the present disclosure.
FIG. 4 is a flow diagram of one method of operation of the valve control system of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The multi-process electronic control valve system as disclosed herein provides at least three functions relating to the control and flow of fluids. These functions are pressure, flow, and fluid depth. Although the embodiments are described with particular reference to an embodiment to be utilized with water wells, it is understood that the device of the present disclosure is readily adaptable to any fluid flow control application needing the functionality disclosed herein. Therefore the examples of the multi-process electronic control valve system in this specification is meant to be exemplary only, and not meant to be limiting in any way.
Referring now to FIG. 1 , a schematic diagram of a control valve system installed on a well according to aspects of the present disclosure is shown. The system 100 is installed onto a water well 102 or other fluid reservoir. The system 100 selectively controls a pressure output, a flow rate, and a well depth, as will be described herein. A water level 104 of the well 102 may be monitored and reported by a depth transducer 106 . An electrical signal indicating a depth of the water 104 or other fluid may be transmitted electronically on an electronic signal line 108 . This information is monitored and utilized by the control unit 110 . In the present disclosure, all transducer signal lines may be analog or digital depending upon the transducer employed. A pump 112 may be submerged in the well 102 or may be placed remotely therefrom. The pump 112 provides fluid under pressure to a valve assembly 200 that may be connected to a well output 114 . In some embodiments, the control unit 110 may also activate and deactivate the pump 112 by pump signal line 113 .
The control unit 110 may connect to the valve assembly 200 by at least two signal lines. An open signal line 116 may provide a signal from control unit 110 to valve assembly 200 indicating to open or increase the opening of the valve assembly 200 . A close signal line 118 interconnecting the control unit 110 and the valve assembly 200 may provide for a signal indicating that the valve assembly 200 should be partially or fully closed.
A flow transducer 120 may be provided on or near the output 114 for providing an electric signal on signal line 121 to the control unit 110 indicating the flow rate of the output 114 . A pressure transducer 122 may provide a signal on signal line 123 to the control unit 110 indicating a pressure at the output port 114 . It will be appreciated that the control unit 110 , having the combined signals from the depth transducer 106 , the flow transducer 120 , and the pressure transducer 122 may signal the valve assembly 200 to open or close in order to selectively control the depth, flow rate, or pressure of the output 114 .
In the present embodiment, the control unit 110 provides for user selection of the monitoring and control function of the system 100 . In order to facilitate interaction with the user, the control unit 110 may provide various I/O devices, including a view screen 124 and a keypad 126 . Via interaction with the system 100 , using the view screen 124 and keypad 126 , a user can control various modes of operation and parameters of the system 100 .
Referring now to FIG. 2 , a diagram of a valve assembly 200 according to aspects of the present disclosure is shown. The valve assembly 200 interacts with the control unit 110 to open and close in response to signals therefrom. The valve assembly 200 may be able to open or close fully, as well as having a high degree of fine tuning and adjustability between the fully closed and fully open positions. A main valve 202 is provided that interposes the pump 112 and the output port 114 . In the present embodiment, the main valve 202 is a hydraulically operated diaphragm actuated and pilot controlled globe valve, but in other embodiments the valve could be victaulic, threaded, or another type of valve. In the present embodiment, the main valve 202 will close with an elastomer on metal seal. In the configuration of the present embodiment, shown in FIG. 2 , the main valve 202 is interconnected with a needle valve 204 that controls the closing speed of the valve 202 . In order to control the amount of overshoot or hysteresis of the system 100 , the needle valve 204 may be set to a suitable speed to allow the main valve 202 to close with sufficient speed so as to be responsive, but also prevents it from closing so fast as to cause an undesirable amount of overshoot when closing the valve. In some embodiments, the needle valve 204 may be adjustable by the end user.
Some embodiments will provide an isolation ball valve 206 in series with the needle valve 204 . A strainer 208 may be provided to protect the components of the fluid circuit from contamination. A check valve 210 may also operate to prevent reverse flow through the needle valve circuit as well. In the present embodiment, the actual closing of the main valve 202 is controlled by an electric solenoid 212 . In the present embodiment, the solenoid 212 is a normally open electric solenoid pilot valve. The solenoid 212 may be electrically connected to the control unit 110 to receive signals therefrom and to close the main valve 202 in response.
In order to affect an opening of the main valve 202 , a separate valve circuit is provided for a second solenoid 214 . The solenoid 214 in the present embodiment is a normally open electric solenoid pilot valve. In response to a signal from the control unit 110 , the solenoid 214 will open to cause the main valve 202 to open and thereby increase flow rate and pressure on the output port 114 . An isolation ball valve 216 is provided in parallel with the solenoid 214 . Additional isolation ball valves 218 , 226 are provided in series. As on the closing side, the opening side provides a needle valve 220 that may be tuned in order to control the opening speed of the valve 202 . As before, the opening speed may be set to provide a requisite degree of responsiveness from the main valve 202 while being slow enough to prevent an undesirable amount of overshoot. A check valve 222 is provided in the circuit to prevent undesirable reverse flow of fluids through the fluid circuit. A strainer 224 aids in preventing contamination of the components.
The present embodiment shown in FIG. 2 provides a position transmission assembly 228 that interconnects with the main valve 202 . This allows the relative degree of opening or closing of the valve 202 to be provided back to the control unit 110 . In some embodiments, this information may be available to the user. In the present embodiment, the information provided by the position transmission assembly 228 is not necessarily needed by the control unit 110 .
Referring now to FIG. 3 , a schematic diagram 300 of a valve control unit according to aspects of the present disclosure is shown. FIG. 3 provides one possible way in which the control unit 300 can be constructed. It will be appreciated that the control unit 300 is an expansion or elaboration on the control unit 110 shown in FIG. 1 . The control unit 300 may be based around a microcontroller 302 . The microcontroller 302 may be an integrated circuit or a general purpose microprocessor that has been programmed according to the functionality described herein. The microcontroller 302 is provided to a power supply Vcc 301 and a ground source 304 . These may be based upon a battery system or may be a part of the commercial electric grid. A console 306 connects to the microcontroller 302 via data bus 307 . A video display 308 and a keypad 310 are provided to allow a user to interact with the microcontroller 302 .
It can be seen that the microcontroller 302 provides open signal line 116 and closed signal line 118 to the respective pilot valves 214 , 212 . This enables the microcontroller 302 to affect the opening and closing of the main valve 202 . It is understood that a relay network may actually be provided by the open and closed signal lines 116 , 118 , if such are needed to effectively power and operate the solenoids 212 , 214 .
The transducers for depth 106 , flow 120 , and pressure 122 may provide their data on signal lines 108 , 121 and 123 , respectively. These may be read by the microcontroller 302 . It is understood that various signal conditioning and/or analog to digital conversion may take place between the microcontroller 302 and the various transducers.
In operation, a user will interact with the microcontroller 302 using the keypad 310 and the display screen 308 . At this point, a user may indicate to the microcontroller 302 which of the selective operations is desired. Operations available to the user may include, but are not limited to: operating the pump 112 and/or valve assembly 200 to maintain a desired fluid level 104 in the well 102 ; maintaining a specified pressure; and maintaining a specified flow rate. It will be appreciated that, in some instances, more than one of these functions may be controlled at a time. However, in other cases owing to limitations of water supply and pressure, it may only be possible to control one of the desired parameters based upon a selection from the user. For example, if the well has plenty of water, the amount of pressure may be the most critical due to limitations of the downstream irrigation system. In other cases, the amount of water flow required (e.g., for crops) may take precedent over the pressure being generated.
Referring now to FIG. 4 , a flow diagram 400 of one method of operation of the valve control system 100 of the present disclosure is shown. At step 402 , it may be determined whether the system has been set on rain hold. If the system has been set on rain hold, this would indicate that the user did not desire for the control unit 110 to do anything. In this case, the control program may end (or restart) and continue querying at step 402 until such time as the rain hold has been released.
If at step 402 there is no rain hold, at step 404 the determination may be made by the control unit as to whether the pressure monitoring function has been selected by the user. If so, at step 406 a reading may be taken of the pressure transducer 122 in order to determine whether or not the desired pressure has already been achieved. If the desired pressure has not been achieved, the valve may be adjusted at step 408 and the pressure checked again at step 406 . Through iterations of adjusting the valve 408 , it can be determined when the pressure is within the desired threshold at step 406 . Once the desired pressure has been achieved, the control loop will end or repeat until a different parameter is selected or until the rain hold is re-engaged.
It will be appreciated that the step of adjusting the valve 408 may include signaling the valve 202 to open further, or close further, depending on the reading from the appropriate transducer. It may also require several steps of adjusting in order to achieve the desired flow rate or pressure.
If the pressure monitor function has not been selected at step 404 , it may be determined at step 410 whether the flow monitor function has been selected. If so, the flow transducer 120 may be checked or queried at step 412 to determine if the flow rate is within the specified range. If not, the valve may be adjusted at step 414 . The flow rate may be again checked at step 412 and the adjustment and checking process repeated until the flow rate is within the desired parameters. At this point, the controller terminates or continues monitoring or waiting for an additional command.
If at step 410 the flow monitor function has not been selected, this indicates that the depth control function has been selected by the user. At step 416 , a depth reading may be taken by the depth transducer 106 . Depending upon the signal return from the depth transducer 106 , the valve may be adjusted at step 418 . It will be appreciated that changes in depth may occur much more slowly than changes in flow rate or pressure. Therefore, it may be desirable to limit the amount of valve adjustment that can occur at step 418 . It is also understood that the valve assembly 200 cannot be opened beyond full capacity. Thus, the query at step 412 may also include an accounting of the position of the main valve 202 . If at step 416 the depth 104 has fallen below the specified parameter indicating that the valve assembly 200 should be closed off, the control loop simply waits for further additional commands, as there is no further need to adjust the valve at step 418 .
Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the claims. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application Ser. No. 61/284,329, filed Dec. 15, 2009 and entitled “MATERIALS PROCESSING,” which is hereby incorporated herein by reference in its entirety as if set forth herein.
FIELD OF THE INVENTION
The present invention relates generally to the field of powder material production. More specifically, the present invention relates to a process for removing oxide from produced metallic powders.
BACKGROUND OF THE INVENTION
This disclosure refers to both particles and powders. These two terms are equivalent, except for the caveat that a singular “powder” refers to a collection of particles. The present invention may apply to a wide variety of powders and particles. Powders that fall within the scope of the present invention may include, but are not limited to, any of the following: (a) nano-structured powders(nano-powders), having an average grain size less than 250 nanometers and an aspect ratio between one and one million; (b) submicron powders, having an average grain size less than 1 micron and an aspect ratio between one and one million; (c) ultra-fine powders, having an average grain size less than 100 microns and an aspect ratio between one and one million; and (d) fine powders, having an average grain size less than 500 microns and an aspect ratio between one and one million.
Powders are used in a wide variety of applications. Currently, metallic powders (particles having a core that is either a pure metal or a metal alloy) are offered having an oxide shell. FIG. 1 is a cross-sectional side view of a metallic particle 100 having a metal, or metal alloy, core 102 covered by an oxide layer 104 . As seen in FIG. 1 , the oxide layer 104 can be quite thick, accounting for approximately 60% (sometimes more) of the entire size of the particle 100 . This substantial oxide shell may be useful in certain applications. However, in other situations, it may be undesirable to have such a significant oxide presence.
SDC Materials, LLC has developed an in situ process that employs the use of flowing plasma and a vacuum system in order to produce particles having a reduced oxide layer. FIG. 2 is a cross-sectional side view of a metallic particle 200 resulting from this process. The particle 200 has a metal, or metal alloy, core 202 covered by an oxide shell 204 . As can be seen by comparing FIG. 2 to FIG. 1 , the thickness of oxide layer 204 for particle 200 is significantly reduced from the thickness of oxide layer 104 for particle 100 . Using this process, the thickness of the oxide layer can be reduced to less than 10% of the entire particle thickness. While providing a considerable improvement over the particle of FIG. 1 , this process still does not achieve complete oxide removal from the particle. As a result, this nano-particle 200 may still prove to be undesirable for certain applications.
Currently, there is no way to create metallic particles having no oxygen. Even the best vacuum system has oxygen in it. As a result, the end product might not be sufficient for those who want oxide-free metallic powder.
What is needed in the art is a method for producing metallic powders that do not contain any oxygen.
SUMMARY OF THE INVENTION
The present invention provides a process for producing metallic powders that do not contain any oxygen. FIG. 3 is a cross-sectional side view of a powder particle 300 that is produced using the process of the present invention. Particle 300 comprises a metal, or metal alloy, core 302 , and is characterized by the absence of an oxide shell, in contrast to the particles of FIGS. 1 and 2 .
In one embodiment, the process of the present invention comprises providing a powder defined by a plurality of particles. Each particle in the plurality of particles has a metallic core and an oxide layer surrounding the metallic core. The plurality of particles are then etched. This etching serves to remove the oxide layer from each particle in the plurality of particles, leaving only the metallic core. In this fashion, bare metallic powder has been provided free of any oxide.
Additional steps may then be taken to prepare the powder for its eventual application. Each particle in the etched plurality of particles can be coated with an organic layer. The etched powder may also be dispersed using a dispersing solution.
The steps of etching, coating and dispersing are performed in situ with the plurality of particles disposed in liquid, absent any exposure of the metallic cores to air both during and in between these steps.
The final product may be provided as a dispersion of particles stored in a liquid. Alternatively, the final product may be provided as a dried and settled powder absent any liquid.
In another embodiment, a method for removing silicon-dioxide from silicon powder is provided. The method comprises providing a silicon powder defined by a plurality of particles. Each particle in the plurality of particles has a silicon core and a silicon dioxide layer surrounding the silicon core. The plurality of particles is dispersed in a dispersing solution, preferably methanol. An etching solution, preferably hydrofluoric acid, is added to the dispersing solution. The etching solution removes the silicon dioxide layer from each particle.
An organic solvent, such as cyclohexane or toluene, is then added to the mixture of the dispersing solution and the etching solution. The addition of the organic solvent produces an organic phase and an aqueous phase. The organic phase comprises substantially all of the silicon cores and substantially all of the organic solvent, and the aqueous phase comprises substantially all of the dispersing solution, substantially all of the etching solution, and substantially all of the by-products resulting from the silicon dioxide removal. Each silicon core in the plurality of particles is then coated with an organic material from the organic solvent. The aqueous phase is drained out and the organic phase is washed, removing substantially all of the remaining aqueous phase material from the organic phase. The silicon powder can then be provided as a plurality of silicon cores that are absent a silicon dioxide layer surrounding each silicon core, with each silicon core having an organic coating. The steps of dispersing, adding an etching solution, adding an organic solvent, coating, draining, and washing are performed in situ with the plurality of particles disposed in liquid, absent any exposure of the silicon cores to air.
In yet another embodiment, a method for removing copper-oxide from copper powder is provided. The method comprises providing a copper powder defined by a plurality of particles, with each particle in the plurality of particles having a copper core and a copper-oxide layer surrounding the copper core. The plurality of particles are disposed in an etching solution in a container. The etching solution, preferably comprising acetic acid and water, removes the copper-oxide layer from each particle. The etching solution and the by-products resulting from the copper-oxide removal are then decanted, and the plurality of particles are washed, removing substantially all of the remaining etching solution and substantially all of the by-products from the container holding the plurality of particles.
The washed plurality of particles is disposed in an organic solvent, preferably comprising tetraethylene glycol and water. Each copper core in the plurality of particles is then coated with an organic material from the organic solvent, and the plurality of particles is dispersed in the organic solvent. The copper powder may then be provided as a plurality of dispersed copper cores that are absent a copper-oxide layer surrounding each copper core, with each copper core having an organic coating. The steps of dispersing in the etching solution, decanting, washing, disposing in the organic solvent, coating, and dispersing are performed in situ with the plurality of particles disposed in liquid, absent any exposure of the copper cores to air.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of a powder particle having an oxide shell.
FIG. 2 is a cross-sectional side view of a powder particle having a reduced oxide shell.
FIG. 3 is a cross-sectional side view of a powder particle having no oxide shell in accordance with the principles of the present invention.
FIG. 4 is a flowchart illustrating one embodiment of a general work flow in accordance with the present invention.
FIGS. 5A-F illustrate exemplary embodiments of the different powder states during the general work flow in accordance with the present invention.
FIG. 6 is a flowchart illustrating one embodiment of a work flow for silicon powder in accordance with the present invention.
FIGS. 7A-F illustrate exemplary embodiments of the different powder states during the silicon powder work flow in accordance with the present invention.
FIG. 8 is a flowchart illustrating one embodiment of a work flow for copper powder in accordance with the present invention.
FIGS. 9A-H illustrate exemplary embodiments of the different powder states during the copper powder work flow in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the described embodiments will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein.
FIG. 4 is a flowchart illustrating one embodiment of a general work flow 400 in accordance with the principles of the present invention. At step 402 , a powder is provided in the form of a plurality of particles having a metallic core and an oxide layer surrounding the metallic core. As previously mentioned, this metallic core may be a pure metal or a metal alloy. The powder is preferably provided in a dry state. FIG. 5A illustrates one embodiment of the powder 500 being provided in a container as a plurality of particles having a metallic core 502 and an oxide layer 504 . Typically, the dry powder 500 is settled at the bottom of the container as shown. It is to be understood that FIGS. 5A-F are only provided to illustrate the general principles of the present invention and should not be used to limit the scope of the claims with respect to details such as size, shape and quantity.
At step 404 , the particles are then etched in situ. This etching serves to remove the oxide layer from each particle in the plurality of particles, leaving only the metallic core. Preferably, each one of the plurality of particles retains substantially all of its metallic core. In this fashion, a metallic powder has been produced free of any oxide. In a preferred embodiment, the etching is achieved by disposing the powder in an etching solution. FIG. 5B illustrates one embodiment of an etching solution 506 being introduced into the container and interacting with the oxide layer 504 of each particle. The powder 500 can be stirred in the etching solution 506 in order to assist with this interaction. The application of the etching solution 506 may cause the particles to become slightly suspended for a period of time before settling. FIG. 5C illustrates one embodiment of the resulting removal of the oxide layer 504 from the metallic core 502 of each particle.
The powder may then go through an in situ coating/dispersion process at step 406 in order to prepare it for its eventual application. The coating process involves coating each particle that has been etched with an organic layer. This coating may be achieved by disposing the etched powder in an organic solvent. The dispersion process involves dispersing the plurality of etched particles. This dispersion may be achieved by disposing the etched powder in a dispersing solution. While the coating and dispersing processes are grouped together at step 406 , they do not necessarily need to occur at the same time. The coating may be performed prior to the dispersing, and likewise, the dispersing may be performed prior to the coating. Furthermore, the existence of one does not necessarily depend on the existence of the other. In fact, the achievement of an oxide-free metallic powder may be achieved in the absence of either or both of these operations. However, in a preferred embodiment, the powder is both coated and dispersed in order to attain optimum stability and preparation. FIG. 5D illustrates one embodiment of a coating and dispersing solution 508 being introduced into the container and interacting with each particle. As a result, the powder is dispersed, and each metallic core 502 becomes coated with an organic material 510 , as seen in FIG. 5E .
At step 408 , the powder may be provided as a dispersion of particles, with each particle having a metallic core and no oxide shell. Preferably, the powder is maintained as a dispersion in a storage liquid, with each particle having an organic coating surrounding its metallic core. This storage liquid may simply be the coating/dispersing solution or may be some other type of liquid appropriate for storing the powder.
For certain applications, such as sintering, it may not be desirable to provide the powder in a liquid. Instead, circumstances may dictate that the powder be provided in a dry state. In these situations, the oxide-free particles can be dried in situ at step 410 . The powder may then be provided at step 412 as dried particles, each having a metallic core, preferably surrounded by an organic coating, and no oxide shell, as seen in FIG. 5F . In the example of sintering, the dried powder may then be placed in a Spark-Plasma Sintering (SPS) machine having a reducing atmosphere. The reducing atmosphere matches the organic layer and serves to reduce the organic layer by burning it off, leaving a pure metallic core and a gas by-product. The metallic cores are then fused together, resulting in an ultra-pure block of metal having nano-properties.
The present invention may be used for a wide variety of metallic powders. Such powders may include, but are not limited to, silicon and copper.
FIG. 6 is a flowchart illustrating one embodiment of a work flow 600 for removing the oxide layer from silicon powder in accordance with the present invention. At step 602 , the powder is provided as-produced, with each particle having a silicon core and a silicon-dioxide shell layer. This silicon core may be pure silicon or a silicon alloy. The powder is preferably provided in a dry state. FIG. 7A illustrates one embodiment of the powder 700 being provided in a container as a plurality of particles having a silicon core 702 and a silicon-dioxide shell 704 . Typically, the dry powder 700 is settled at the bottom of the container as shown. It is to be understood that FIGS. 7A-F are only provided to illustrate the general principles of the present invention and should not be used to limit the scope of the claims with respect to details such as size, shape and quantity.
At step 604 , methanol 706 a is added to the container and then stirred in order get a dispersion of particles, as seen in FIG. 7B .
At step 606 , a hydrogen fluoride (HF) solution (i.e., hydrofluoric acid) is added to the container in order to remove the oxide. As seen in FIG. 7C , the result is a plurality of silicon cores 702 dispersed in a mixture 706 b of water, HF and methanol. In a preferred embodiment, the solution contains approximately 10% HF and is applied to the particles for between approximately 1 to 5 minutes at about room temperature. However, it is contemplated that the HF concentration, time applied and environment temperature may vary according to the particular circumstances in which the present invention is being employed.
At step 608 , an organic solvent is added to the container. Such organic solvents may include, but are not limited to, cyclohexane and toluene. As seen in FIG. 7D , the addition of the organic solvent produces an organic phase 708 , having the organic solvent, on top of an aqueous phase 709 , having the silicon cores 702 dispersed in the HF/water/methanol mixture, with a sharp interface in between the two phases. Due to their hydrophobic properties, the silicon cores 702 then diffuse up into the organic phase 708 , as seen in FIG. 7E , leaving the HF/water/methanol mixture and any etching products in the aqueous phase 709 .
At step 610 , the aqueous phase 709 is drained out of the container, taking most, if not all, of the HF/water/methanol mixture and etching products with it, and leaving behind the organic phase 708 with the silicon cores 702 each coated with an organic layer 710 , as seen in FIG. 7F .
At step 612 , the organic phase 708 may be washed with water in order to remove residual HF and any other undesirable polar material. This washing step may be repeated as many times as necessary in order to achieve optimum residue removal. However, in a preferred embodiment, the organic phase is washed twice with water.
At this point, the process may take two separate paths, either drying the particles at step 614 a or dispersing the particles at step 614 b.
At step 614 a , the organic phase is dried down to only the powder in the container. The particles are then immediately stored in a storage liquid at step 616 a , where they may be re-dispersed. The storage liquid is either in the polar-organic range, such as tetraethylene glycol or other glycol solvents, or the hydrophobic range. This path allows the powder to be used in water-based applications at step 618 and/or organic coating applications at step 620 .
At step 614 b , a dispersant is added to the washed organic phase, thereby dispersing the particles. The dispersant may then be used as a storage liquid at step 616 b . This path allows the powder to be used in organic coating applications at step 620 .
FIG. 8 is a flowchart illustrating one embodiment of a work flow 800 for removing the oxide layer from copper powder in accordance with the present invention. At step 802 , the powder is provided as produced, with each particle having a copper core and a copper-oxide shell layer. This copper core may be pure copper or a copper alloy. The powder is black and is preferably provided in a dry state. FIG. 9A illustrates one embodiment of the powder 900 being provided in a container as a plurality of particles having a copper core 902 and a copper-oxide shell 904 . Typically, the dry powder 900 is settled at the bottom of the container as shown. It is to be understood that FIGS. 9A-H are only provided to illustrate the general principles of the present invention and should not be used to limit the scope of the claims with respect to details such as size, shape and quantity.
At step 804 , the powder is treated with acetic acid in water. The mixture of acetic acid and water forms an etching solution that is used to remove the oxide layer 904 from the copper core 902 . In a preferred embodiment, the solution contains approximately 0.1% to 1% acetic acid. However, it is contemplated that a variety of different concentrations may be employed. FIG. 9B illustrates one embodiment of the acetic acid solution 906 being introduced into the container and interacting with the oxide layer 904 of each particle. The application of the solution 906 may cause the particles to become slightly suspended for a period of time before settling at the bottom of the container. FIG. 9C illustrates one embodiment of the resulting removal of the oxide layer 904 from the copper core 902 of each particle. The etching products (removed copper-oxide, etc.) rise to the upper portion of the mixture, while the resulting copper-colored powder resides on the bottom, typically in a non-dispersed arrangement.
At step 806 , one or more decantations is performed in order to remove a majority, if not all, of the etching solution and products. As seen in FIG. 9D , any remaining etching solution 906 and/or etching products is minimal.
At step 808 , the powder may then be washed with water 907 , as seen in FIG. 9E , in order to remove any remaining etching solution or etching products. This washing step may be repeated as many times as necessary in order to achieve optimum residue removal. However, in a preferred embodiment, the powder is washed twice. Preferably, a minimal amount of the washing water 907 is left in the container, as seen in FIG. 9F .
At step 810 , the powder is treated with a tetraethylene glycol (or some other glycol solvent) and water solution 908 , as seen in FIG. 9G . The interaction of this solution 908 with the copper cores 902 forms a dispersion of copper cores 902 each having an organic coating 910 , as seen in FIG. 9H .
At step 812 , the resulting copper particles may be stored in the glycol solvent and water solution. This powder can maintain the same copper coloring for weeks without any discoloration.
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. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2002-188407, filed Jun. 27, 2002, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a connector usable in, for example, medical instruments, such as ultrasonic diagnostic equipment, semiconductor testing equipment, computers, and industrial equipment with a multicore electric input/output section, such as communications equipment.
[0004] 2. Description of the Related Art
[0005] More particularly, this invention relates to a multicore connector with a plug and a receptacle used for an electrical connection between electronic apparatuses utilizing a multi-core cable or the like.
[0006] Sophisticated electronic apparatuses, including medical instruments, semiconductor testing equipment, computers, and communications equipment, have been getting smaller in size and more sophisticated. In addition, the signals they have to transmit and receive have become more diversified and complex. Thus, the input/output and transmission/reception cables of a plurality of electronic apparatuses connected to one another tend to have more cores, which thus requires multicore connectors smaller in size, higher in density, and of higher reliability.
[0007] Multicore connectors involve connection of many contact parts. When a plug and a receptacle are connected to each other, and when the plug is pulled out of the receptacle, it is desirable that the insertion force and the pulling force be very small. Furthermore, there have been demands for long-service-life connectors with less wear of the contact parts.
[0008] [0008]FIG. 11 shows an example of a conventional multicore connector 100 . The multicore connector 100 is composed of a plug 101 , connected to one (not shown) electronic apparatus, and a receptacle 102 , connected to another (not shown) apparatus. When they are connected to each other, after the plug 101 is inserted into the receptacle 102 (with zero insertion force) and joined with each other, a handle 103 is turned, thereby rotating a cam shaft 104 provided on the plug central part.
[0009] By this process, the action of a cam 105 provided in the lower part of the cam shaft 104 slides an actuator 106 in the lateral direction, thereby moving a contact 108 formed at the tip of a contact pin 107 to a contact 109 of the receptacle 102 in such a manner that the contact 108 comes into contact with the contact 109 . Each contact pin is displaced elastically, causing the contact 108 of the plug 101 to press against the corresponding contact 109 of the receptacle 102 , which connects the plug and receptacle to each other electrically. The rotation of the cam shaft 104 sets a lock between the plug 101 and the receptacle 102 , which secures the plug 101 to the receptacle 102 reliably.
[0010] For instance, in an ultrasonic apparatus, when this type of connector is used to connect the signal cable of the ultrasonic sensor to the apparatus body, the following approach is used: the receptacle 102 is fixed to the circuit board (not shown) in the ultrasonic apparatus and each contact terminal 110 is soldered to the corresponding wire on the circuit board, and the plug 101 is engaged with the receptacle 102 , thereby making an electrical connection. To wire the plug with a multicore cable, the cores of the multicore cable (not shown) are contact-bonded or soldered to contact terminals 111 . Alternatively, the contact terminals are mounted on a specific circuit board. Then, a cable is drawn out of the wiring of the circuit board. However, in the conventional multicore connector of FIG. 11, the contacts 108 and 109 are long, which permits crosstalk or a similar problem to occur between the contacts, depending on usage.
[0011] [0011]FIG. 12 shows a conventional example of a multicore connector 200 developed to solve the crosstalk problem or the like. The multicore connector 200 is also composed of a plug 201 and a receptacle 202 as the connector of FIG. 11. FIG. 12 shows a state where the plug 201 and the receptacle 202 are connected to each other electrically in the conventional example.
[0012] The plug 201 has a plug housing 203 . In the lower part of the housing 203 , there is provided a plug board 204 composed of a multilayer wiring insulating board. On the top surface of the plug board 204 , a plurality of electrode pads 205 are formed which are to be connected to the individual cores (not shown) of the multicore cable extending from one electronic apparatus to be connected. A plurality of contact pads 206 corresponding to the electrode pads 205 are formed on the bottom surface of the plug substrate 204 , which connects the contact pads 206 corresponding to the electrode pads 205 to the electrode pads 205 electrically inside the plug board 204 . The plug 201 further has a cam shaft 207 provided rotatably in the central part of the plug. At the top of the cam shaft, there is provided a handle 208 for pressing the plug 201 against the inside of the receptacle 202 and at the same time, rotating the cam shaft 207 .
[0013] Moreover, the housing 203 is provided with a spring support section 209 for actuating the cam shaft 207 upward, and a spring 220 . The cam shaft 207 has a ringed brim projecting from its side which presses against the spring 220 .
[0014] The receptacle 202 has a receptacle housing 209 . In the lower part of the housing 209 , a receptacle board 210 is provided. On the top surface of the receptacle board 210 , a plurality of contact pads 211 (or contact strips) to be pressed against the contact pads 206 of the plug are formed. On the bottom surface of the receptacle board 210 , a plurality of electrode sections 213 are formed which are internally connected to the contact pads 211 and electrically connected to the printed wiring board 212 of the other electronic apparatus.
[0015] The receptacle 202 further has a stiffener 214 serving as a support member in its lower part. The printed wiring board 212 of the other electronic apparatus is inserted between the stiffener 214 and the bottom surface 215 of the receptacle housing 209 and then screwed there (not shown), thereby fixing the receptacle 202 to the circuit board 212 . The receptacle 202 is provided with a set of folding doors 222 on both sides. When the plug 201 is not inserted, the doors 222 are turned horizontally to close the receptacle 202 .
[0016] To connect the plug 201 and the receptacle 202 , the plug 201 is inserted into the receptacle 202 in such a manner that the doors 222 are forced open left and right and the cam shaft 207 is further pressed downward, opposing the actuation of the spring 220 . Then, the cam shaft 208 is rotated with the handle 208 , thereby pulling a projecting part 216 sticking out of the cam shaft 207 under the locking surface 218 of the central concave part 217 of the bottom surface of the stiffener 214 . As a result, the elastic force of the spring 220 makes an electrical connection between the individual contact pads 206 , 211 of the plug and receptacle. To remove the plug 201 , the cam shaft 207 is pressed downward, opposing the actuating force of the spring 220 , and then is rotated in the opposite direction, thereby unlocking the projecting part 216 .
[0017] In the conventional multicore connector 100 of FIG. 11, turning the handle causes the contacts to move in the lateral direction by means of the cam mechanism near the center, which assures the operation capability with a ZIF (zero insertion force) structure. Since the contact pins 107 , 109 are deformed elastically to make contact with one another, as the number of cores increases, the rotational torque of the cam shaft 104 becomes larger at the time of engagement, which is a problem. Furthermore, since spring actions are needed, this lengthens the signal line, making interference, such as crosstalk, liable to take place in the transmission characteristic of the electric signals, which tends to have an adverse effect on the transmission of high-speed signals.
[0018] Furthermore, in a conventional multicore connector 200 of FIG. 12, since no contact pin is used, the signal lines in the longitudinal direction become shorter, enabling the height of the connectors in the longitudinal direction to be reduced. However, to increase the rigidity of the connector 200 and connect the connector 200 to the circuit board 212 on which the connector 200 is to be mounted, a stiffener 214 to fix the connector 200 to the board 212 has to be provided on the back of the board 212 . Furthermore, an opening 223 has to be made in the board. As a result, the connector 200 is made larger on the whole and the parts mounting area is made smaller, which is a problem. In addition, there is another problem: even if the plug housing 203 and receptacle housing 209 are made of a metal, it is difficult to make electrical connection to cause them to be grounded completely.
[0019] An object of the present invention is to provide a multicore connector which makes the rotational torque of the cam shaft smaller and shortens the signal lines to improve the EMI characteristic, or the transmission characteristic of electric signals, and prevent interference, such as crosstalk, and which is suitable for the transmission of high-speed signals. Another object of the present invention is to provide a multicore connector which reduces the number of parts to be mounted on an electronic apparatus, makes the parts mounting area smaller by downsizing the whole connector, and enables the plug housing and receptacle housing to be grounded completely.
BRIEF SUMMARY OF THE INVENTION
[0020] As explained in embodiments of the present invention shown in FIGS. 1 to 10 , such contact pads 17 as contact the electrical contact sections 34 of a receptacle 2 directly to make an electrical connection are formed on one side of the plug board 5 of a plug 1 . On the mating receptacle 2 , a plurality of spring contactors, or receptacle contacts 34 , are formed. By doing this, the signal lines on the whole connector can be shortened.
[0021] The contacts 34 on the receptacle 2 side can be modularized in units of a specific number of contacts as shown in FIG. 6. Although the present invention is not limited to the modularization of contacts, use of a structure with a plurality of contact modules enables a great many contact sections to be formed. Use of a plurality of contact modules conforming to the same standard according to the number of contacts needed makes it possible to form various types of multicore connectors easily according to the number of cores needed. Consequently, it is possible to give flexibility to the design.
[0022] Furthermore, a plurality of spring contacts bringing the shell section of the plug frame 3 and the receptacle housing 11 into contact with each other, or grounding plate springs 25 can be provided on the inner periphery of the receptacle housing 11 . This structure makes a reliable electrical connection between the plug frame 3 and the grounded receptacle housing 11 , which provides a structure capable of improving the EMI characteristic of the multicore connector related to the present invention.
[0023] In addition, a grounding conductive pattern 30 is provided on the periphery of the plug board 5 , which provides a structure where the shell section of the plug frame 3 connected to the grounding pattern makes contact with a number of grounding springs provided around the module connector.
[0024] A connector according to the present invention has a structure where an engaging section including rollers 15 for engaging the plug frame with the receptacle housing and a shaft 6 is provided inside the connector. For instance, as compared with a conventional multicore connector shown in FIG. 12, the plug pulling-in action can be completed only within the multicore connector. This makes it unnecessary to use the support member 214 provided under the conventional circuit board 212 .
[0025] According to the present invention, there is provided a connector for connecting a plurality of signal lines to a specific electronic apparatus that uses the signal lines. The connector comprises: a first structural unit which includes a board having a plurality of contact pads to be electrically connected to the plurality of signal lines and a substantially hollow cylindrical shaft to rotate, the shaft passing through the board, extending perpendicular to the board and having a projecting part protruding from one side; and a second structural unit which includes a bottom, a plurality of spring contact sections provided on the bottom and a rotatable roller provided on the bottom, each of the spring contact sections facing, at one end, the corresponding one of the contact pads and being connectable, at the other end, to the specific electronic apparatus. The first structural unit can be inserted, in part, into the second structural unit. The roller comes close to the shaft when the shaft and a part of the first structural unit are inserted into the second structural unit. When the first structural unit is inserted, in part, into the second structural unit and the shaft is rotated through a specific angle, the projecting part comes to a position beneath to push the board against the contact sections. The contact pads therefore contact the contact sections, respectively.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0026] [0026]FIG. 1 is a perspective view, from diagonally above, of a plug and a receptacle constituting a multicore connector according to an embodiment of the present invention;
[0027] [0027]FIG. 2 is a perspective view, from diagonally below, of the plug and receptacle constituting the multicore connector according to the embodiment;
[0028] [0028]FIG. 3 is a detailed perspective view, from diagonally above, of the receptacle 2 of the multicore connector according to the embodiment;
[0029] [0029]FIG. 4 shows a state where a plug board is assembled into a plug frame;
[0030] [0030]FIG. 5 shows the bottom surface of the plug board with a plurality of contact pads;
[0031] [0031]FIG. 6 is a perspective view of a contact module;
[0032] [0032]FIG. 7 is a sectional view of the plug and receptacle which are combined completely;
[0033] [0033]FIGS. 8A to 8 C are partly sectional views to help explain the operation of the multicore connector according to the embodiment;
[0034] [0034]FIGS. 9A and 9B are partial sectional views to help explain the operation of the multicore connector according to the embodiment;
[0035] [0035]FIGS. 10A and 10B are diagrams to help explain another embodiment of the present invention;
[0036] [0036]FIG. 11 shows an example of a conventional multicore connector; and
[0037] [0037]FIG. 12 shows another example of a conventional multicore connector.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Referring to the accompanying drawings, embodiments of the present invention will be explained. FIGS. 1 to 10 show multicore connectors according to embodiments of the present invention. In the detailed explanation below and the description of the drawings, like elements are indicated by like reference numerals.
[0039] [0039]FIG. 1 is a perspective view, from diagonally above, of a plug 1 and a receptacle 2 constituting a multicore connector according to the present invention. The terms representing directions, including up, down, longitudinal, and lateral directions, used in this specification are used on the basis of examples shown in the accompanying drawings. Actually, the multicore connectors may be placed diagonally or upside down on the accompanying drawings.
[0040] In FIG. 1, a plug 1 includes a plug frame 3 made of, for example, a metal member, so that at least its surface is conductive, a plug board 5 attached to the lower part of the plug frame 3 with, for example, screws 4 (see FIG. 2), and a cam shaft 6 composed of a substantially cylindrical shaft provided rotatably on a cylindrical section 9 formed in almost the central part of the plug board 5 with respect to the plug frame 3 .
[0041] The cam shaft 6 is provided in the vertical direction with respect to the board 5 . As shown in FIG. 2, the cam shaft 6 passes through a through hole 28 made in the board 5 , with its lower part penetrating the board 5 . In the upper part of the cam shaft 6 , a handle 7 is fixed to the shaft 6 with a screw 8 . The handle 7 makes it easy to insert and remove the plug 1 into and from the receptacle 2 and enables the cam shaft 6 to rotate on its axis to fix the plug 1 to the receptacle 2 .
[0042] A ring-shaped frame cover 10 is fixed to the upper part of the cylindrical section 9 with screws. Although it is desirable that the cam shaft 6 be formed in the central part of the plug frame 3 as shown in FIG. 1, it is not necessarily formed in the center.
[0043] The receptacle 2 includes a receptacle housing 11 made of, for example, a metal member, so that at least its surface is conductive, a plurality of grounding plate springs 25 composed of, for example, elastic metal plates provided along the inner wall of the receptacle housing 11 , and a plurality of metal contact strips or contacts 34 provided in lines in the lower part of the receptacle housing 11 . The contacts 34 may be composed of a contact module formed by arranging a plurality of contact strips beforehand. As shown in FIG. 1, the contact module may be divided into groups, which may be used as contact modules 12 . It is desirable to divide the contact module in this way. The springs 25 , which are conductive, enable an electrical connection between the plug frame 3 and the receptacle housing 11 . The springs 25 are not limited to a plate-like shape bent convexly in the middle as shown in FIG. 1, and may have a coil-like shape.
[0044] In the central part of the receptacle housing 11 , there is provided a substantially cylindrical bushing 13 with an opening 50 into which the lower part of the cam shaft 6 is inserted. While in the embodiment, the bushing 13 is formed separately from the receptacle housing 11 and then mounted on the receptacle housing 11 , the bushing 13 and the receptacle housing 11 may be formed integral.
[0045] [0045]FIG. 2 is a perspective view of the plug 1 and receptacle 2 , both obliquely seen from below. The plug 1 and the receptacle 2 constitute a multi-core connector according to the invention. A pair of rod-like projecting parts 14 protrude from the lower part of the cam shaft 6 . The projecting parts 14 have an almost oval cross section and horizontally extend from the side of the cam shaft 6 . The projecting parts 14 are used in association with a pair of rollers 15 that are provided in the bushing 13 of the receptacle 2 . Thus, they work as a cam for pressing the lower part of the plug 1 against the upper part of the receptacle 2 . The cross section of the projecting parts 14 is not limited to an oval one. It may have any other appropriate shape, as long as the parts 14 can come to positions beneath he rollers 15 to push the rollers 15 upwards when they are rotated in a horizontal plane. For example, each part 14 may have a circular cross section or a rectangular cross section. Moreover, the number of projecting parts is not limited to two.
[0046] As shown in FIG. 2, on the bottom surface 16 of the plug substrate 5 , a plurality of contact pads 17 are formed. In the lower part of the plug frame 3 , to protect the contact pads 17 , a protective cover 18 with a plurality of circular or almost rectangular openings 29 is provided in the lower part of the plug board 5 and fixed to the plug frame 3 with screws 4 . The lower part of the cam shaft 17 passes through the circular opening. In the rectangular openings, the corresponding contact pads 17 can be exposed.
[0047] In the bottom 20 of the receptacle housing 11 , a plurality of almost rectangular holes 21 are made. Contact modules 12 , which will be explained by reference to FIG. 6, are pressed into the rectangular holes 21 from above. The way of mounting the contact modules 12 in the receptacle housing 11 is not limited to pressing the modules into the holes. In the lower part of the contact modules 12 , a plurality of connecting terminals 22 are so formed that they project downward. The connecting terminals 22 are for making an electrical connection with the electric wiring (not shown) or the circuit board (not shown) of such an electronic apparatus as a medical instrument, semiconductor testing equipment, a computer, and communication equipment.
[0048] Furthermore, to make it possible to mount multicore connectors of the present invention in lines on the printed wiring board (not shown) of an electronic apparatus, for example, an alignment pin 23 and/or a mounting hole 24 may be provided on the bottom 20 of the receptacle housing 11 .
[0049] [0049]FIG. 3 is a detailed perspective view, looked diagonally down from above, of the receptacle 2 of the multicore connector according to the present invention. Shown at left are four contact modules 12 pressed into holes 21 made in the bottom of the receptacle housing 11 . The way of mounting the modules 12 in the receptacle housing is not limited to pressing the modules into the holes, and may be, for example, fixing the modules with screws. Shown at right are four contact modules 12 before being pressed into the holes. The number of contact modules 12 used in the connector can be determined suitably according to the number of contacts.
[0050] In FIG. 3, a projecting part or a shoulder 26 is formed on the side of each substantially rectangular hole 21 in the bottom 20 of the receptacle housing 11 . The projecting part or shoulder 26 is combined with a projecting brim 27 formed on the side of the contact module 12 , which determines the longitudinal position of the pressed-into contact module 12 with respect to the receptacle housing 11 .
[0051] [0051]FIG. 4 shows a state where the plug board 5 with the through hole 28 through which the lower part of the cam shaft 6 is passed is assembled into the plug frame 3 on which the cam shaft 6 has been installed. A grounding conductive pattern 30 is formed on the periphery of the top surface 29 of the plug board 5 . The conductive pattern 30 contacts the shoulder 31 of the plug frame 3 which can be grounded as shown in FIG. 7, thereby grounding the plug board 5 reliably.
[0052] The plug board 5 mounted on the plug frame 3 can be formed by, for example, using either a circuit board with the top-surface wiring and the bottom-surface wiring connected to each other in specified parts or a multilayer wiring circuit board. On the top surface 29 of the plug board, a plurality of electrical connecting parts (not shown) corresponding to the contact pads 17 are formed on the bottom surface. The individual core lines of the multicore cable, such as signal lines from the specified electronic apparatuses connected to a multicore connector of the present invention, are connected to the electrically connecting sections. The present invention is not restricted to the method of making an electrical connection. For instance, an electrical connection may be made by soldering the connections.
[0053] [0053]FIG. 5 shows the bottom surface 16 of the plug board 5 with a plurality of contact pads 17 . The contact pads 17 are connected electrically to the corresponding electrically connecting parts on the top surface of the plug board via the internal wiring (not shown) of the plug board. The contact pads 17 may be formed by partly gold-plating the wiring section of the plug board 5 to assure a good contact state. Alternatively, the contact pads 17 may be made by using metal contact strips provided suitably on the plug board 5 . In the plug board 5 , a through hole 28 is made which enables the lower part of the cam shaft 6 to pass through.
[0054] [0054]FIG. 6 is a perspective view of a contact module usable in the present invention. A plurality of grooves 33 passing through in an up and down direction are made in a frame section 32 made of an insulating material. In each groove 33 , a spring metal contact strip 34 is inserted, positioned by a suitable method, and fixed there. When the plug 1 is combined with the receptacle 2 completely, the top 35 of the metal contact strip 34 comes into contact with the contact pad 17 on the bottom surface 16 of the plug board 5 . The lower part of the metal contact strip 34 forms a connector terminal 22 . The connector terminal 22 is connected to the circuit board of an electronic apparatus with a multicore connector, or to a multicore cable.
[0055] [0055]FIG. 7 is a sectional view of the plug 1 and receptacle 2 which are combined together completely. A ringed bearing plate 37 on which force acting in the direction of the axis of the cam shaft 6 during engagement is exerted is provided on a step part 36 looking to the upper part of the inner wall of the cylindrical section 9 of the plug 1 . With the plug 1 inserted in the receptacle 2 , the bearing plate 37 facilitates the rotation of the cam shaft 6 . The bearing plate 37 is so provided that it faces, in a up and down direction, a ringed projecting part 38 formed on the side of the cam shaft 6 , thereby limiting the downward movement of the cam shaft 6 .
[0056] Inside the sidewall of the substantially cylindrical bushing 13 provided in the central part of the receptacle housing 11 , a pair of roller axes 44 is provided in such a manner the axes project horizontally with respect to the axis of the cam shaft 6 . A cylindrical roller 15 provided with a clearance so as to be close to the cylindrical side of the cam shaft 6 is mounted rotatably on the roller axes 44 .
[0057] Further on the side of the cam shaft 6 , a rod-like projection 39 projecting laterally in the lower part of the frame cover 9 is preferably formed. When the plug 1 and the receptacle 2 are combined completely, the rod-like projection 39 fits in a specific position of the concave portion of the lower part of the frame cover 9 , thereby limiting the rotation of the cam shaft 6 .
[0058] Furthermore, to clarify the on and off positions of the cam shaft 6 , a pair of plate-like return springs 41 are provided on the side of the cam shaft 6 . When the combination of the projecting parts 14 of the cam shaft 6 and the rollers 15 is unlocked to remove the plug 1 , the cam shaft 6 is actuated so that it may rotate back to the initial position.
[0059] Furthermore, as shown in FIG. 7, the lower part 42 of the sidewall of the plug frame 3 can come into electrical contact with the top surface of the bottom of the receptacle housing 11 via the plate springs 25 . Therefore, after the plug 1 and the receptacle are combined, a reliable electrical continuity for grounding the plug 1 and receptacle 2 can be obtained.
[0060] The operation of a multicore connector according to the present invention will be explained briefly by reference to FIGS. 8A to 8 C and FIGS. 9A and 9B. FIG. 8A is a sectional view of the plug 1 in the course of being inserted into the receptacle 2 . FIG. 8B is a sectional view of the plug 1 almost inserted in the receptacle 2 . FIG. 8C is a sectional view of the completed combination after the cam shaft 6 is rotated.
[0061] [0061]FIG. 9A is a perspective view, from diagonally below, of the plug 1 almost inserted into the receptacle 2 before the rotation of the cam shaft, which corresponds to FIG. 8B. In FIG. 9A, the circuit board 46 of FIGS. 8A to 8 C is not shown. FIG. 9B is a perspective view of the completed combination after the cam shaft 6 is rotated, which corresponds to FIG. 8C. In FIGS. 8A to 8 C, the connecting terminals 22 actually used are connected to the wiring section (not shown) of the circuit board 46 of the electric apparatus with, for example, solder. The parts indicated by numeral 47 in FIGS. 8A to 8 C are a part of the bottom 20 of the receptacle housing 11 .
[0062] The combination in the connector is carried out as follows: the plug 1 is inserted and pressed into the receptacle 2 (FIG. 8A) until the lower end 43 of the cam shaft 6 has reached a position deeper than the rollers 15 (FIG. 8B), then the shaft 6 is rotated, for example, clockwise about 100 degrees (FIG. 8C).
[0063] Rotating the cam shaft 6 clockwise about 100 degrees with the handle 7 causes the pair of projecting parts 14 (see FIG. 8C) provided in the lower part of the cam shaft 6 to get into under the rollers 15 incorporated into the bushing 13 of the receptacle 2 , pushing up the lower part of the rotating surface of the rollers 15 . The rotation of the rollers 15 makes it easy for the projecting parts 14 to move to positions beneath the rollers 15 . Since the roller axes 44 are fixed, the projecting parts 14 are actually actuated downward by the rollers 15 . This enables the receptacle 2 to be pulled downwards into the body of the plug 1 .
[0064] This makes it possible to bring the upper parts 35 of the spring contacts in the contact module 12 incorporated in the bottom 20 of the receptacle 2 into reliable electrical contact with the contact pads 17 provided on the bottom surface 16 of the board 5 of the plug 1 .
[0065] At the same time, the grounding plate springs 25 mounted on the receptacle 2 are pressed by the lower part 42 of the peripheral part of the plug frame 3 . As a result, the lower part 42 of the sidewall of the plug frame 3 comes into electrical contact with the top surface of the bottom of the receptacle housing 11 via the springs 25 , thereby making a reliable electrical connection between the plug frame 3 and the receptacle housing 11 . As a result, grounding one of the plug 1 and the housing of the receptacle 2 by a suitable method makes it possible to ground the other at the same time. In addition, it is possible to ground the plug board 5 to which the conductive pattern 30 on the periphery contacting the shoulder 31 of the plug frame 3 contacts.
[0066] To remove the plug 1 from the receptacle 2 , the cam shaft 6 is rotated counterclockwise about 100 degrees with the handle 7 , which is the reversal of insertion. Rotating the cam shaft 6 of the plug 1 counterclockwise causes the projecting parts 14 of the cam shaft 6 to come off the rollers 15 of the receptacle 2 , which enables the plug 1 to move upward. Therefore, pulling up the plug 1 enables the plug 1 to be unplugged from the receptacle 2 . At this time, the contact top 35 of the contact module 12 and the grounding plate springs 25 are separated from the corresponding contact parts, which breaks the individual electrical connections.
[0067] [0067]FIGS. 10A and 10B show another embodiment of the present invention. FIGS. 10A and 10B are a plan view and a sectional view of the embodiment. A multicore connector of FIG. 10 further comprises a lid member 49 with a multicore cable insert section 48 in addition to the multicore connector of FIG. 1. The number of contact modules 12 is 6 , smaller than in FIGS. 1 to 9 .
[0068] According to the present invention, the rotational torque of the cam shaft can be made smaller than the conventional multicore connectors. In addition, the signal lines in the contact section are made shorter, thereby improving the signal transmission characteristic and preventing interference, such as crosstalk, which makes it possible to provide a multicore connector suitable for the transmission of high-speed signals.
[0069] Furthermore, it is possible to provide a multicore connector which reduces the number of parts to be mounted in an electronic apparatus, makes the parts mounting area smaller by downsizing the whole connector, and enables the plug housing and receptacle housing to be completely grounded.
[0070] The present invention is not limited to the above embodiments and may be practiced or embodied in still other ways without departing from the spirit or essential character thereof. | 4y
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BACKGROUND OF THE INVENTION
Rotary joints are employed to introduce a heat exchanging fluid medium into a heat exchanger drum, or remove the medium from the drum. Such joints are widely used in the paper and fabric industries for drying a web rapidly moving over the drum surface, and the most common heat exchanging medium utilized is steam. If the drum is used for cooling purposes the rotary joint may convey water.
Typical rotary joints include a housing rotatably mounted upon a nipple concentric to the drum axis of rotation and rotating therewith. Annular seals interposed between the joint housing and the nipple produce a fluid-tight sealing, and as the seals are mounted within the rotary joint housing the seals are exposed to the internal pressure within.
The pressure within the rotary joint tends to bias the seals against the sealing areas and such forces cause the seal pressures to be excessive accelerating seal wear and increasing the seal friction which elevates the seal temperature further increasing wear.
Several approaches have been utilized with rotary joint construction to minimize excessive seal wear due to seal pressure produced by the pressurized medium being conveyed. Internal self-compensating joint constructions use designs wherein the seal faces exposed to the internal pressures substantially counteract each other to reduce seal wear. Also, external self-compensating apparatus is used with rotary joints to impose an axial force on the joint housing itself to reduce seal wear and typical examples of this type of external compensation are shown in U.S. Pat. Nos. 1,896,062; 2,700,558; 3,098,665 and 3,874,707.
In known externally compensated rotary joint systems an expansible chamber motor is axially fixed with respect to the rotary joint housing which is axially displaceable, and the motor is concentrically located with respect to the axis of rotation of the drum nipple and rotary joint housing. The interior of the joint housing directly communicates with the interior of the expansible chamber motor which includes a piston, or piston structure, engaging the housing. As the compensating force exerted on the housing by the expansible chamber motor equals the pressure within the housing times the piston area of the motor the degree of compensation achieved is always proportional to the pressure within the rotary joint housing, and the degree of compensation achieved is a fixed percentage of the housing pressure as determined by the area of the piston within the compensating expansible chamber motor. Thus, due to the "fixed" ratio of compensation it is not possible to vary the compensation once the equipment is installed and the degree of compensation can only be varied by making major mechanical changes, such as by utilizing different sizes of pistons.
Expansible chamber motors of the external types used for compensating rotary joints either use pistons having O-rings for sealing purposes, or the pistons are of a metal diaphragm type. Both piston arrangements create problems. Pistons utilizing O-rings seals limit the use of the compensator with respect to high steam pressures due to the temperature limitations of the material of the O-ring as O-ring materials quickly deteriorate a elevated steam temperatures. Diaphragm type piston structures have limited axial travel due to the inherent nature of construction of the metal diaphragm, and as bearing wear occurs and increased piston movement is required for compensation adjustments must be made in view of the limitations of metal diaphragm pistons.
The concepts of the invention overcome the aforedescribed limitations of known external rotary joint compensators.
It is an object of the invention to provide an external load bearing compensator for rotary joints wherein previous problems encountered with the piston structure of prior compensating expansible chamber motors are eliminated.
Another object of the invention is to provide an external self-compensator for rotary joints utilizing an expansible chamber motor wherein the pressurized medium within the expansible chamber motor is a separate medium from that within the rotary joint, and the expansible pressurized medium is not at an elevated temperature and is non-corrosive.
An additional object of the invention is to provide an external self-compensator for rotary joints wherein &he degree of compensation can be easily and accurately varied for each rotary joint without requiring structural modifications.
Yet a further object of the invention is to provide an external self-compensator for rotary joints wherein high pressure steam is within the joint housing and compressed air is employed to produce the compensating forces upon the rotary joint.
In the practice of the invention the basic structural arrangements previously utilized with conventional externally compensated joints are employed. For instance, the rotary joint includes axially displaceable bearings to seal the housing interior with respect to the rotary drum mounted nipple upon which the housing is mounted. The housing is mounted for limited axial displacement. An expansible chamber motor includes piston structure coaxial with the joint housing axis of rotation and is axially fixed and engages the housing whereby displacement of the piston axially displaces the rotary joint housing.
However, rather than the chamber of the expansible chamber motor directly communicating with the interior of the rotary joint housing as is the usual practice, the expansible chamber motor receives compressed air having a controlled pressure. The compressed air received by the expansible chamber motor is controlled by sensing and regulating means which senses the pressure within the rotary joint by sensing the pressure within the header supplying steam or other pressuring medium to the rotary joint. Accordingly, it will be appreciated that the pressurized medium being supplied to the rotary joint differs from that being supplied to the compensating expansible chamber motor.
A transmitter is used to sense the pressure within the steam header, or within the rotary joint housing. This transmitter controls multiplying and amplification apparatus which regulates the pressure of compressed air supplied to the compensating expansible chamber motor. The multiplying and amplifying apparatus may be very easily regulated to accurately control the pressure within the compensating expansible chamber motor, and in this manner the compensation of each rotary joint may be "customized", i.e. the axial force imposed upon each rotary joint may be very accurately regulated to compensate for the individual characteristics of that particular rotary joint.
As the pressurized medium being supplied to the compensating expansible chamber motor is clean, cool compressed air the expansible chamber piston may include an elastomeric diaphragm to provide one hundred percent sealing between the piston and the cylinder wall of the expansible chamber motor, and the diaphragm may be so constructed as to provide sufficient axial piston movement without necessitating adjustment throughout the entire compensating range as the seals wear. The use of compressed air eliminates the previously experienced corrosion and deterioration of seal material, and piston structure utilizing a high temperature elastomer and fabric will provide effective sealing for a long period of time while permitting extensive piston movement during compensation.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects of the invention and the advantages thereof will be appreciated from the following description and accompanying drawings wherein:
FIG. 1 is a plan view of a typical rotary joint and external compensator installation in accord with the invention, a portion of the rotary joint housing being broken away for purpose of illustration,
FIG. 2 is an enlarged, diametrical, elevational sectional view of the compensating expansible chamber motor of the invention,
FIG. 3 is an end view of FIG. 1 as taken from the left thereof, and
FIG. 4 is a schematic diagram illustrating the basic components of the apparatus used to practice the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A typical arrangement of a rotary joint having an external compensator is shown in FIG. 1, and this arrangement is very similar to that shown in the assignees U.S. Pat. No. 3,874,707.
The rotary joint is generally indicated at 10 and includes a housing 12 having a conduit inlet port 14. The housing includes an inner wall plate 16 attached to the housing by bolts, and at its other axial end the housing is closed by the outer wall plate 18 also attached to the housing by bolts. The housing wall 18 also includes a syphon housing 20 whereby syphon structure, not shown, may communicate with the housing 12.
Internally, the housing 12 is mounted upon the rotating tubular nipple 22 which is coaxially connected to the rotating heat exchanger drum for rotation therewith, not shown, receiving the pressurized medium introduced into the rotary joint 10 through the inlet port 14. Sealing structure is located within the housing 10 interposed between the nipple 22 and the housing and such seals are of an annular configuration including collars 24 and 26, at least one of which may be axially displaceable on the nipple, and an annular sealing ring 28 is located between collar 24 and inner wall 16 while the annular seal 30 is located between collar 26 and outer wall 18. A compression spring 32 biases the collars 24 and 26 into engagement with the associated sealing ring and sealing surfaces exist between the collars and their associated sealing rings, and between the sealing rings and their associated housing end wall plates.
As will be appreciated, as the housing sealing structure is directly exposed to the pressurized medium, usually steam, within the housing 10 significant internal pressures exist within the housing that are also imposed upon the sealing structure causing the engaging surfaces of the seals and collars to firmly engage.
The rotary joint housing 10 is supported upon a pair of radially extending arms 34 which have holes at their outer ends for slidable association with the support rods 36 which are attached to fixed support structure adjacent the rotary drum, not shown. The support rods 36 are threaded at their outer ends for providing support for the compensating external expansible chamber device or motor 38 as later described. The aforedescribed rotary joint structure is known and fully described in the assignees U.S. Pat. No. 3,874,707.
The construction of the compensating expansible chamber motor 38 is best appreciated from FIG. 2. The compensator comprises an expansible chamber motor 38 having a housing defined by an outer cover plate 40, an annular spacer plate 42, and a body plate 44. These three plates are maintained in assembled relationship by eight threaded bolts 46 having heads bearing against the cover plate 40, and threads which thread into holes defined in the body plate 44. As will be appreciated from FIG. 2, plates 40 and 42 are each provided with an internal cylindrical surface of equal diameters to define the cylindrical chamber 48 of the compensator motor.
The plate 44 includes a pair of radially extending arms 50 having threaded nuts 52 affixed thereto and by the use of lock nuts 54, the axial position of the compensator motor 38 to the support rods 36, and to the joint housing 12, can be accurately determined and maintained. It is to be appreciated that the rotary joint arms 34 are supported upon the support rods 36 for axial displacement of the housing 12 relative thereto, while the compensator 38 is axially fixed with respect to the support rods and the joint housing.
The compensator 38 includes a piston 56 axially extending through the center of the body plate 44 through a bushing 58, and internally, a circular rigid head 60 is mounted upon the piston by bolt 62. A flexible diaphragm 64 formed of a high temperature resistent elastomer and fabric, such as commercially known under the trademark Viton, is mounted upon the piston head by a lip retainer 66 held in position by the bolt 62, and at its outer region the flexible diaphragm is received between the joining surfaces of the cover plate 40 and the spacer plate 42 so that the outer circumference of the diaphragm is sealed with respect to the compensator housing. A compression spring 68 circumscribing to the boss 70 formed on the cover plate bears against the lip retainer 66 to bias the piston head and piston to the right, FIG. 2., into engagement with the anvil 72 defined on the rotary joint syphon housing 20.
An inlet port 74, FIG. 2, is formed in the cover plate and is tapped with a 1/2" pipe thread for receiving the air supply tube 76, FIG. 1.
With reference to FIG. 4, the circuitry and operation of the external rotary joint bearing compensator of the invention will be explained.
The pressurized medium, such as high temperature steam, supplied to the rotary joint 10 through the port 14 is supplied from a header 78. A transmitter 80 is in communication with the header 78 sensing the pressure within the header. The transmitter 80 produces a signal proportional to the pressure within the header and this signal is transmitted to the multiplier 82. The multiplier 82 in turn produces a signal fed to the amplifying relay 84 which is in the form of a compressed air regulator receiving compressed air through supply conduit 86 The pressure of the compressed air from the regulator 84 is determined by the signal received from the multiplier 82, and the regulated compressed air is supplied through conduit 88 to the compensator expansible chamber motor 38 through tube 76, and accordingly, the pressure within the compensator chamber 48 will be determined by the regulator 84 and the axial force imposed on the rotary joint housing 12 by the piston 56 is accurately determined by the value of the compressed air within the compensator 38. In FIG. 4 a plurality of compensators 38 are shown as being controlled in parallel by the compressed air from regulator 84, and it will be appreciated that a plurality of rotary joints 10 may be controlled by a single regulator or each rotary joint may have its own regulator.
It will be appreciated from the above description that the compressed fluid medium used to control the compensator expansible chamber motor 38 is separate and distinct from the pressurized fluid medium within the header 78 and joint 10. As the preferred control pressurized medium is compressed air, and as compressed air will be relatively cool, no significant deterioration of the flexible diaphragm 64 will occur due to the compensator medium, and as will be appreciated from FIG. 2, the "fold" of the diaphragm may be significantly long to permit sufficient piston travel to accommodate the entire range of movement required for compensation as the seals wear without necessitating adjustment of the compensator upon the support rods 36.
In the disclosed control circuitry shown in FIG. 4 the transmitter 80 and multiplier 82 are air controlled, and compressed air is supplied to the transmitter and multiplier through the compressed air conduit 90. The transmitter 80 may be a FOXBORO pressure transmitter and the multiplier may also be a FOXBORO pneumatic computer multiplier while the amplifying relay regulator may be a standard model manufactured by Moore Products. As the transmitter 80 receives a steam pressure signal from the header, the transmitter produces an air pressure signal corresponding to the steam pressure and the pneumatic computer multiplier 82 produces an air pressure signal proportional to the amount of compensation force needed. This air pressure signal from the multiplier 82 is then supplied to the amplifying relay regulator 84 where it is boosted to provide the necessary pressure for the compensator 38. While, in the enclosed embodiment, the sensing and control of the air pressure supplied to the compensator utilizes air controlled devices, it will be appreciated that electronically operated transmitter and multiplier devices may be used and the amplifying relay would constitute an electrically controlled compressed air regulator.
The computer multiplier 82, or transmitter 80, or both, include readily adjustable controls so that the air pressure supplied to or through the conduit 88 may be very accurately regulated merely by adjusting such controls. Thus, the practice of the invention permits the amount of load bearing compensation of the rotary joints to be very accurately regulated to accommodate the particular conditions present.
To obtain maximum seal ring life the force exerted on the seal rings 28 and 30 and the temperature of the seal rings must be maintained at a minimum. However, the axial sealing force on the seal rings must be sufficient to produce effective sealing. Excessive force on the seal rings causes faster than normal wear and high temperature causes rapid deterioration. The axial force on the seal rings is determined by the pressure of the medium within the rotary joint, and the temperature of the seal rings is determined by both the temperature of the medium within the joint and the heat generated by contact between the seal rings and the associated collars and plates. While the temperature of the medium within the joint cannot be regulated, the degree of seal friction can be controlled by the compensation provided by the practice of the invention, and by regulating the output signals of the transmitter and multiplier the degree of axial compensating force imposed on a rotary joint may be very accurately regulated and varied if desired. Such "customized" adjustment has not been previously available with either external or internal compensated rotary joints.
By utilizing compressed air as a control pressurized medium for the compensator expansible chamber motor problems previously encountered due to condensate within the expansible chamber motor compensating motor are eliminated, the seal structure within the compensator is not exposed to high temperatures, and sufficient axial piston movement can be achieved with 100% effective sealing between the piston and chamber by the use of the diaphragm is present as compared to the limited metal diaphragm movement of prior art devices, and with the practice of the invention the ability of an exteriorly compensated rotary joint to handle nonconcentric installations is maintained while simultaneously providing a degree of control of compensation not heretofore achievable.
It is appreciated that various modifications to the inventive concepts may be apparent to those skilled in the art without departing from the spirit and scope of the invention. | 4y
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a discharging roller which discharges a recording medium on which data recording has been performed, a method of manufacturing the discharging roller, and a recording apparatus incorporating the discharging roller.
[0002] An ink jet printer that is one of recording apparatuses is generally constituted so as to supply a sheet stored in a sheet feeding tray to a sheet feeding roller, transport the supplied sheet to a recording section while holding between a sheet feeding roller pair, cause a recording head to eject an ink droplet onto the sheet to perform recording, and discharge the sheet to a sheet ejection tray while holding between a discharging roller pair. Since recording on the sheet is thus performed between the discharging roller pair and the feeding roller pair, a rotary speed of the discharging roller is set slight higher than that of the feeding roller to tense the sheet between the discharging roller and the feeding roller, whereby the sheet becomes flat to improve recording accuracy.
[0003] [0003]FIG. 13A is a perspective view showing a first related-art discharging roller as disclosed in Japanese Patent Publication No. 10-129910A. This discharging roller 1 is formed so that a shaft portion 2 made of plastics becomes longer than at least recordable maximum sheet width, and plural roller portions 3 made of rubber are fitted in the shaft portion 2 with constant intervals. As shown in FIG. 13B, such the discharging roller 1 is formed so that a circular portion of a sectional shape of the shaft portion 2 has diameter Ds and a cross-shaped portion thereof has thickness t, and the diameter Ds must be smaller than diameter Dr of the roller portion 3 . Specifically, the diameter Ds is 6.80 mm and the diameter Dr is 11.26 mm. Therefore, the proportion of the outer diameter of the shaft portion to the outer diameter of the roller portion is 60.4%.
[0004] [0004]FIG. 14 is a section view showing a second related-art discharging roller as disclosed in Japanese Patent Publication No. 10-291874A. This discharging roller comprises a cylindrical body 30 and shaft portions 20 extended from both longitudinal ends of the cylindrical body 30 and having a smaller diameter than that of the cylindrical body 30 . The cylindrical body 30 and the shaft portions 20 are made of plastics. The shaft portions respectively have a hollowed portion which are formed by a core 75 or a resin injection port 77 . One of the hollowed portion is communicated with a cavity 31 formed inside the cylindrical body 30 .
[0005] In case that the first related-art discharging roller 1 is formed of synthetic resin, it is necessary to provide thickness deletion (thick removal) so as not to make the discharging roller thick in order to prevent deformation or sink of the shaft caused by internal stress in molding. Therefore, only rigidity of a certain level can be secured. Further, since the rotation speed of the discharging roller 1 is set so as to become higher than that of the feeding roller, power pulled onto the feeding roller side acts on the discharging roller. Therefore, there is anxiety that deformation such as a flexure is produced in the discharging roller 1 .
[0006] Since the deformation of the discharge roll 1 such as the flexure is restored when a rear end of the sheet is released from the feeding roller pair, there are instances where a so-called flip phenomenon of sheet is produced at this time. In case that an ink jet printer can record data on the whole surface of sheet or the nearly whole surface thereof, recording is continued to the rear end of the sheet even after the rear end of the sheet is released from the feeding roller pair. Therefore, in case that the above flip phenomenon is produced, a bad influence is exerted on recording accuracy.
[0007] Regarding the second related-art discharging roller shown in FIG. 14, the sink 34 tends to be produced when auxiliary cavities 40 are filled with the injected resin. This causes deformation or the rigidity reduction of the discharging roller surface. Moreover, if flashes are formed on an outer circumferential surface of the shaft portions 20 and the cylindrical body 30 at the plastic molding process performed by the gas injection method, for example, there is anxiety that the flashes cause sliding load increase of a bearing portion or deterioration of sheet feeding accuracy.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the invention to provide a discharging roller which can prevent the flip phenomenon at the discharging time of a recording medium, a method of manufacturing such a discharging roller, and a recording apparatus incorporating such a discharging roller.
[0009] In order to achieve the above object, according to the invention, there is provided a discharging roller which discharges a recording medium from a recording apparatus, comprising a hollowed shaft portion comprised of synthetic resin.
[0010] Preferably, the synthetic resin is comprised of an additive to enhance stiffness of the shaft portion.
[0011] Preferably, the discharging roller further comprises a roller portion formed on an outer periphery of the shaft portion. Here, a proportion of an outer diameter of the shaft portion with respect to an outer diameter of the roller portion is not less than 60.5%.
[0012] According to the invention, there is also provided a die for molding a discharging roller which discharges a recording medium from a recording apparatus, the die comprising;
[0013] a first die, formed with a first recess extending in an axial direction of a shaft portion of the discharging roller; and
[0014] a second die, formed with a second recess extending in the axial direction, the second die combined with the first die such that the first recess and the second recess face to form a continuous cavity for molding a bore portion of the shaft portion.
[0015] Preferably, the first recess is formed on a bottom face of a recessed portion of the first die, and the second recess is formed on a convex portion of the second die which is fitted into the recessed portion.
[0016] Here, it is preferable that an entrance corner of the recessed portion and a corner portion opposing to the entrance corner are tapered.
[0017] Preferably, at least one of the first die and the second die is formed with a fluid passage through which a fluid for cooling the cavity flows.
[0018] According to the invention, there is also provided a method of manufacturing a discharging roller which discharges a recording medium from a recording apparatus, the method comprising steps of:
[0019] providing a first die, formed with a first recess extending in an axial direction of a shaft portion of the discharging roller;
[0020] providing a second die, formed with a second recess extending in the axial direction;
[0021] combining the first die and the second die such that the first recess and the second recess face to form a continuous cavity; and
[0022] injecting synthetic resin into the cavity to mold a bore portion of the shaft portion.
[0023] Preferably, the manufacturing method further comprises a step of regulating temperature of the cavity such an extent that the injected synthetic resin is solidified in a state where it is adhered onto an inner face of the cavity.
[0024] Preferably, the manufacturing method further comprises a step of injecting gas into the cavity to form a void in the injected synthetic resin in the cavity.
[0025] Since the discharging roller molded by the above die or manufactured by the above method has enhanced flexural rigidity, even if force in the opposite direction to the discharging direction is applied onto the discharging roller, the deformation of the discharging roller such as a flexure can be suppressed. Accordingly, the flip phenomenon of the recording medium due to the discharging roller can be prevented, and particularly recording accuracy in recording on the whole surface can be improved.
[0026] According to the invention, there is also provided a recording apparatus comprising the above discharging roller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein:
[0028] [0028]FIG. 1 is a perspective view of the whole of the exterior structure of an ink jet printer, in a state where a sheet ejection port is closed;
[0029] [0029]FIG. 2 is a perspective view of the ink jet printer, in a state where the sheet ejection port is opened;
[0030] [0030]FIG. 3 is a perspective view of the whole of the internal structure of the ink jet printer in a state where an upper housing is removed;
[0031] [0031]FIG. 4 is a sectional side view of an essential portion of the ink jet printer;
[0032] [0032]FIG. 5A is a perspective view showing a discharging roller in the ink jet printer;
[0033] [0033]FIG. 5B is a section view of the discharging roller;
[0034] [0034]FIG. 6 is a perspective view showing an upper die and a lower die used in molding of the discharging roller, according to a first embodiment of the invention;
[0035] [0035]FIG. 7A is a plan view of the upper die and the lower die;
[0036] [0036]FIG. 7B is a section view taken along the line A-A in FIG. 7A;
[0037] [0037]FIGS. 8A and 8B are perspective views showing the lower die;
[0038] [0038]FIG. 9 is a side view showing a fitting part of the upper die and the lower die;
[0039] [0039]FIG. 10A is a plan view of the lower die, showing a fluid passage for cooling liquid;
[0040] [0040]FIG. 10B is a section view taken along the line B-B in FIG. 10A;
[0041] [0041]FIG. 11 is a section view of an injection molding machine incorporating the dies;
[0042] [0042]FIG. 12 is a section view showing a die used in molding of the discharging roller with a gas injection method, according to a second embodiment of the invention;
[0043] [0043]FIG. 13A is a perspective view showing a first related-art discharging roller;
[0044] [0044]FIG. 13B is an enlarged perspective view of the first related-art discharging roller, and
[0045] [0045]FIG. 14 is a section view showing a die used in molding of a second related-art discharging roller with a gas injection method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] Preferred embodiments of the invention will be described below in detail with reference to accompanying drawings.
[0047] As shown in FIGS. 1 and 2, an ink jet printer 100 which is one of recording apparatuses comprises an upper housing 101 and a lower housing 102 . The upper housing 101 and the lower housing 102 are engaged with each other by snap fitting.
[0048] On the rear side of the upper housing 101 , a sheet feeding port 103 is formed. In this sheet feeding port 103 , a sheet feeding tray 110 on which sheets to be supplied are stacked is attached. The sheet feeding tray 110 is attached so as to protrude to the diagonally upper backside, and holds the sheets in a slanting state. On the front side of the upper housing 101 , a sheet ejection port 104 is formed. On the front sides of the upper housing 101 and lower housing 102 , a stacker 120 on which the ejected sheets are stacked is provided.
[0049] The stacker 120 is attached to the front sides of the upper housing 101 and lower housing 102 pivotably about a rotary shaft located at its lower portion. When the stacker 120 is not used, it is pivoted upward to close the sheet ejection port 104 . When it is used, it is pivoted downward to open the sheet ejection port 104 , and stops at a position where it protrudes from the lower housing 102 to the diagonally upper front side to receive the sheet in the slanting state. This stacker 120 has two-stage structure comprising a first stacker member 121 and a second stacker member 122 which is slidably attached to the first stacker member 121 at a distal end portion thereof. The second stacker member 122 is housed in the first stacker member 121 when it is not used, and pulled out from the first stacker member 121 when it is used.
[0050] A window 105 is formed from the upper portion of the upper housing 101 to the front surface thereof. This window 105 is covered with a transparent or semitransparent openable cover 106 . By opening this cover 106 , an exchanging work of ink cartridge and a maintenance work of the internal mechanism can be readily performed. Further, a push button type of power switch 131 and operational switches 132 , 133 are provided on the left backside of the upper housing 101 .
[0051] As shown in FIG. 3, in the lower housing 102 , a control board 130 constituting a printer controller is placed vertically, and a recording section 140 constituting a print engine, a sheet feeder 150 and a transporter 160 shown in FIG. 4 are installed.
[0052] A control element and a memory element such as CPU, ROM, RAM, ASIC (they are not shown), and other various circuit elements are mounted on the control board 130 . At the upper end of the control board 130 , light emitting diodes 133 and 134 are located protrusively, which emit lights respectively when the power switch 131 or the operational switches 132 , 133 are pushed on, whereby a user can confirm switch-ON.
[0053] The recording section 140 comprises a carriage 141 , a recording head 142 , a carriage motor 143 , a timing belt 144 , and a suction pump 145 . On a sheet transported by the transporter 160 , data is recorded by the recording head 142 mounted on the carriage 141 scanned by the carriage motor 143 and the timing belt 144 . From ink cartridges 146 of four colors, for example, yellow, magenta, cyan, and black, housed in the carriage 141 , each color ink is supplied to the recording head 142 so that full color printing can be performed.
[0054] The feeder 150 comprises the sheet feeding tray 110 , a sheet feeding guide 111 , a sheet feeding roller 151 , a hopper 152 , and a separation pad 153 . Sheets P stacked on the sheet feeding tray 110 and aligned by the sheet feeding guide 111 are pushed against the sheet feeding roller 151 with the separation pad 153 by rising of the hopper 152 with rotation of the sheet feeding roller 151 , separated one by one from the uppermost sheet P, and transported to the transporter 160 .
[0055] The transporter 160 comprises a feeding roller 161 , a driven roller 162 , a discharging roller 163 , a serrated roller 164 , a sheet feeding motor 165 , and the stacker 120 . The sheet P supplied from the feeder 150 is transported to the recording section 140 while being held between the feeding roller 161 driven by the sheet feeding motor 165 and the driven roller 162 , and further transported to the ejected sheet stacker 120 while being held between the discharging roller 163 driven by the sheet feeding motor 165 and the serrated roller 164 .
[0056] As shown in FIGS. 5A and 5B, the discharging roller 163 is formed so that a shaft portion 163 a made of plastics elongates longer than at least recordable maximum sheet width and has a hollowed portion 163 c extending axially. Further, plural roller portions 163 b made of elastomer such as rubber are joined to the shaft portion 163 a at a constant interval. The shaft portion 163 a of the discharging roller 163 is molded by an injection method or a gas injection method which generates a void that can prevent a sink and a warp by suppressing internal stress produced when molding is performed using a die. The roller portion 163 b of the discharging roller 163 is molded on the shaft portion 163 a by an injection method.
[0057] Since the shaft portion 163 a of the discharging roller 163 is thus formed in the hollowed shape having larger sectional area than sectional area of the related-art discharging roller 1 , flexural rigidity of this discharging roller 163 can be enhanced more than that of the related-art discharging roller 1 . Specifically, the diameter Dr1 (see FIG. 5B) is 11.26 mm and the diameter Ds1 is 8.25 mm. Therefore, the proportion of the outer diameter of the shaft portion to the outer diameter of the roller portion is 73.3%. Consequently, when the sheet is tensed between the discharging roller 163 and the feeding roller 161 , deformation of the discharging roller 163 such as a flexure can be suppressed. Therefore, a flip phenomenon caused by the discharging roller 163 can be avoided, and particularly recording accuracy in recording on a whole surface can be improved.
[0058] As a material of the shaft portion 163 a of the discharging roller 163 , thermoplastic resin is used, for example, ABS (copolymer of acrylonitrile, butadiene and styrene), PS (polystrene), POM (polyacetal), modified PPE (polyphenylene ether), PC (polycarbonate), PBT (polybutylene terephthalate), and alloy system. Further, in order to heighten more the flexural rigidity, an additive such as GF (glass fiber), GR (glass beads), carbon, nylon, or potassium titanate is added. The amount of this additive is preferably 5 to 50% and particularly 10 to 30% in order to further enhance the flexural rigidity.
[0059] As shown in FIG. 6, in a die 200 used in molding of the shaft portion 163 a of the discharging roller 163 , according to a first embodiment of the invention, cavity portions 201 and 202 are formed in order to mold one shaft portion 163 a of the discharging roller 163 , and the die 200 comprises an upper die 210 and a lower die 220 that are divided in the radial direction of the discharging roller 163 . Here, since the conventional shaft portion of the discharging roller, formed of metal is high in rigidity, distortion can be prevented by double point support structure in which both ends are supported. However, since the shaft portion 163 a of the discharging roller 163 according to the invention is formed of plastics that is lower in rigidity than the metal, five point support structure in which not only the both ends but also intermediate portions are supported is adopted to prevent the distortion.
[0060] Since molding accuracy of each bore part in the shaft portion 163 a of the discharging roller 163 affects greatly accuracy of rotation of the discharging roller 163 , in order to improve the molding accuracy, the upper die 210 and the lower die 220 are respectively divided into three parts at portions where a part other than the bore portions is molded. In other words, each bore section including at least one bore portion is molded by a single die (a first upper die 211 , a second upper die 212 , a third upper die 213 , a first lower die 221 , a second lower die 222 , and a third lower die 223 ) as shown in FIGS. 6, 7A and 7 B.
[0061] Thus, through-work such as wire cut electrical discharge machining or cutting can be performed at the time of manufacturing the die, working accuracy of the die can be enhanced, and a die manufacturing cost can be reduced. Accordingly, the molding accuracy of the shaft portion 163 a of the discharging roller 163 can be improved, and the eccentric rotation of the discharging roller 163 can be suppressed. Further, since the sectional shape of the shaft portion 163 a of the discharging roller 163 is simplified, a cost of the discharging roller 163 can be reduced.
[0062] Due to limitation of a shape in the vicinity of each bore portion, there may be portions where the cavity portions 201 and 202 cannot be collectively formed. However, insert dies 214 and 224 are inserted into these portions to obtain desired shape of the cavity portions. FIGS. 8A and 8B are perspective views showing the second lower die 222 in detail. In this second lower die 222 , five insert dies 224 are inserted. Each insert die 224 , is inserted into a through hole 222 a from a bottom face 222 c side to constitute a part of the cavity portion 202 . Though not shown, the first upper die 211 , the second upper die 212 , the third upper die 213 , the first lower die 221 , the third lower die 223 have also the similar structure.
[0063] As shown in FIG. 9, a fitting part 215 of the upper die 210 and a fitting part 225 of the lower die 220 are formed in the shapes of concave and convex that can be fitted to each other, and lower corners 215 a of the upper fitting part 215 and the upper corners 225 a of the lower fitting part 225 are tapered so as to facilitate the fitting operation.
[0064] Since the cavity portion 201 in the upper die 210 and the cavity portion 202 in the lower die 220 can be faced with each other with high accuracy, occurrence of flash extending in the axial direction of the periphery of the shaft portion 163 a can be suppressed and the molding accuracy can be improved, so that the eccentric rotation of the discharging roller 163 can be suppressed.
[0065] As shown in FIGS. 10A and 10B, the cavity portions 201 and 202 are heat-regulated. Inside of this second lower die 222 , a fluid passage 204 through which cooling liquid (e.g., water) for heat regulation of the cavity portion 202 flows is formed. As shown in FIG. 10B, the fluid passage 204 extends perpendicularly from a bottom face 222 c at one end face 222 b side, it turns at a nearly right angle, extends from one end face 222 b side to the other end face 222 d side, and thereafter turns at a nearly right angle to run through the bottom face 222 c at the other end face 222 side. Such the fluid passages 204 , as shown in FIG. 10A, are formed respectively on both widthwise sides of the cavity portion 202 . Though not shown, the similar fluid passages are formed in the first lower die 221 and the third lower die 223 .
[0066] [0066]FIG. 11 is a section view showing a state where the die 200 is attached to a die attaching portion 300 of an injection molding machine. In the die attaching portion 300 of the injection molding machine, a fluid passage 301 through which cooling liquid (e.g., water) for heat-regulating the die attaching portion 300 itself flows is formed. Moreover, a fluid passage 302 through which cooling liquid for heat-regulating the cavity portions 201 , 202 is formed so as to communicate to the fluid passage 204 of the die 200 .
[0067] Hereby, since the inner surfaces of the cavity portions 201 , 202 can be cooled, when the melted plastic is injected, the outer surface of plastic is solidified in a state where it is adhered onto the inner surfaces of the cavity portions 201 , 202 , and void is easy to be produced on the inside thereof. Therefore, occurrence of internal stress of molded products for the shaft portion 163 a can be suppressed, so that a sink and a warp can be prevented. Further, dimensional accuracy of outer diameter of the shaft portion 163 a can be improved, so that the eccentric rotation of the discharging roller 163 can be suppressed. Further, since the die 200 is cooled relatively quickly, an operation cycle for molding can be reduced.
[0068] Further, as the injection method, a gas injection method can be adopted. FIG. 12 shows this configuration as a second embodiment of the invention. To a die attaching portion of an injection molding machine of this embodiment, a die 400 and a die 450 are attached. The die 400 has the similar structure as the die 200 , in which cavity portions 401 , 402 for molding one shaft portion 163 a of a discharging roller 163 are formed. An auxiliary cavity 451 is attached to an exhaust port 404 .
[0069] Under a condition that the cavity portions 401 , 402 of the die 400 are heat regulated at a predetermined temperature, the predetermined amount of the melted plastic is injected from an injection port 403 of the die 400 . Subsequently, the predetermined amount of gas is injected from the injection port of the die 400 . Hereby, a plastic outer surface coming into contact with the inner surfaces of the cavity portions 401 , 402 is quickly cooled and pressed by gas pressure from the plastic inside. Therefore, the plastic is solidified in a state where it is adhered onto the inner surfaces of the cavity portions 401 , 402 .
[0070] Melting plastic inside the plastic between the injection port 403 of the die 400 and the exhaust port 404 is pushed out from the exhaust port 404 by gas and fed out into the auxiliary cavity 451 . Hereby, occurrence of internal stress of molded products for the shaft portion 163 a of the discharging roller 163 can be suppressed, so that the sink and the warp can be prevented. Further, the dimensional accuracy of outer diameter of the shaft portion 163 a can be improved, and a uniform hollowed portion 163 c can be formed stably in the shaft portion 163 a throughout the entire region in the axial direction. Therefore, the eccentric rotation of the discharging roller 163 can be suppressed.
[0071] Though the invention has been described in the above various embodiments, it is not limited the above embodiments but may be applied also to other embodiments within the scope of the appended claims. For example, though the ink jet printer has been described as an example of a recording apparatus, the invention is not limited to this but can be applied to another recording apparatus having a discharging roller, for example, a thermal transfer type printer, and an ink jet type or thermal transfer type facsimile or copying machine. | 4y
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FIELD OF THE INVENTION
This disclosure is directed to the cooling of linear motors. More particularly the disclosure relates to a structure for cooling the coil assembly of a linear motor and preventing heating of the surrounding environment.
BACKGROUND
Excessive heating of the coils of a linear motor causes an increase in the resistance of the coils, exacerbating the heat problem and reducing the performance of the motor. In addition, this heat is carried away to the outside air and often to the rest of the machine in which the motor is utilized. Heat changes the index of refraction of air and consequently reduces the accuracy of laser interferometers and other optical systems. In addition, the heat causes thermal expansion of machine components, resulting in inaccuracy of precision mechanical systems.
Most commercially available linear motors are not actively cooled. Typically the coils are potted in a moderately conductive epoxy and the motor is cooled through convection into the surrounding air. Trilogy Systems provides an option to their motor where cooling fluid is circulated through a metal mounting bracket of the coil assembly. Because this bracket is mounted only to the top of the motor, not all of the heat is carried away from the motor and a significant portion of it is still convected into the surrounding environment.
U.S. Pat. No. 4,749,921 issued to Anwar Chitayat describes a linear motor. Included is a concept for cooling the linear motor coils. FIG. 8 in this patent shows a system of hollow tubes that are potted with the coil assembly. Coolant can flow through these tubes providing cooling. In U.S. Pat. No. 4,625,132 also issued to Anwar Chitayat, a controlled flow of cooling gas is directed between the motor stator and the moving element with flexible seals on each arm of a U-shaped channel mount a wound stator. In another Chitayat U.S. Pat. No. 4,839,545 an armature of a linear motor is cooled by coolant flowing through a lower serpentine channel in thermal contact with laminations of the motor armature.
U.S. Pat. No. 4,906,878 discloses a linear motor with cross-flow passageways or tubes connecting between inlet and outlet manifolds to remove heat from the motor coils. U.S. Pat. No. 4,916,340 utilizes heat insulating materials with a cooling medium (water) flowing through passageways on coil supporting members. U.S. Pat. No. 5,073,734 discloses a coolant for cooling between linear motor spacers and a screen support having cooling fins.
Yaskawa Japan Laid Open Application Heisei 8-168229 provides a linear motor that is enclosed in a stainless steel can (housing). This can has a small gap along the outside of the coils, which enables (not disclosed) coolant to be forced along the gap between the can and the coils to provide cooling of the motor. Yaskawa Utility Model Application Heisei 5-45102 includes a coil bobbin with a cooling path inside the bobbin.
Typical linear motors that are not cooled have inefficient motor operation due to increased coil resistance with temperature, heating of surrounding air, and heating of surrounding machine elements as discussed above. Motors that are only cooled through the mounting bracket do not provide direct cooling of the coils and suffer from the same disadvantages. The cooled motor of U.S. Pat. No. 4,749,921 and others of the above patents require cooling passages to be created within the coil assembly. This is difficult and can typically only be done by wrapping the coils with tubing and encapsulating the assembly in an epoxy. It also does not completely isolate the motor from the outside air because the cooling tubes do not completely enclose the coils. The Yaskawa disclosures include cooling arrangements which cannot be completely adapted to all motor configurations. In addition, both rely on an exterior thermal insulation or an exterior can (13 and 29, respectively) that may be difficult to fabricate. In both Yaskawa disclosures the cooling is on the inside of the bobbin or inside the can; coil heat may be transferred directly from the coil outer surfaces to the outside environment resulting in detriment to the machine in which the motor is being utilized.
SUMMARY
This disclosure is directed to novel cooling structures for linear motors. In accordance with some embodiments, no extra cooling tubes or components are needed within the coil assembly itself and cooling is accomplished by flowing coolant in a passage or a space between the surfaces of the coils and the coil enclosures. This prevents heat from the coils from reaching, for example, nearby interferometer or other optical systems, where the heat can change the index of refraction of air and reduce the accuracy of such systems or cause thermal expansion of machine components with resultant inaccuracies of the precision mechanical systems.
Typically in a lithographic (e.g. stepper) machine used in the processing of semiconductors wafers and the like, as many as eight linear motors are used to drive positioning elements (such as the reticle stage and wafer stage) of the stepper. This multiplicity of motors obviously compounds the problem of detrimental heat from the individual linear motors. In most applications, motors are cooled to prevent the motor from overheating and the coolant transfers the motor heat to the environment.
In the case of lithographic machines, the problem as recognized by the present inventors is not motor overheating but preventing the motor heat from reaching the environment and thereby adversely affecting the machine's interferometry systems. Hence here the motor heat is confined to the coil and coolant so that it is not transferred to the motor coil housing. Thus direct thermal contact between the motor coils and their housing is minimized.
One embodiment solves these problems in a band coil arrangement by providing integrally cast recesses forming cooling channels in a cast encapsulant block partially surrounding the coil assembly, along with closure members affixed over the cooling channels. An overall linear armature of a required substantial length with a minimal transverse thickness results. The structure allows coolant flow parallel to the length of the coil assembly along the height and length of the exterior surfaces of the coil assembly, the flow being between the coil assembly and the conforming coil enclosure, thus preventing heat from the coils escaping into the surrounding air.
While in one embodiment the coil assembly is partially encapsulated in e.g. a cast rigid epoxy which has a relatively low thermal conductance and a minimal thickness to provide a short heat path to the flowing coolant, preferably no such epoxy is present between most of the actual coil surfaces and the coolant. In order to prevent short-circuiting of the flowing coolant in the cast recesses, in one embodiment an integrally cast longitudinal spacer is provided extending over part of the length of the recesses in the cast encapsulant forming the coolant channels. The spacers terminate short of the ends of the recesses so that a cast divided annular channel is formed on each of opposite surfaces of the encapsulated coil assembly. Sealing of the channel is provided by a sheet metal or plastic closure member which with the ends of the assembly form an enclosure around the assembly of coils. The member may be adhered to or otherwise connected to the encapsulation block surrounding the respective recesses. The insulation block also contains a coolant inlet and plenum with coolant bores directing coolant to one end of the sealed recesses and a coolant outlet and plenum with coolant bores directing pumped coolant from the other end of the recesses to the coolant outlet.
In another embodiment called a centerpole cooling arrangement, physical insulating spacers are placed between each coil and extending between the outside enclosure (can or housing), and an inside enclosure, with a gap therebetween. Cooling fluid flows along the outside of the coils and through a gap between the coils and the inner enclosure and between the coils and inner surface of the outer enclosure.
The centerpole motor cooling arrangement includes a coil assembly with a thin e.g. metal enclosure on both the inside and the outside. The coils are separated slightly by insulating spacers along the axis of travel. The insulating spacers are slightly larger than the coils and create a small gap between the coil and the outside and inside enclosures. Cooling fluid can then be pumped or forced into an inlet plenum in the top of the enclosure and along the top of the coils. As the fluid flows along this channel the fluid runs along the coils and down the small channels along the sides of the coils. The fluid collects in an outlet plenum and flows out of the enclosure. This cooling approach is advantageous because the outside environment is affected only by the heat of the cooling fluid as transmitted through the enclosure. The much hotter coils are in all locations insulated from the outside by the cooling fluid. Thus, provided the flow rate of the cooling fluid can carry away the generated heat without excessive temperature rise, the heat transfer rate from the coils is unimportant, provided that the temperature of any coil does not rise to the point of causing damage.
A double layer coil cooling arrangement uses an array of coils that are stacked such that internal cooling passages exist between the coils. In this arrangement, pockets exist in the center of each coil. The coils are configured to allow for small passages between adjacent pockets and the conforming enclosure, thus coolant can flow from one pocket to the next along the length of the coil assembly. The coil assembly is sandwiched between thin e.g. metal or plastic sheets, creating an enclosure around the coils. Thus, coolant can be introduced at one end of the coil assembly into an inlet plenum, carry heat away from each of the coils along the length of the assembly, and exit at the other end of the assembly from an outlet plenum.
In a dogbone motor coil cooling arrangement an enclosure for the coil has the shape of a conforming “dogbone”. A small gap is defined between the coils and the enclosure inside walls, along the sides, top, and bottom, using insulating spacers. Cooling fluid can then be introduced at the inlet plenum end of the coil assembly inside the enclosure, and will flow along the outside of the coils in the gap created by the spacers to an outlet plenum. This fluid will carry away the heat generated by the coils. As in other of the embodiments the coolant flows between the coils and the surrounding environment, thus preventing heat from the coils from escaping.
Hence in one embodiment a cooling structure and method for a coil of a linear motor include an enclosure member conforming to at least one side wall of the motor coil. Coolant passages are provided between the enclosure member and the motor coil sidewall. Inlet and outlet connections are provided to flow a fluid coolant through the coolant passages.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic top view of a stage for a stepper (lithographic) machine with the linear motor driving the stage.
FIG. 1B is a side view of an entire lithographic apparatus which may use the FIG. 1A structure.
FIG. 2 is a schematic end view of the FIG. 1A structure.
FIG. 3 is a cross-sectional view of the band coil embodiment of the linear motor.
FIG. 4 is a perspective view of the encapsulated coil assembly thereof.
FIG. 5 is a perspective partial view of the coolant inlet and outlet and coolant bores of the coolant loop broken away to show the encapsulated coils.
FIG. 6A is a schematic partially cutaway perspective view of the centerpole embodiment;
FIG. 6B is a side cutaway view of the same structure.
FIG. 7 is a cross-sectional side view thereof taken on the line 7 — 7 of FIG. 6 A.
FIG. 8 is a cross-sectional view taken on the line 8 — 8 of FIG. 7 .
FIG. 9 is a schematic perspective view of the double layer of coils embodiment less an enclosure therearound.
FIG. 10 is a top view thereof.
FIG. 11 is a longitudinal cross-sectional view of the coil assembly taken on the line 11 — 11 of FIG. 10 .
FIG. 12 is a magnified cross-sectional view of the circled portion A of FIG. 11 .
FIG. 13 is a magnified plan view of the gap in the circled portion B of FIG. 12 .
FIG. 14 is a schematic side view of the overall double layer embodiment including the exterior outer enclosure.
FIG. 15 is a schematic perspective of the dog-bone-shaped coil embodiment less the outer enclosure.
FIG. 16 is a cross-sectional view taken on the line 16 — 16 of FIG. 15 also showing in cross-section the outer enclosure and the motor magnet track.
DETAILED DESCRIPTION
FIG. 1A schematically shows a top view of a stepper chamber 14 in a lithographic measuring and processing system 10 (e.g., a stepper machine). The lithographic system 10 includes a stage 12 (e.g., a wafer stage) and an apparatus floor support surface 21 . A yoke 18 and two linear guideways 19 are mounted on the floor support surface 21 . The stage 12 has a mirror system 9 and a wafer table 22 mounting a wafer on the upper surface thereon, and has a linear motor coil assembly 11 driving the stage 12 on the under surface. In order to measure the position of the stage 12 , the interferometry measurement system 26 emits a laser beam 20 incident on the mirror system 9 . As is known in the interferometry measurement art, the beam is split through a 45° beam splitter in system 26 . One beam is reflected off a fixed reference mirror in system 26 and the other beam is reflected off mirror system 9 attached to the wafer stage. These beams are then recombined and a sensor in system 26 detects changes in the position of the wafer stage mirror 9 . While FIG. 1A illustrates a wafer stage, the present invention is also applicable to reticle stages and other applications of linear motors.
FIG. 1B is taken from Nishi U.S. Pat. No. 5,473,410 FIG. 3, issued Dec. 5, 1995, incorporated herein by reference in its entirety. This illustrates a projection exposure (lithographic) apparatus in which the FIG. 1A structure may be used as an x-y wafer stage or as the reticle stage (with suitable design adaptations apparent to one skilled in the art).
The follow description of present FIG. 1B follows that of FIG. 3 of U.S. Pat. No. 5,473,410, except that the reference numbers, instead of being identical to those of U.S. Pat. No. 5,473,410 FIG. 3, each have the letter “a” appended thereto for convenience of reference.
In FIG. 1B a projection lens PL is a projection optical system. Exposure illumination light emitted from a mercury lamp 2 a is condensed at a second focal point through an elliptical mirror 4 a . Disposed at the second focal point is a rotary shutter 6 a . This operates with the aid of a motor 8 a . The exposure illumination light passing through shutter 6 a is reflected by a mirror 10 a . The illumination light beam is incident on a fly eye lens system 14 a via an input lens 12 a . The illumination light falls on a lens system (condenser lens) 18 a via a beam splitter 16 a . Removable blades BL 1 , BL 2 , etc. at the blind mechanism 20 a are individually independently moved by a driving system 22 a . (This blind system is not required in such lithographic machines, however.) A reticle R is illuminated with the illumination light via a lens system 24 a , a mirror 26 a and a main condenser lens 28 a .
The reticle R undergoes the illumination light defined by the aperture, defined by the blades and is held on the reticle stage 30 a moving at least in the x direction on a column 32 a . The reticle stage 30 a is moved by driving system 34 a . A movable mirror 36 a reflects a length measuring beam emitted from a laser interferometer 38 a is fixed to one end of the reticle stage 30 a . A fixed mirror 40 a for the laser interferometer 38 a which is fixed to an upper edge of the lens barrel of the projection lens PL. Wafer W is held, with a fiducial mark FM, by a wafer holder 44 a , capable of making microscopic rotation. The holder 44 a is installed on a z stage 46 a capable of effecting a micromotion in the z (vertical) direction.
The z stage 46 a is installed on an x-y stage 48 a moving two dimensionally in the x and y directions. Stage 48 a is driven by a driving system 54 a . Yawing and coordinates of x-y stage 48 a are measured by a laser interferometer 50 a . A fixed mirror 42 a for laser interferometer 50 a is fixed to a lower edge of the lens barrel of projection lens PL. A movable mirror 52 a is fixed to one edge of the z stage 46 a . There is an alignment system 60 a , using through the reticle alignment, for detecting the alignment mark (or fiducial mark fm) on wafer W. There is also an alignment system 62 a , using through the lens alignment, for detecting the alignment mark or fiducial mark FM on the wafer W through the projection lens.
Photoelectric sensor 64 a receives light from a luminescent mark (when the fiducial mark FM is luminescent) via the projection lens PL, the reticle R, the condenser lens 28 a , the lens systems 24 a , 18 a and the beam splitter 16 a . This determines the position of the reticle R. Sequence and controlling this system is performed by main control unit 100 a . This controls the structures shown connected thereto by the depicted lines terminating in arrows.
FIG. 2 shows the side-face of the stage 12 of FIG. 1 A. The stage 12 is supported by e.g. air bearings 15 on the linear guide 19 , typically a smooth flat granite surface. Roller bearings or magnetic bearings may also be utilized. Coil magnets or permanent magnets 17 are mounted on inwardly-facing surfaces 16 of the yoke 18 . The magnets 17 on one side of the coil assembly 11 and those on the other side of coil 11 are aligned so the magnets 17 produce a strong magnetic field between them. Magnets 17 and yoke 18 collectively are a magnet track. A housing block 28 contains a coolant inlet and outlet.
Referring to FIGS. 3-5 which show the band coil embodiment, the linear motor 60 includes a yoke 18 which mounts a pair of spaced permanent magnets 17 . A coil assembly 11 passes linearly through the magnets 17 with a gap 90 therebetween. Magnets 17 typically are neodymium iron boron (NdFeB) magnets. The overall armature 61 (FIG. 4) includes coils 62 , such as band coils which are coils formed e.g. by insulated wire and which are supported by a cast structure 63 . In one embodiment, eight coils are so supported, the coils being electrically connected in series. Typically, the cast support is a cast epoxy resin such as CB-1054A available from Dolph Co. of Monmouth Junction, N.J. Other casting resins may be employed. The casting resin may contain heat transmitting metal powders such as Alumina (assuming the coils are electrically insulated).
The resultant cast support 63 thus forms an elongated parallelogrammatic block 65 . The block 65 is preferably such that a maximum amount of the coil's outer surface is not covered by the epoxy, but is in direct contact with the coolant. Cast in the block 65 are elongated recesses or slots 66 and 68 which extend along the outwardly facing opposite sides 67 and 69 , respectively, of the coils 62 . The recesses have a width and length substantially the same as the width and length of the banded coils 62 . An integrally cast spacer 70 extends longitudinally of the recesses with the ends 71 , 72 of the spacer terminating short of the ends 73 of the recesses, thus forming a divided pathway 74 having a first channel portion 75 connected to a parallel second channel portion 76 . The spacer also functions as a central structural support since it is abutted and bonded to by a closure member 48 . The spacer prevents “ballooning out” of the closure member which can affect the clearance provided by gap 90 . Closure members 48 are in the form of rectangular thin sheets which with the assembly ends 65 a and 65 b form an outside enclosure (can) around the embedded coils. The thickness of the sheets may be from about 0.4 mm to about 2 mm.
The sheets may be metal, such as titanium or non-magnetic stainless steel, plastic such as nylon, or ceramic such as alumina. The sheets 48 are bonded to block 65 by an adhesive such as an epoxy adhesive (not shown) available from 3M Co. of Minneapolis, Minn., or otherwise connected to the block 65 so that the recesses are sealed at their peripheries. The interior surfaces of the closure members face the gap 90 between the overall armature 61 and the magnets 17 . The block 65 has a T-configuration including a vertical portion 80 and a horizontal top cross-piece 81 . A coolant inlet port (not shown) is provided in cross-piece 81 forming part of an inlet plenum 47 and a coolant outlet port (not shown) forming part of an outlet plenum 45 is provided in vertical portion 80 with a connecting outlet port in cross piece 81 . Four electrical terminals 78 provide connections to the coils.
In one embodiment, the recesses have a depth 8 of from about 0.4 mm to about 2 mm. The coolant is e.g. Fluorinert coolant FC-77 available from the 3M Co. Typically a pumped coolant flow rate of about 3 liters/minute is employed with a 1° C. temperature rise being able to carry away about 90 watts of heat from the coils. A thermoelectric cooler in the coolant circulation system removes heat from the coolant.
FIGS. 6A-8 illustrate the centerpole motor cooling arrangement which includes a coil assembly 30 with a thin metal enclosure (can) 33 on the inside of the assembly and a second enclosure structure 34 on the outside thereof. The thin inside enclosure 33 is typically of non-magnetic stainless steel and has an oval configuration as seen in FIG. 7 . FIG. 6A shows a cutaway perspective view; FIG. 6B shows a corresponding side view, but showing the full length of the structure FIG. 7 is a cross-sectional view along line 7 — 7 of FIG. 6 A and FIG. 8 is a cross-sectional view along line 8 — 8 of FIG. 7 . The outer enclosure 34 includes the side edges of block 35 and thin e.g. metal plates 34 a , typically non-magnetic stainless steel sheets abutting and welded to the side edges of block 35 and extending laterally and vertically spaced from the exterior side walls of a series of coils 31 aligned side-by-side. Structures 33 , 34 , 35 are e.g. one piece or a welded assembly.
The individual coils 31 a through 31 e are separated by a series of insulating spacers 32 a through 32 f which have inner ends abutting the inner enclosure 33 and outer ends abutting the metal side plates 34 . The spacers are constructed of a phenolic or other thermally insulating material and have dimensions so as to create a series of gaps 39 a between the exterior of the inner enclosure 33 and the interior walls of the coils 31 and gaps 39 b between the interior wall of outer enclosure structure 34 and the exterior walls of the coils 31 . The arrows represent the flow of pumped coolant fluid from a plenum inlet 38 in a top-piece 36 to an outlet 37 of the assembly 30 . Both elements 37 , 38 are e.g. tapped holes into which respective screw-in pipe fittings 37 b , 38 b (FIG. 6B) fit. The coolant fluid flows outwardly and downwardly along the top of coils 31 through both the gaps 39 a and 39 b to draw off heat generated by the operation of the coils. Spacing between the coils and the cans is e.g. 1 to 2 mm. The coolant fluid with its acquired heat out flows through outlet 37 . Thus the environment outside the outer enclosure structure is only exposed to the heat of the cooling fluid as transmitted through the outer enclosure structure. The much hotter coils 31 are at all locations insulated from the outside environment by the cooling fluid. The flow rate of the cooling fluid is chosen so that the cooling fluid carries away the coils-generated heat without an excessive, i.e. not more than about 1° C., temperature rise in the coolant fluid.
FIGS. 9-14 illustrate the double layer coil cooling arrangement which includes a coil assembly 40 having layers 41 and 42 of coils, 41 a through 41 f and 42 a through 42 f , respectively, the layer 42 being staggered with respect to layer 41 . The respective coils are stacked such that internal cooling passages exist between the coils. Pockets (gaps) exist in the center of each coil so there is a serpentine coolant flow 48 under a coil 41 and over a coil 42 as seen in FIG. 12 . The coils are configured to allow for a small gap, e.g. about 1 mm, between adjacent coils so that coolant fluid can flow from one pocket to the next pocket along the length of the coil assembly 40 . The coil assembly is sandwiched between thin e.g. metal or plastic sheets 47 creating an outer enclosure 49 . FIG. 13 illustrates chamfered edges 46 a and 46 b of the coils, which together form one of the gaps 46 , namely between two of the stacked and staggered coils 42 b and 41 c . At each end of the assembly 40 are generally rectangular spacers 43 and 44 which also serve as an inlet plenum and an outlet plenum, respectively, by defining suitable passages.
FIGS. 15 and 16 illustrate the dog-bone shaped motor coil embodiment where a coil assembly 100 includes bent-ended coils 91 and 92 , which when placed in an abutted side-by-side relationship, together form coils having, in one section of the coil, a profile approximating a dog-bone shape. Elongated longitudinal spacers 93 are adhesively affixed to transverse parallel portions of the exterior of both sides of the coil assembly. A conforming dog-bone shaped enclosure 94 surrounds the coil assembly with the spacers forming coolant channels 95 between the exterior surfaces of the coils 91 , 92 and the inner surfaces of enclosure 94 . The width of the channels 95 is determined by the thickness of the spacers 93 .
The dog-bone enclosure is welded to the inner edges of a top-piece 96 having cooling fluid inlet 97 and an outlet 98 which permits coolant flow and a thickness of coolant liquid between the exterior of the coils and the interior of the enclosure 94 . The environment outside the enclosure 94 is only exposed to the heat from the flowing coolant. FIG. 16 also shows the associated magnet track 98 (similar to that shown in FIG. 3) The arrows 99 in FIG. 15 show the flow of coolant across the exterior surfaces of one side of the coils 91 , 92 . Flow of coolant is also across the exterior surface of the coils on the opposite side of the assembly.
The above is intended to be illustrative and not limiting. Other embodiments and modifications will be obvious to those skilled in the art in view of the above disclosure and are intended to fall within the scope of the appended claims. | 4y
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CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] This invention relates to a rotor for a power generator, in particular electrical power, based on a fluidic flow capable of being air or water in particular. It relates more specifically to a wind turbine rotor. It also applies to an electrical power generating device, in particular a wind turbine, comprising a generator coupled to at least one rotor.
[0007] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0008] Environmental concerns and rising prices of fossil fuels have led, in recent years, to an increase in interest in alternative forms of energy, in particular in the field of wind turbines.
[0009] The most common wind turbine solutions consist of wind turbines with a horizontal axis having a propeller perpendicular to the wind and mounted on a wind tower.
[0010] This technology is often used for large installations for generating a large amount of electrical power.
[0011] Lower-profile solutions have been proposed, in particular for installations near buildings consuming electrical power. This is the context of the device described in document FR A 2 872 867, disclosing a machine for generating power by means of wind force, in the form of a wind generator having a rotor of which the blades have a semi-frusto-conical shape and are quasi-parallel to the axis of rotation. Essentially used with a horizontal axis of rotation, this type of device is highly efficient and compact, making it suitable for multiple installation areas in particular on building rooftops.
[0012] The blades of this type of generator are, however, large and therefore have a large surface of contact with the fluid, involving mechanical strength considerations requiring sizing of the structures suitable for taking up the stresses produced by winds of highly variable force.
[0013] The invention proposed here is intended to improve the technology of rotors with blades positioned obliquely with respect to the axis of the rotor.
[0014] U.S. Pat. No. 4,159,191 describes a rotor for a power generator based on a fluid flow, comprising a plurality of flexible blades positioned obliquely with respect to the axis of the rotor, which is arranged so as to allow for a variation in the obliqueness of the blades, during operation. More specifically, the front end of the blades is rigidly attached on a circular crown, while the remaining portion thereof is free. In this way, the blades are mounted so as to float, by means of their front ends, on the circular crown, itself rigidly connected to the horizontal rotary shaft of the rotor. According to the force of the wind engulfing in the front opening of the rotor defined by the circular crown, the rear free end of the flexible blades moves away from or toward the horizontal rotary shaft. There is therefore a variation in the obliqueness of the blades of the rotor, but this possible variation of the obliqueness cannot be considered to be an adjustment of the latter. Such a solution appears to be purely theoretical and does not appear to have led to practical applications. A construction enabling satisfactory, lasting and quiet operation of such a rotor applied to wind turbines indeed appears to be very difficult to obtain.
BRIEF SUMMARY OF THE INVENTION
[0015] The invention provides a solution to the aforementioned problems of the wind turbine machines having blades positioned obliquely.
[0016] In particular, the invention has the advantage of making it easy to adapt the fluid flow rate, which can be highly variable in particular when wind is concerned.
[0017] To this end, the configuration of the rotor recommended in this document changes according to the force of the wind, protecting the electrical generation installation from risks of breakage of the rotor and making it possible to optimize the structure of the assembly, in particular with regard to the mechanical stresses imposed by the wind. The applicant has thus noted that it was possible to clearly reduce the weight of the rotor by implementing the invention while maintaining sufficient mechanical reliability.
[0018] Other objectives and advantages will appear in the description, which presents a detailed embodiment of the invention, which embodiment cannot however be considered to be limiting.
[0019] It is first noted that the present invention relates to a rotor for a power generator based on a fluid flow comprising a plurality of blades positioned obliquely with respect to the axis of the rotor, characterized in that it comprises means for controlling the variation in the obliqueness of the blades.
[0020] According to preferred but non-limiting alternatives, this rotor is such that:
the means ensuring the variations in inclination of the blades are controlled so as to slave the obliqueness of the latter to the speed of the fluid flow, the blades have a generally semi-frusto-conical shape, the obliqueness of the blades is variable in a plane substantially perpendicular to the plane defined by the longitudinal edges of the blades, the device comprises a shaft according to the axis of the rotor and means for connection between the shaft and each blade, the connection means comprise, for each blade, a hinge near the leading edge of the blade and at least one variable downstream connection, the variation means comprise means for modifying the length of the downstream connections, the variation means comprise means for modifying the position of the connections along the shaft, the obliqueness of the blades is variable between 0 and 45°, the leading edge of the blades forms an angle of between 20 and 30° toward the outside with the plane normal to the longitudinal axis of the blades, the trailing edge of the blades forms an angle of between 20 and 30° at the outside with the plane normal to the longitudinal axis of the blades.
[0031] The invention also relates to an electrical power generating device comprising a generator coupled to at least one rotor as defined above.
[0032] The appended drawings are provided as examples and do not limit the invention. They merely represent an embodiment of the invention and will enable it to be understood easily.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 shows a perspective view of a first configuration of the invention that can be applied to fluid flows of average speed.
[0034] FIG. 2 shows a view according to direction F.
[0035] FIG. 3 shows a perspective view of the invention in the case of a more powerful fluid flow.
[0036] FIG. 4 is a view according to direction E.
[0037] FIGS. 5 and 6 show two different inclinations of a blade of a rotor according to the invention.
[0038] FIGS. 8 and 9 show an alternative of the invention in comparison with the embodiment diagrammatically shown in FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0039] The rotor presented here comprises a plurality of blades 4 shown in the various figures and having a longitudinal direction with a non-zero component according to the axis of rotation 2 of the rotor. In this way, the blades 4 are formed obliquely with respect to the axis of the rotor.
[0040] Each blade 4 extends longitudinally toward the rear from its front end or leading edge 5 and radially outwardly, so as to progressively move away from the axis of rotation 2 . The obliqueness of the blades thus positioned can vary between 0 and 45°.
[0041] In the case shown, three blades 4 are provided, but this number is non-limiting. In addition, the example shown has 4 identical blades, uniformly distributed and produced by a semi-frusto-conical casing that is slightly convoluted between the leading edge 5 and the trailing edge 6 by an angle of between 20 and 30°. The blades 4 are angularly offset with respect to the direction defined by the axis of rotation 2 by an angle on the order of 5 to 15° in the XY plane shown in FIGS. 5 and 6 .
[0042] By way of indication, the diameter of the base of the cone frustum used to form the leading edge 5 is on the order of 0.25 times the length of the blade while the diameter of the apex of the cone frustum used to produce the trailing edge 6 is on the order of 0.083 times said length.
[0043] The rotor thus formed by these blades 4 rotating about the axis 2 formed by the shaft 1 can be used in particular in an electrical power generating device, in particular for wind turbines. In this context, and as shown in particular in FIGS. 1 and 3 , the shaft of the rotor is coupled to a generator 10 enabling electrical power to be produced. The assembly is pivotably mounted around a vertical axis, so as to enable it to be positioned automatically in the direction of the wind.
[0044] According to the embodiment shown, the assembly is supported by a base 7 connected by support arms 12 a , 12 b with a substantially vertical position, to front 8 and rear 9 bearings guiding the rotation of the shaft 1 . The base 7 is itself advantageously pivotably mounted so as to perform a wind vane function and adapt to the direction of the wind when the fluid flow is of the wind energy type.
[0045] An electrical box 11 is also represented for the control of the assembly. This box may be at the base of the wind tower used to raise the wind turbine if necessary.
[0046] According to the invention, the configuration of the rotor can be modified according to the fluid flow rate. In particular, the obliqueness of the blades 4 is variable and advantageously slaved to the flow rate.
[0047] The variation in the obliqueness of the blades is preferably performed in the YZ plane shown in FIGS. 5 and 6 , formed by a plane substantially perpendicular to the plane defined by the longitudinal edges of the blades.
[0048] Also preferably, for dynamic balancing reasons, the variation in obliqueness is identical and simultaneous for each of the blades 4 .
[0049] Different means for controlling the variation in this obliqueness can be provided.
[0050] In reference to the drawings, an embodiment has been shown in which each blade 4 is connected to the shaft 1 by means of a coupling member 13 , in particular by a pivot hinge 18 .
[0051] This hinge can be produced by means of a device with a threaded axis, also optionally capable of being moved in an oblong hole formed on the blade so as also to enable the obliqueness to be adjusted according to a direction XY in reference to FIGS. 5 and 6 .
[0052] Further behind the rotor, a coupling member 14 mounted on the shaft 1 cooperates with connections 15 , 16 , 17 each connecting the coupling member 14 to a blade 4 . Preferably, the member 14 acts as a hub.
[0053] Preferably, the ends of each connection are pivotably connected in a swivel joint with respect to the coupling member 14 and the upper surface of the blades 4 .
[0054] As diagrammatically shown, the variation in obliqueness of the blades 4 is produced by a variation in the length of the connections 15 , 16 , 17 . To this end, each connection can include an electrical, pneumatic or hydraulic and controlled cylinder.
[0055] According to an alternative solution, the coupling member 14 can be moved along the shaft 1 so as to modify the inclination of the connections 15 , 16 , 17 causing the trailing edges 6 to move toward or away from the shaft 1 .
[0056] Although the control may be manual, it is advantageous to provide automatic means capable of producing the variation in obliqueness of the blades 4 , so that the rotation speed is quasi-constant. To this end, the installation advantageously comprises means for measuring the fluid flow rate, in particular in the form of an electronic anemometer in the case of a wind turbine installation. These measurement means are connected to a servo circuit capable of producing an output signal for controlling means ensuring the variation in obliqueness. These means for maneuvering the blades can be mechanical, electromechanical, pneumatic or hydraulic.
[0057] It is easily understood that once a variation in speed is measured, the configuration of the rotor is adapted in particular so as to reduce the obliqueness in the event of strong winds. Providing less resistance to the air, the blades 4 are subject to lower mechanical stresses than if they remained in a more oblique position.
[0058] Advantageously, the obliqueness can be adjusted between 0° and 45°.
[0059] In addition, the orders for controlling the actuation of the blades are advantageously routed by means of the rotation shaft 2 which is hollow.
[0060] In addition to the optimal recovery of the energy of the fluid, regardless of the force of the flow, the invention enables greater safety by moving the angle of obliqueness toward 0. It is also possible to associate a disk brake 19 with hydraulic or mechanical control installed at the end of the shaft 1 under the wind. Uncontrolled mechanical vibrations that currently may occur if the rotation speed is excessive are also prevented. A reduction in the noise level is also observed due to a quasi-constant rotation speed. This constancy also improves the reliability of the assembly.
[0061] FIGS. 8 and 9 show an alternative embodiment of the downstream 21 and upstream 20 external borders extended with respect to the plane (x, z).
[0062] In the specific example described above, under average winds, the obliqueness may have a value of around 30°. At this value, the leading edge will be in a plane containing the perpendicular to the blade passing through the axis of rotation and forming an angle of 25° with said axis, in front of the blade. The effect of this is that the external border of the blade is extended and thus increases the effective surface of the blade 4 by approximately 6%, further improving the energy efficiency. | 4y
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BACKGROUND TO THE INVENTION
This invention relates to a container comprising a receptacle and a lid, preferably for use as a one-way transport container for disposable matter such as poisonous substances and/or hospital waste.
One-way transportion containers are known of greatly varying design, and which are made from very greatly differing materials. It is known, for example, to store washing powder or the like in cardboard cylinders. Such cardboard cylinders are environmentally acceptable, but expensive to produce. Moreover, they are extremely sensitive to moisture, so that they are unsuitable for containing liquids, or for storage in spaces that are not completely dry.
For the purpose of receiving fluids it is, therefore, usual to use injection-moulded plastics buckets. These are, however, relatively expensive to produce.
It is also known to use refuse bags made of paper or plastics material. Such refuse bags can be stored in a space-saving manner when not in use, and they are economical to produce. However, they are extremely sensitive to sharp-edged refuse.
In the case of special types of refuse, for example medical refuse from hospitals, doctors' surgeries or laboratories, it is known (see DE-PS No. 22 33 435) to collect such refuse in, for example, refuse bags or in cardboard cylinders lined with water-tight material. These bags or cylinders are then sealed, and taken to a place where the refuse is burnt. These known containers suffer from the disadvantage that they cannot, with certainty, prevent the escape of liquid such as blood. Moreover, there is the risk that pointed or sharp articles (such as throw-away syringes) in the refuse will pierce the walls, so that there is danger of injury to persons handling the containers.
For this reason, hospitals often make use of large-capacity domestic plastics buckets produced by injection moulding. As previously mentioned, such containers are comparatively expensive. Moreover, still greater expense is entailed in emptying such buckets for further use, and in then cleaning and disinfecting them.
The aim of the invention is, therefore, to provide a reliable transportable container, which can be stored in a space-saving manner, which can be sealed in an air-tight manner and which offers protection as regards the escape of liquids and against sharp-edged refuse.
SUMMARY OF THE INVENTION
The present invention provides a container comprising an open-mouthed receptacle and a lid, the receptacle having side walls and a base and being formed with an outwardly-extending rim which surrounds the open mouth of the receptacle, wherein the receptacle is formed by vacuum moulding, and wherein the ratio of the thickness of the rim to that of the rest of the receptacle is at least 4.5:1.
A receptacle made by vacuum moulding plastics sheet material results in the container being relatively economical to produce, and hence in it being usable as a throw-away article. Moreover, the use of such material ensures liquid-tightness and sufficient rigidity, when shaped by a suitable method, so that the containers can be stacked both when empty and when filled.
It is known to use vacuum-moulded containers, for example for accommodating foods such as curds or yoghurt intended for immediate consumption. However, because of their structure, the known containers are not suitable for safely transporting fairly large quantities of refuse sealed up in an airtight manner. The container of the invention is designed for capacities in excess of 25 liters.
Advantageously, the external dimensions of the rim correspond to the external dimensions of the sheet from which the receptacle is formed by vacuum moulding. This ensures that there is no wastage of material when making the receptacle, as there is no need to cut the rim down to the required size.
The side walls of the receptacle may be formed with reinforcing corrugations. Preferably, the receptacle has a generally square cross-section, and the reinforcing corrugations are distributed symmetrically along each of the four side walls thereof. Advantageously, spacer corrugations are formed in the side walls immediately below the rim.
Advantageously, the side walls of the receptacle taper from the rim to the base. Where the receptacle is square and has walls which taper from the rim to the base, the container is such that stacking can be carried out very easily when the containers are empty, so that very little space is required for storing them. Moreover, the filled containers can be advantageously disposed more closely together in a rectangular arrangement on the loading surface of a transport vehicle. The good stackability of the empty containers is further increased by the corrugations formed in their walls, which corrugations prevent the empty containers, stacked one within the other, from locking together.
Advantageously, the upper surface of the rim is provided with an adhesive foil, and the adhesive foil is covered by a protective strip. Preferably, the adhesive foil and the protective strip are formed with notches which extend from the exterior over parts of their width.
Preferably, the base of the receptacle is formed with an inwardly-directed reinforcing and stacking curvature, and the lid is formed with an outwardly-directed reinforcing and stacking curvature shaped to correspond with said inwardly-directed reinforcing and stacking curvature. This helps to ensure good stacking properties.
Advantageously, the side walls of the receptacle have, in the zone below the rim, inwardly-directed inclined surfaces which act as centering and bearing surfaces for the lid, and the lid is formed with an outwardly-extending rim which has inwardly-directed inclined surfaces, which co-operate with the inclined surfaces of the rim of the receptacle. The inwardly-directed inclined surfaces of the rim of the lid co-operate in a shape-locking manner with the inclined surfaces of the rim of the receptacle, and thus prevent transverse forces from acting on the adhesive foil arranged between the container and the lid. The fitted lid thus provides a safe surface on which the next container can be stacked.
Conveniently, the lid has an upwardly-directed stacking bead. The stacking beads fix the containers, stacked one upon the other, in position. This fixing effect is reinforced by co-operation between the curvatures of the lids and the receptacles.
Preferably, the lid is formed by vacuum moulding a substantially thinner sheet of material than that from which the receptacle is formed.
In a preferred embodiment, the stacking bead is provided with a tear-off strip. This arrangement is particularly advantageous when the lid is unreleasably secured on the receptacle with the aid of a foil-welding machine. The arrangement is also particularly advantageous in the case of pulverulent substances such as washing powder and the like. Conveniently, the stacking bead is a double bead and the tear-off strip is formed between the two beads and is made of thicker material.
Alternatively, the lid may be provided with a snap-action seal. In this case, the rim of the lid is connected to the rim of the receptacle by means of lugs, the lugs being formed integrally with the rim of the lid. The lugs resiliently engage over the rim of the receptacle.
In a special arrangement, the receptacle and the lid are made in one piece by a vacuum moulding process. In this case, the lid is attached to the receptacle along a portion of the rim of the receptacle, said portion being of reduced thickness. The price of such containers is a decisive selling factor. The total savings due to reduced handling and machine times, as well as the saving in material and avoidance of scrap, reaches a very high level as a result of using the invention.
The invention also provides a method of making a receptacle having a base, side walls and an open mouth surrounded by an outwardly-extending rim, the method comprising the steps of taking a sheet of plastics material whose external dimensions correspond to those of the rim of the finished receptacle, and vacuum moulding the base and side walls in such a manner that the thickness of the rim is at least 4.5 times the thickness of the base and the side walls.
BRIEF DESCRIPTION OF THE DRAWINGS
Two forms of container constructed in accordance with the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a plan view of the first form of container;
FIG. 2 is a cross-section taken on the line II--II of FIG. 1;
FIG. 3 is a plan view of the lid of the container of FIGS. 1 and 2;
FIG. 4 is a cross-section taken on the line IV--IV of FIG. 3; and
FIG. 5 is a perspective view of the second form of container.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, FIGS. 1 to 4 show a container designated generally by the reference numeral 1. The container 1 consists of a receptacle 3 and a lid 13. The receptacle 3 has a handling and reinforcing rim 2, the thickness of which is at least 4.5 times as great as the thickness of the walls 4 of the receptacle. An adhesive foil 10 is provided on the upper surface of the reinforcing rim 2, the adhesive foil being covered by a protective film 11. Preferably, the adhesive foil 10 and the protective film 11 are each made in one piece; and, at the corners 12 of the receptacle 2, they have incisions (notches) which extend at least over portions of their width. The upper parts of the downwardly-tapering walls 4 of the receptacle 3 are formed by inclined surfaces 7. The inclined surfaces 7 act as centering and supporting surfaces for corresponding inclined surfaces 15 of the lid 13 (as is described below). Since the walls 4 of the receptacle 3 are relatively thin, reinforcing corrugations 5 are provided for increasing their strength. Furthermore, corrugations 6 are formed in the walls of the receptacle 3, the corrugations 6 preventing locking of the empty receptacles when they are stacked one within another. The base 8 of the receptacle 3 is additionally rigidised by an inwardly-directed reinforcing and stacking curvature 9.
The receptacle 3 can be closed in an air-tight manner by means of the lid 13. The lid 13, therefore, likewise has a rim 14, the dimensions of which correspond to those of the reinforcing rim 2 of the receptacle 3. After removal of the protective film 11, the stable rim 14 of the lid 13 is pressed on to the adhesive foil 10, and seals off the receptacle 3 in an air-tight manner. To prevent this adhesive seal from being affected by transverse loads, inclined surfaces 15 are incorporated in the lid 13. These inclined surfaces 15 co-operate with the inclined surfaces 7 of the receptacle 3. The lid 13 also has a stacking bead 16, the dimensions of which are selected to suit the outer contour of the base 8 of the receptacle 3. This stacking bead 16 thus prevents slipping of the filled containers, stacked one upon another. The lid 13 is formed with an upwardly-directed reinforcing and stacking curvature 19, which, when stacking is carried out, engages in the reinforcing and stacking curvature 9 of the vessel arranged above it. This results in additional stability.
Although the above-described inherently rigid container is designed preferably for special refuse, such as occurs, for example, in hospitals or the like, it is also eminently suitable as a one-way transport receptacle. Thus, for example, after the receptacle 3 has been filled with the material that is to be carried away, the lid 13 is unreleasably sealed by means of a foil-welding machine or the like. In order to open the container, a tear-off strip 23 is provided, this being formed integrally with the stacking bead 16. For this purpose, the stacking bead 16 is designed as a double bead 21, the tear-off strip 23 being provided between the two projecting parts 22. The tear-off strip 23 is made of thicker material, and extends over a short distance. The strip 23 can be easily torn from the lid 13, so that the receptacle 3 becomes accessible.
The receptacle 3 is made by vacuum moulding a sheet of plastics material. The sheet of plastics material is chosen to have the same external dimensions as those of the rim 2 of the finished receptacle. By making the receptacle 3 from a sheet of material of these dimensions, the amount of material wasted is negligible. Thus, there is no need to cut the rim 2 of the receptacle 3 down to the required size. Moreover, thicker sheets can be used in the moulding process, so that it is possible to draw the material which flows during the vacuum moulding operation completely from the material positioned within the edge portion of the sheet that is to form the rim. Consequently, the edge portion is largely unaffected by the vacuum moulding operation, so that the thickness of the rim 2 is substantially the same as that of the sheet.
By vacuum moulding using the negative-mould method, no core mould is required, so that the material thickness can be adjusted as desired. The relatively rigid rim 2 of the receptacle 3 permits handling of the container 1 without damaging the thin walls or base of the receptacle. Moreover, the rim 2 forms an ideal connection surface for the lid 13 which must be attached thereto in an air-tight manner. The lid 13 may be stuck to the rim 2 by means of a double-sided adhesive tape. Alternatively, it can be welded to the receptacle rim 2 by means of a heat-welding machine. The lid 13 is also made by vacuum moulding.
In place of an adhesive foil or a tear-off strip, other types of seal are possible. Thus, the rim 14 of the lid can be provided with lugs or recesses 18, which engage over the reinforcing rim 2 of the receptacle 3, and provide a snap-action seal which can be opened when necessary.
Although the inherently rigid container of the invention is preferably of two-part construction, that is to say it consists of a receptacle 3 and a separate lid 13, it is possible to produce a container as a one-piece article. In this form of construction, (see FIG. 5), a break-away edge 20, which preferably takes the form of an extended channel 24 is provided between the rim 2 of the receptacle 3 and the rim 14 of the lid 13. In this case, the edge 20 may be provided with a row of perforations. The perforations facilitate bending of the lid 13 relative to the receptacle 3, and the remaining thicker portions of the edge 20 stiffen the connection and so increase security during transport.
Obviously, the containers described above could be modified in a number of ways. For example, the receptacle 3 could be of double-walled formation. In other words, two receptacles could be pushed one into the other so that a sufficiently large gap is left between their respective side walls that hypodermic syringes or other pointed objects which may be in the refuse cannot penetrate to the exterior and cause injuries to personnel. Where the receptacle is of double-walled formation, the interspace between the walls can be filled with an inert gas. This is particularly useful where the container is used to transport strongly oxidising materials. Alternatively, the interspace could be foam-filled.
Moreover, the lid could be modified by providing inwardly-extending indentations which enable the lid to be snapped shut.
Where the lid is provided with a tear-off strip, the container can also be used for the bulk storage of large packages of chemicals, powder, foodstuffs etc.
The container described above could be used as a cold or "thermos" container. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION(S)
The present application claims priority under 35 U.S.C. §365 to International Patent Application No. PCT/KR2012/000148 filed Jan. 6, 2012, entitled “METHOD AND APPARATUS FOR MEASURING SYSTEM SIGNAL”. International Patent Application No. PCT/KR2012/000148 claims priority under 35 U.S.C. §365 and/or 35 U.S.C. §119(a) to Korean Patent Application No. 10-2011-0001840 filed Jan. 7, 2011 and which are incorporated herein by reference into the present disclosure as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system signal measurement method and apparatus.
2. Description of the Related Art
The mobile communication systems targeted by the present invention may include the 1 st Generation analog, the 2 nd Generation digital, the 3 rd Generation IMT-2000 high speed multimedia service, and the 4 th Generation ultrahigh speed multimedia service mobile communication systems.
Among the 3 rd generation mobile communication systems, CDMA HRPD (High Rate Packet Data) system and WCDMA HSPA (High Speed Packet Access) are representative mobile communication systems having the channel formats for high data rate. The CDMA HRPD system is the system using Code Division Multiple Access (CDMA).
FIG. 1 is a diagram illustrating architecture of conventional HRPD system.
The HRPD system includes a Packet Data Service Node (PDSN) 101 connected to the Internet for transmitting high speed packet data to the base station 103 and a Packet Control Function (PCF) for controlling the base station 103 . The base station 103 performs radio communication with plural terminals 104 and transmits high speed packet data to the terminal having the best data rate.
The 4 th Generation mobile communication system evolved from the 3 rd Generation mobile communication system such as HRPD system aims at the data rate of 20 Mbps or higher for high speed multimedia service. The 4 th generation mobile communication system uses the orthogonal frequencies scheme such as Orthogonal Frequency Division Multiplexing (OFDM). LTE and LTE-Advanced (LTE-A) systems are under the standardization process as representative 4 th generation mobile communication systems.
FIG. 2 is a diagram illustrating architecture of a typical LTE system.
The LTE system performs radio communication with plural UEs 201 and includes eNBs 202 for providing high speed multimedia service, MME/S-GWs (Serving Gateway) 203 responsible for managing UE mobility, call processing, and data path management, and a Packet Data Network Gateway (PDN-GW or P-GW) 204 connected to Internet and delivers the high speed packet data to the UE 201 via the eNBs 202 .
With the advance of communications technologies, it is a tendency that conventional standalone devices operating without connection to a communication network such as control devices, metering devices, and electric appliances are being connected through wired and/or wireless communication system. Such devices connected to the communication system are capable of metering without human intermediary so as to improve efficiency and reduce maintenance cost.
Compared to the conventional human-centric communication, the communication between the communication system and the control devices, metering devices, and electric appliances are referred to as Machine to Machine (M2M) communication. In the early 1990s when the concept of M2M communication has been introduced, the remote control and telematics are considered as the examples of M2M communication and the related market has been also very limited. However, the M2M communication technology has grown rapidly to be widespread all around world as well as in our country for with the diversification of M2M-capable devices for last a few years. Particularly, the M2M communication gives a large influence in the fields such as Point Of Sales (POS) and Fleet Management in security-related application market, remote monitoring of machine and equipment, and smart metering for measuring operation time of construction equipment and metering heat and electricity consumption.
The M2M terminal has several characteristics as compared to the convention terminal. Among them, the representative characteristics are as follows.
1. The devices such as controller and moves not at all or a sporadically.
2. Some M2M terminals may perform communication of data for predetermined time duration.
3. Some M2M terminals are tolerable to delay in data communication (delay tolerant).
4. Some M2M terminals are not necessary to have voice telephony function.
5. The M2M terminal is not necessary to receive paging from the mobile communication system and but capable of requesting for connection setup when data communication is required.
6. There may be the M2M terminals greater than the conventional communication terminals in number in the area with high density population as the M2M devices are diversified.
7. The battery-powered M2M device is required to consume the battery efficiently because it may not allowed for changing the battery frequently. That is, the M2M device has to be designed to consume the power efficiently.
In the case of the M2M device operating without paging, there is no need of monitoring the messages transmitted by the eNB frequently to receive the paging. In this case, it is possible to achieve its object only by receiving the control channel sporadically to acquire the system information transmitted by the system. It is also very important technique for securing high power utilization efficiency to reduce the frequency of receiving the control channel.
In order to introduce such an operation in the LTE system, a method for increasing the system observation period in the idle state has been introduced. The period at which the UE observes the system in idle state is referred to as Discontinuous Reception (DRX) period.
FIG. 3 is a diagram illustrating the DRX periods of the conventional terminal and the M2M terminal.
In FIG. 3 , the horizontal axis 301 denotes system frame number as transmission period of LTE. The M2M terminal may be designed to have the DRX period 303 which is relatively long as compared to that of the conventional terminal.
In the LTE system, the radio channel observation period is defined in association with the DRX period. That is, the UE perform received signal strength of the radio channel as many as given in the DRX period. Accordingly, if the DRX period is elongated, this means that the conventional channel variation monitoring period is elongated too and, as a consequence, the terminal cannot reflect the change in radio environment immediately. That is, even when aggregating multiple radio channel measurement results to determine cell reselection in the bad channel environment, the cell reselection determination is also delayed due to the long radio channel measurement period. This may cause a problem of paging reception failure for several DRX periods.
DISCLOSURE OF INVENTION
Technical Problem
The present invention has been made in an effort to solve the above problem, and it is an object of the present invention to provide a system signal measurement method and apparatus that is capable of reflecting the ambient environment immediately while consuming the power efficiently.
Solution to Problem
In order to accomplish the above object, a signal measurement method includes determining whether a current subframe corresponds to a measurement period; measuring, when the current subframe corresponds to the measurement period, of a serving cell signal; determining whether current measurement mode is a normal scan mode or a short scan mode for measuring the serving cell signal more frequently than the normal scan mode; determining, when the current measurement mode is the normal scan mode, whether the measured serving cell signal is less than a predetermined low signal threshold; and switching, when the measured serving cell signal is less than the low signal threshold, the current measurement mode to the short scan mode.
In order to accomplish the above object, a terminal includes a controller which determines whether a current subframe corresponds to a measurement period; and a transceiver which measures, when the current subframe corresponds to the measurement period, a serving cell signal, wherein the controller determines whether current measurement mode is a normal scan mode or a short scan mode for measuring the serving cell signal more frequently than the normal scan mode; determines, when the current measurement mode is the normal scan mode, whether the measured serving cell signal is less than a predetermined low signal threshold, and switches, when the measured serving cell signal is less than the low signal threshold, the current measurement mode to the short scan mode.
Advantageous Effects
According to an embodiment of the present invention, it is possible to provide a system signal measurement method and apparatus capable of reflecting the adjacent environment quickly while using the power efficiently.
According to an embodiment of the present invention, a M2M terminal is capable of selecting the best eNB quickly in a bad channel environment so as to avoid failing connection setup or missing SMS message.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating architecture of conventional HRPD system.
FIG. 2 is a diagram illustrating architecture of a typical LTE system.
FIG. 3 is a diagram illustrating the DRX periods of the conventional terminal and the M2M terminal.
FIG. 4 is a diagram illustrating a DRX period configuration procedure according to an embodiment of the present invention.
FIG. 5 is a flowchart illustrating the signal measurement procedure of the M2M terminal according to the first embodiment of the present invention.
FIG. 6 is a flowchart illustrating the signal measurement procedure of the M2M terminal according to the second embodiment of the present invention.
FIG. 7 is a block diagram illustrating the configurations of the terminal 730 and the eNB 700 according to an embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Exemplary embodiments of the present invention are described with reference to the accompanying drawings in detail. The same reference numbers are used throughout the drawings to refer to the same or like parts, and Detailed description of well-known functions and structures incorporated herein may be omitted to avoid obscuring the subject matter of the present invention. Further, the following terms are defined in consideration of the functionality in the present invention, and may vary according to the intention of a user or an operator, usage, etc. Therefore, the definition should be made on the basis of the overall content of the present specification.
As aforementioned, it is proposed to increase the DRX period as the system observation period in idle mode to support the characteristics of the M2M terminal efficiently. In the LTE system, the radio channel listening period is in interoperation with the DRX period. That is, the terminal measures the received signal strength as many as given in the DRX period. Accordingly, when the DRX period is extended, the channel variation observation period is extended too and, as a consequence, the terminal cannot reflect the change in ratio environment immediately.
In order to solve this problem, the present invention proposes a method for the M2M terminal to change the signal measurement period according to the ambient channel environment including the serving eNB so as to reflect the channel condition immediately.
FIG. 4 is a diagram illustrating a DRX period configuration procedure according to an embodiment of the present invention. The M2M terminal measures signals at every DRX cycle as denoted by reference number 401 . In the following description, the state of measuring signals as many as a predetermined number of times is referred to as “Normal scan mode.”
Afterward, the M2M terminal detects that the received signal strength of the serving eNB is less than a predetermined low threshold as denoted by reference number 402 . In this case, the M2M terminal reduces the signal measurement period to a value negotiated between the eNB and the terminal (a value less than the original period) so as to perform measurement frequently. In the following description, this state of measuring the signals more frequently is referred to as “Short scan mode.”
The M2M terminal detects that the received signal strength from the serving eNB is greater than a predetermined high threshold as denoted by reference number 403 . In this case, the M2M terminal recovers the measurement period to the original length. In the case of changing the communication target to a new eNB (reselection), it may recover the signal measurement period to the original signal measurement period (normal scan mode) at the timing 403 .
The present invention proposes a method for changing the DRX period according to the channel condition to change the signal measurement period. At this time, the number of signal measurement times may be maintained identically within the DRX period. Also, the present invention proposes a method for changing the number of measurement times within the DRX period while maintaining the DRX period.
FIG. 5 is a flowchart illustrating the signal measurement procedure of the M2M terminal according to the first embodiment of the present invention.
Referring to FIG. 5 , the M2M terminal determines whether it is operating in the DRX mode at step 501 . If it is not in DRX mode, the terminal performs the operation as specified in legacy LTE. Since the legacy LTE operation is well-known, detailed description thereon is omitted herein. If the terminal is operating in DRX mode, the procedure goes to step 502 .
The M2M terminal determines whether the subframe k corresponds to the signal measurement period at step 502 . If the subframe k does not correspond to the signal measurement period, the terminal performs the operation specified in the legacy LTE. If the subframe k corresponds to the signal measurement period in DRX mode, the procedure goes to step 503 .
The M2M terminal performs signal measurements for neighbor eNBs at step 503 . Next, the terminal performs filtering by reflecting a certain ratio of newly measured value to the previous measurement value of the adjacent signals at step 504 . The terminal uses the value filtered at step 504 as the measurement value to the neighbor eNB. The filtering operation of step 504 may be omitted. Afterward, the terminal determines whether it operates in short scan mode for receiving the adjacent signals at the short period at step 505 . If it is not operating in the short scan mode, the procedure goes to step 506 .
The terminal determines whether the signal measurement value of the serving eNB which is observed for call reception is less than the low threshold (threshold_a) at step 506 . If the signal measurement value of the serving eNB is less than the low threshold, the procedure goes to step 507 . The terminal initializes the previously stored measurement values at step 507 . The terminal sets the DRX period to a value negotiated with the eNB at step 508 . The DRX period may be set to a value less than the period for the normal scan mode at step 508 . The terminal also sets the signal measurement period for the short scan mode at step 508 . The steps subsequent to step 508 follow the operations of legacy LTE. If the signal measurement value of the serving eNB is equal to or greater than the low threshold at step 506 , the subsequent process follows the operation of legacy LTE.
If it is operating in the short scan mode at step 505 , the procedure goes to step 509 . The terminal determines whether the signal measurement of the serving eNB is greater than a predetermined high threshold (threshold_b) at step 509 . If the signal measurement of the serving eNB is greater than the high threshold, the procedure goes to step 510 .
The terminal resets the DRX period to the period for the legacy normal scan mode and switches the adjacent signal measurement mode to the normal scan mode at step 510 . The steps subsequent to step 510 follow the operations specified in the legacy LTE system.
If the signal measurement value of the serving eNB is equal to or less than the high threshold at step 509 , the procedure goes to step 511 . The UE performs operation associated with the serving eNB at step 511 . The operation at step 511 is out of the scope of the present invention, detailed description thereon is omitted herein. The terminal determines whether a new serving eNB is selected as a result of step 511 at step 512 . If a new serving eNB is selected, the procedure goes to step 510 . As described above, the terminal resets the DRX period to the value for use in the normal scan mode and switches the adjacent signal measurement mode to the normal scan mode at step 510 . If no new serving eNB is selected at step 512 , the terminal performs the subsequent operation as specified in the legacy LTE.
FIG. 6 is a flowchart illustrating the signal measurement procedure of the M2M terminal according to the second embodiment of the present invention.
Referring to FIG. 6 , the M2M terminal determines whether it operates in the DRX mode at step 601 . If it is not in the DRX mode, the terminal performs the operation specified in the legacy LTE. Since the legacy LTE operation is well-known, detailed description thereon is omitted herein. If the terminal is operating in DRX mode, the procedure goes to step 602 .
The M2M terminal determines whether the subframe k corresponds to the signal measurement period at step 602 . If the subframe k does not correspond to the signal measurement period, the terminal performs the operation specified in the legacy LTE. If the subframe k corresponds to the signal measurement period in DRX mode, the procedure goes to step 603 .
The M2M terminal performs signal measurements for neighbor eNBs at step 603 . Next, the terminal performs filtering by reflecting a certain ratio of newly measured value to the previous measurement value of the adjacent signals at step 604 . The terminal uses the value filtered at step 604 as the measurement value to the neighbor eNB. The filtering operation of step 604 may be omitted. Afterward, the terminal determines whether it operates in short scan mode for receiving the adjacent signals at the short period at step 605 . If it is not operating in the short scan mode, the procedure goes to step 606 .
The terminal determines whether the signal measurement value of the serving eNB which is observed for call reception is less than the low threshold (threshold_a) at step 606 . If the signal measurement value of the serving eNB is less than the low threshold, the procedure goes to step 607 . The terminal initializes the previously stored measurement values at step 607 .
The terminal sets the DRX period to a value regardless of the DRX period negotiated with eNB at step 608 . That is, the terminal may set the number of neighbor signal measurement within the DRX period to a value greater than a predetermined number. The terminal is also set to the period for measuring and determining the ambient signal strength to a length shorter or longer than the predetermined time. Also, it is possible to weight the value measured newly by changing the filtering scheme as compared to the previously measured signal so as to be applied to the final measurement value more significantly. The terminal sets the short scan mode for the adjacent signal measurement afterward at step 608 . The process subsequent process of step 608 follows the operation of the legacy LTE. If the signal measurement value of the serving eNB is equal to or greater than the low threshold at step 606 , the subsequent process follows the operation of the legacy LTE.
If it is operating in the short scan mode at step 605 , the procedure goes to step 609 . The terminal determines whether the signal measurement of the serving eNB is greater than a predetermined high threshold (threshold_b) at step 609 . If the signal measurement of the serving eNB is greater than the high threshold, the procedure goes to step 610 .
The terminal resets the signal measurement-related settings to the values for use in the legacy normal scan mode and switches the neighbor signal measurement mode to the Normal scan mode at step 610 . The process subsequent to step 610 follows the operation of the legacy LTE system.
If the signal measurement value of the serving eNB is equal to or less than the high threshold at step 609 , the procedure goes to step 611 . The UE performs operation associated with the serving eNB at step 611 . The operation at step 611 is out of the scope of the present invention, detailed description thereon is omitted herein. The terminal determines whether a new serving eNB is selected as a result of step 611 at step 612 . If a new serving eNB is selected, the procedure goes to step 610 . As described above, the terminal resets the DRX period to the value for use in the normal scan mode and switches the adjacent signal measurement mode to the normal scan mode at step 610 . If no new serving eNB is selected at step 512 , the terminal performs the subsequent operation as specified in the legacy LTE.
FIG. 7 is a block diagram illustrating the configurations of the terminal 730 and the eNB 700 according to an embodiment of the present invention.
According to an embodiment of the present invention, the eNB 700 includes a scheduler & controller 710 , a Radio Frequency (RF) unit 720 , and a data queue 715 . According to an embodiment of the present invention, the terminal includes a transceiver 735 , a demodulator 740 , a decoder 750 , a controller 760 , an encoder 755 , and a modulator 745 .
The controller 710 of the eNB 700 configures the parameters for controlling the signal measurement period such as thresholds and setting values and DRX period for use in one of the embodiments of the present invention. The control unit 710 may configure the parameter values in the middle of or after the connection setup, in negotiating the configuration values related to the radio access between the terminal 730 and the eNB 700 , or based on the broadcast to all terminals within the coverage of the eNB 700 . The data queue 715 of the eNB 700 stores the data received from a higher layer network node for per terminal or service. The scheduler & and controller 710 controls the user-specific or service-specific data inconsideration of the downlink channel condition, service properties, and fairness provided by the terminals. The RF unit 720 sends the selected data signal or control signal to the UE 730 .
The controller 760 of the terminal 730 increases or decreases the signal measurement period based on the channel condition of the neighbor eNBs as well as the serving eNB according to any of embodiments of the present invention. If a new serving eNB is selected, The controller 760 resets the signal measurement period to the initial value. The terminal measures the signals received by the transceiver 735 at the measurement period determined by the controller 760 . The terminal 730 demodulates the received signal by means of the demodulator 740 , decodes the demodulated signal by means of the decoder, and determines and processes the decoded signal by means of the controller 760 . The encoder 755 encodes the data to be transmitted, and the modulator 745 modulates the encoded data.
INDUSTRIAL APPLICABILITY
Although the description has been made with reference to particular embodiments, the present invention can be implemented with various modification without departing from the scope of the present invention. Thus, the present invention is not limited to the particular embodiments disclosed but will include the following claims and their equivalents. | 4y
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FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a closure system, particularly for door locks, in which the closing of the lock determined by mechanically or magnetically controllable tumblers is variable in that a closure code of the lock corresponds initially to a coding of a first key, and can be varied by reshifting of at least one tumbler element within the lock to the coding of a successor key.
In the known devices of this type which operate on the basis of magnetic release of the closure (European Patent 24 242), the recoding is effected by a tool, for instance in the form of an insertion key, which can be inserted from the outside into the lock through an opening in the lock cover. This key engages into the center of a rotatable carrier. In the rotatable carrier there is located at least one permanent magnet which forms a tumbler element. The carrier can be held detained in different angular positions. Each of the angular positions incorporates a different magnetic coding of the lock. This type of recoding is user-unfriendly and impairs the dependability of operation, including security against breaking-in. In this connection there is the danger, in particular, that an unauthorized person will effect the turning of the carrier by means of a tool and that the lock can no longer be opened by the key which was previously intended for it.
Considerable difficulties can arise if it is not known, in particular upon the existence of several turnable carriers, into what position they have been turned. These possibilities by themselves make it necessary that the possibility of resetting the lock not be made known, insofar as possible, to all users of the lock and that this knowledge and the corresponding tool remain restricted to certain trusted individuals. Accordingly, the recoding of the lock can also not be included in the continuous, normal course of operation as is, for instance, frequently the case in hotel locking systems which operate purely electrically. In those locks which operate with pure magnetic-track coding and on an electronic basis, in order to increase the security of electronic basis and of operation, recoding has been proposed in the manner that a key dispensing device which is present at the hotel reception desk issue a different key in a certain updating program or the like for, in each case, the next-following guest in such a manner that the hotel door lock, after the use of this new guest key, no longer accepts the preceding guest key as a suitable key (cf. Federal Republic of Germany Patent 24 01 602). If, in this connection, wires from the dispensing computer at the reception desk up to each hotel door lock are to be avoided, the hotel door lock must have a corresponding updating program stored in it. This greatly complicates such a lock system. That version, on the other hand, also requires sources of voltage in each individual hotel door lock and includes the disadvantage that disturbances in operation occur when a guest does not enter his room at all with a newly issued key and leaves the hotel without entering the room, in which case the next following guest receives a key which the room door lock cannot accept since the intermediate guest key never became known to it.
In the case of structural forms of locks operating on the basis of mechanical release of the lock and which can be closed with multi-bit keys, a recoding of the closing code of the tumblers is known in the form that upon operation with the first key a barrier must, in addition, be released manually, it eliminating a basic position of the tumblers which is secured by combination engagement, whereupon, upon operating the lock by means of a successor key, the setting of the tumblers to the closing code of the successor key is effected, including the restoring of the combination engagement. These structural forms also have the same disadvantages from the standpoint of operation. If the key is lost, the only thing possible is to destroy the lock.
It is furthermore known from U.S. Pat. No. 3 234 768 to effect a permutation change on cylinder locks. In connection with one of the pin tumblers of this solution, a tumbler member in the form of a ball is provided between core pin and housing pin. At the height at the place of separation between the pin bore and the turning gap of the cylinder core, the closure cylinder housing forms a channel which extends to the outside and the diameter of which is somewhat larger than that of the ball. If this cylinder lock is actuated with a first key, then this key in addition to arranging the other pin tumblers, arranges the special pin tumbler in such a manner that the place of separation between ball and housing pin lies at the height of the core turning gap. If this first key is to be blocked out, this can be done with a successor key, the so-called occupants key. By means of the latter, upon the key insertion movement, in addition to the other pin tumblers, the special tumbler is controlled in such a manner that the place of separation between core pin and ball is located at the height of the core turning gap. Upon the following closure turning, the ball passes outward through the channel. The special pin tumbler then operates in the same way as the others. A closing action can no longer be effected by means of the first key. Furthermore no further permutation change can be obtained unless the ball is introduced again in some way.
SUMMARY OF THE INVENTION
The object of the present invention is so to develop a closure system of the type set forth in the introductory paragraph above in which, dispensing with actuation by a tool or hand knob, it is possible to effect a recoding which, in particular, as a result of the use of a compulsory sequence in the use of the keys, can, with the least possible expense, also be included in the normal operating use of the closure system and therefore, for instance, in the case of hotel closure systems, be placed also within the field of competence of the guests. According to the invention the displacement of the tumbler member by means of the corresponding successor key is effected in the manner that the successor key is divided into a first region (e.g. A) which is associated exclusively with the closure code of the tumblers and a second, supplementation region (e.g. E) which enters into action when the first region agrees with the closure code of the tumblers, the supplementation region shifting the tumbler element into the position actuated by the supplementation region of the next successor key.
As a result of this there is created a closure system in which the successor key in each case effects the recoding in positive manner, i.e. solely by its use. The lock housing therefore need no longer have, for instance, any special additional tool entrance openings Safety against breaking-in and misuse is improved since the recoding cannot be effected by just any insertion tool. The possessor of the key therefore need not even know that he has received a key which effects the resetting. With this key he actuates the lock in customary manner without knowing that a recoding is effected upon this actuation. The predecessor key is blocked out; a resetting to its code by using it is therefore not possible.
One can therefore, in this way, with relatively minimum expense, arrive at a possibility of recoding which permits the optimal use of such locks in hotel closure systems. In each case, the next guest decodes his hotel room lock by the first opening actuation with the key which he has received so that the key of the previous hotel room guest can no longer close the lock. The successor key is from then on the normal key. There is also a necessary sequence in the use of the successor keys. The skipping over of the successor key is not possible. This has the result in practice that the successor keys can be inserted only in sequence, one after the other, which considerably reduces misuse. If for instance, a successor key is skipped over, then the corresponding tumbler member can not be engaged by the supplementation region of the previously issued successor key. The tumbler member namely, has not yet been shifted in position by the proper successor key. This system is furthermore suitable in connection with cylinder locks. After a change in the position, the tumbler member is still always in a position which can be engaged by the successor key. The tumbler member, in contradistinction to the cylinder locks of the prior art is therefore, after use of the successor key, still included in the permutation of the lock. In this way, there is advantageously obtained a rhythmic recurrence, a so-called repeat, in the change in position of the tumbler members, both in the case of locks with mechanical coding and in the case of locks with magnetic coding.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages and details will become evident from the following description of various embodiments of the invention which are shown in the drawing, in which:
FIGS. 1 to 17 show mechanically operating structural forms;
FIGS. 18 to 27 show a structural form which cooperates with a multi-bit key; and
FIGS. 28 to 39 show a structural form which also operates mechanically and has a closure cylinder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The description is divided into three sections corresponding to the three categories of structural form. The first category of structural form is now described.
In detail,
FIG. 1 shows a lock adapted to be fastened to a door and having a key in the form of a card,
FIG. 2 is a top view of FIG. 1,
FIG. 3 shows the lock of the first embodiment in a larger view, partially in longitudinal section and partially in elevation, before the insertion of the key,
FIG. 4 is a section at the level of one wide side of the pusher, showing the carriers which are in toothed engagement with each other,
FIG. 5 is a section along the line V--V of FIG. 4,
FIG. 6 is a showing corresponding to FIG. 4 but with the carriers turned forward one step after displacement of the pusher by means of a command key,
FIG. 7 is a section along the line VII--VII in FIG. 6,
FIG. 8 is a top view of the pusher in accordance with the second embodiment, shown on a larger scale,
FIG. 9 is a greatly enlarged detail view of a portion of the pusher in the region of the carrier and of the control member associated with it, arranged on the housing side,
FIG. 10 is an intermediate position upon the forward displacement of the pusher, with the control member swung by the control magnet,
FIG. 11 shows the following intermediate position, indicating the forced turning movement of the carrier,
FIG. 12 shows the pusher in the completely advanced position,
FIG. 13 is a partial top view of the pusher with carrier and the multi-member pawl turning it, referring to the third embodiment,
FIG. 14 is a cross section through the pusher at the height of a permanent magnet which is arranged in the manner of a pendulum, referring to the fourth embodiment,
FIG. 15 is a top view of FIG. 14,
FIG. 16 is a cross section through the pusher at the height of a permanent magnet which can be displaced by 180° around a transverse axis, and
FIG. 17 is a top view of FIG. 16.
In all the magnetically operating embodiments, the lock shown in FIGS. 1 and 2 has an elongated lock housing 1 associated with a door (not shown). At its one end, the housing has a rotatable knob 2 by means of which a latch or bolt can be pulled back if the lock is in locking position.
The knob 2 can be coupled with a push pin 3 of square cross section which is the carrier of an inner knob (not shown) lying on the inside of the door. By means of this knob the latch or bolt (not shown) can be pulled back at any time.
In order to be able to actuate the lock from the outside of the door, the lock housing is provided on the edge side opposite the turn knob 2 with an insertion slot 4 into which a card-shaped key 5 can be inserted. The key 5 is a card provided with magnetic coding which is of sufficient stiffness in order to be able by means of it to displace a pusher 6 which is guided within the lock housing 1.
The pusher 6 is received by an inner housing 7 which is inserted into the lock housing 1 and bears two guide plates 8 and 9 which are arranged parallel to the pusher 6. The guide plate 8 is a plate consisting of ferromagnetic iron while the other guide plate is anti-magnetic. The guide plate 8 is thicker than the guide plate 9 which is adjacent to it, and it is acted on by a leaf spring 10 which, on its part, rests against the bottom 11 of the inner housing 7. Before the insertion of the key 5, the guide plates 8, 9 lie flat against each other. If the key 5 enters between the guide plates 8 and 9, the guide plate 8 moves out, under spring action, in the direction towards the bottom 11.
The antimagnetic guide plate 9, on its part, rests against a blocking plate 12 consisting of non-magnetizable material. In the embodiment shown, brass is used for the blocking plate. In the blocking plate 12 there are, suitably distributed, circular blocking openings 13 which, in the initial position of the pusher 6, correspond to blind holes 14 in the latter. In some of the blind holes, pin-shaped permanent magnets 15 are introduced which, in their turn, are attracted by the guide plate 8 and pass through the blocking openings 13. Depending on their arrangement, the permanent magnets, in this case, act with their south pole or north pole on the guide plate 9. Accordingly, the pusher 6 cannot be displaced. Furthermore, it is under the action of a tension spring 16 which urges it in the direction towards the insertion slot 4. The tension spring 16 is connected at one end to a pin 17 of a cover 18 covering the pusher 6 and on the other end to a control projection 19 extending from the pusher 6. The projection is provided with an oblique surface 20 by means of which, upon forward displacement of the pusher 6, a leaf spring 21 which is fastened to the inner housing 7 at the height of the insertion slot 4 can be shifted in the direction indicated by the arrow X, it carrying along with it a coupling sleeve 22 and thereby bringing the turn knob 2 into a coupling position with the push pin 3, which then permits the door to be opened.
The forward displacement of the pusher 6, however, is possible only after insertion of the proper key 5 which, in the completely inserted position, rests with its edge side 5' against a drive shoulder 23 of the pusher, said shoulder lying towards the inside of the lock. In the key-insertion position, the corresponding permanent magnets 15 are then aligned with correspondingly positioned magnetization regions of the key. In this way, the permanent magnets are repelled in the direction towards the blind holes 14 and accordingly leave the blocking openings 13 of the blocking plate 12.
In order to change the magnetic closing code, the pusher 6 in accordance with the first embodiment has four turnable carriers 24, 25, 26, 27 which are coupled with each other and each of which is provided with a recoding magnet 28, 29, 30, 31 developed as tumbler member. On the outside, the carriers 24 to 27 are provided with a toothing by which they are in toothed engagement with each other. In order to receive the carriers, holes 32 of suitable diameter are provided in the pusher 6. The carriers, each of which is provided with a recoding magnet, are so arranged with respect to each other that the recoding magnets, due to the turning motion of the carriers, move one after the other in each case into the position in front of an obstacle or out of said position. The obstacle 33 is formed by a transverse edge of a longitudinal groove 34 which extends in the direction of displacement y of the pusher 6. Since four recoding magnets or tumbler members are present, four such longitudinal grooves 34 are also provided. They are located in the cover 18 of the inner housing 7 which covers the pusher 6. The two longitudinal grooves 34 which are arranged further inward in the lock have a greater distance from each other than the other two longitudinal grooves 34.
However, of the four recoding magnets 28 to 31, only one in each case acts as true coding magnet or true tumbler member. In accordance with FIGS. 4 and 5, this is the recoding magnet 28. With its end which faces the blocking plate 12, it extends, when the successor key 36 is not inserted, into a longitudinal slot 35 lying in direction of displacement in the blocking plate 12. The other recoding magnets 29, 30, 31 can then extend into corresponding blocking openings 13 of the blocking plate 12 so that they assume in this case a function similar to the permanent magnets.
If the lock is associated, for instance, with a hotel-room door, the guest has a guest key which is comparable to the key 5. With it, all permanent magnets 15 and recoding magnets 29, 30, 31 are so displaced that they come out of engagement with the blocking openings 13. In this way, the pusher 6 can be pushed in the direction of the arrow y, producing a coupling with the turn knob 2. Only the recoding magnet 28 or tumbler member is not shifted in this case. Movement of the pusher is nevertheless possible due to the longitudinal slot 35 in the blocking plate 12.
If another guest moves into the hotel room which was previously used, then a recoding of the lock is effected prior to this by the hotel, using the command key shown in FIG. 5, which serves as successor key. It has a first region E which causes the resetting. The corresponding regions are shown in dash-dot line in FIG. 5. By means of the first region A all permanent magnets, and by means of the supplementary region E also the recoding magnet 28 or tumbler member, are brought out of engagement with the blocking plate 12. The recoding magnet 28 therefore extends into the longitudinal groove 34. Upon the following displacement of the pusher in the direction indicated by the arrow y by means of the successor key 36, the corresponding end of the recoding magnet 28 then comes against the obstacle 33 of the longitudinal groove 34 and thereby forces the turning of the carrier 24 and of the other carriers meshing with it in the direction shown by the arrow. After a displacement of the pusher 6, the position shown in FIGS. 6 and 7 is reached. The previous recoding magnet 28 has left its position of alignment with the longitudinal groove 34 while the recoding magnet 29 of the carrier 25 has come into the recoding position. It is therefore no longer possible to effect a displacement of the pusher by means of the previous guest key because the recoding magnets or tumbler members have changed position. Furthermore, the new guest must be issued a modified guest key by means of which he can suitably displace all magnet except for the recoding magnets 29. By means of a successor key 36 of the hotel, which also has the regions A and E, also this recoding can be changed again, in which case another recoding pin then comes into the corresponding recoding position; see FIG. 7.
Variations with respect to this embodiment are possible in the manner that the number of carriers is changed. It is also possible to provide each carrier with more than one recoding magnet.
In accordance with the second embodiment, shown in FIGS. 8 to 12, the pusher is designated by the numeral 37. Its construction corresponds to the pusher 6. One change is that the pusher now receives two carriers 38 and 39 which lie alongside each other at the same height. On its end facing away from the insertion slot, each carrier 38, 39 is continued in a switch cam 40 which extends over the corresponding wide surface 37' of the pusher and which forms switch cam edges 41, 42, 43, 44 which, in their turn, are arranged in the manner of a Maltese cross. Each carrier 38, 39 also receives a recoding magnet 45 which is similar to a tumbler member and cooperates with a corresponding blocking opening in the blocking plate 12.
The Maltese-cross-like switch cam 40 passes through an inner opening 46 in a control member 47 which is fixed in position. The mounting pin 48 thereof is seated in suitable manner on the cover 18 of the inner housing 7. The mounting place of the single-arm control member 47 faces, in this connection, the direction of insertion of the key. By an edge which lies approximately perpendicular to the direction of displacement of the pusher 37, the inner opening 46 forms an obstacle 49. The inner opening 46 is so developed that, in the starting position of the pusher, three corners of the Maltese cross form stop surfaces for two inner opening walls 50, 51 which are at right angles to each other. Furthermore, there is also provided on this pusher 37 a stop 52 against which the rear edge 53 of the control member 47 comes. In this way, the latter is secured against turning. Upon displacement of the pusher, this securing is only eliminated when the control magnet 54 has passed, for instance, through the idle stroke. The stop 52 together with the edge 53 also effects the last part of the remaining rotation of the Maltese cross into the basic position shown in FIG. 8 upon the return displacement of the pusher.
At the height of the mounting place of the control member 47, a suitably polarized control magnet 54 is guided in the pusher 37. Upon the use of a normal key, for instance a guest key, this control magnet 54 is not displaced since the end of the control magnet 54 which faces the blocking plate extends in a longitudinal slot in the blocking plate 12.
If a recoding of the lock is to take place, a successor key is to be used as in the case of the preceding embodiment. By the corresponding regions thereof the permanent magnets, the tumbler-member-like recoding magnet 45 and the control magnet 54 are brought out of engagement with the blocking plate. After passing through a small idle stroke, the end of the control magnet 54 which extends beyond the wide surface 37' of the pusher strikes a control flank 55 of the control member 47 and lifts the latter into the position shown in FIG. 10. In this way, the result is obtained that the obstacle 49 then lies at the height of the switch-cam edge 41. Upon further displacement of the pusher 37 the position shown in FIG. 11 is reached. From that Figure it can be noted that the carrier 39 is turned by the obstacle 49 in the direction indicated by the arrow. After complete forward displacement of the pusher 37, the position shown in FIG. 12 is then present. In this position, the carrier 39 and the recoding magnet 45 accordingly assume a different position of angular rotation. If the pusher 37 is now brought again into its starting position, the aforementioned remaining rotation of the carrier 39 takes place, so that the recoding magnet 45 is then aligned with another blocking opening in the blocking plate. The guest key which was previously used then no longer arranges this relocated recoding magnet and the pusher 37, accordingly, cannot be displaced forward in order to open the lock. If the hotel room door is locked, then the next guest is to be issued a correspondingly coded key.
In the case of the modified third embodiment shown in FIG. 13, the control member 56 is developed in the manner of a multi-member pawl. It has an angle lever 58 which is mounted on the housing side by the pin 57. Its one lever arm 58' lies in the region of movement of a control magnet 54. Here also there is a short idle stroke between the control magnet 54 and the lever arm 58'. The other lever arm 58" bears, by means of a pivot pin 59, a pawl lever 60 the locking tooth 61 of which, forming an obstacle, cooperates with the teeth of the carrier 62 developed as a ratchet wheel. This carrier receives a recoding magnet 63 representing the tumbler member. A spring (not shown) urges the angle lever 58 in counterclockwise direction. Its initial position is limited by a stop 64 on the housing side. The pawl lever 60 is also associated with a spring (not shown) which is seated, for instance, on the pivot pin 59 and urges the pawl lever 60 into toothed engagement with the carrier 62.
If the normal key is used, the permanent magnets of the pusher 65 and the holding magnet 63 are brought out of engagement with the blocking plate 12. The control magnet 54 passes, in this connection, through a longitudinal slot in the blocking plate 12 and accordingly does not exert any blocking function.
The change in the closing code is effected in this third embodiment also by means of a corresponding successor key the regions of which displace, in addition to the other magnet pins, also the control magnet 54 and lift it out of the blocking plate. The end thereof which protrudes beyond the wide surface of the pusher 65 thus lies at the height of the lever arm 58' of the control member 56. During the forward movement of the pusher 65, the control magnet 54, after an idle stroke, acts on the lever arm 58 and swings the angle lever 56, the carrier 62, which is mounted in the pusher 65, being turned further as a result of further forward displacement of the pusher 65 and via the pawl lever 60. The recoding magnet 63 is thereby imparted by displacement a different position with respect to the pusher 65. In this position, it is aligned, when the pusher 65 has been displaced backwards, with a blocking opening of the blocking plate 12, so that the previously used key no longer locks. A new key must then, in the case of a lock for a hotel room door, be turned over to the new guest. In this embodiment two similarly shaped carriers 62 with blocking member 56 can also be associated with the pusher 65. A modification of this embodiment could be effected in the manner that instead of the pawl lever 60 an escapement is provided, as in the case of a clockwork. A clock spring which can be wound up is then associated as force storage means with the carrier or its shaft. The lever arm 58 is not necessary in this embodiment. Via the control magnet 54, the escapement, upon the forward displacement of the pusher receives the command to permit the carrier to turn further by one step, which force then results from the clock spring.
In accordance with the fourth embodiment, shown in FIGS. 14 and 15, the pusher is provided with the reference number 66. At least one of the permanent magnets 67 borne by it is guided, by the end thereof facing the blocking plate 12, in a blocking-plate longitudinal-slot opening 69. Parallel to this there extends another blocking-plate longitudinal-slot opening 70. With regard to the permanent magnet 67, it may be a control magnet for a previously described control member. In order to change the closing code, the following guest receives a successor key 68, shown dash-dot line in FIG. 14, which has two adjacent magnetic zones 71, 72 for the permanent magnet 67. These zones form the supplementation region E which effects the resetting. The arranging of the other permanent magnets (not shown) is effected by a first region which is associated with the closing code. The zone 71 is so polarized that it acts in repulsion after the pushing in of the successor key 68. In this way, the permanent magnet or control magnet 67 is pushed into the position shown in dash-dot line in FIG. 14. By the displacement then of the key with the pusher 66, the control member lying in the path of the control magnet 67 is acted upon. After complete forward advance of the pusher, the position shown in dash-dot line in FIG. 15 is reached. In this position there takes place a pendulum displacement of the permanent magnet 67 into the other pendulum position, caused by the magnetic zone 72 of opposite polarity. In order to permit the pendulum-like movement of the permanent magnet 67, the end of the receiving opening 73 which faces away from the key is circular while the opposite end is oval. The longitudinal dimension of this oval is located transverse to the direction of displacement y of the pusher 66. In order that the permanent magnet 67 does not swing prematurely, the blocking plate 12 is provided between the longitudinal slot openings with a thickening, designated 12', in front of which the lower end of the permanent magnet comes upon an attempted displacement. The shifted end 67' is pulled through zone 72 into the adjacent locking-plate longitudinal-slot opening 70 and remains there even upon the further closing actuation by this successor key 68. The key previously used, on the other hand, cannot effect any displacement of the pusher 66. A further resetting can only be caused by a successor key which is issued again and which forms correspondingly magnetized regions.
A modification is possible to the effect that, instead of the control-plate longitudinal-slot opening 69 a circular locking-plate blocking opening is selected. The permanent magnet 67 then acts like the other permanent magnets. After the return of the pusher into its initial position, it always returns to the blocking-plate blocking opening. For the recoding, a successor key is then used which corresponds to the key 68. This means that the pendulum movement takes place in the forward displaced position of the pusher, whereupon the key magnetization or the magnetic zone 72 pulls the shifted end 67' into the blocking-plate longitudinal-slot opening 70. Such an embodiment is then independent of a control function for a carrier.
The fifth embodiment can be noted from FIGS. 16 and 17. The pusher 74 is provided with an elongated recess 75 which extends transverse to its direction of displacement. From the side of the pusher facing the locking plate 12 there extend centrally two mounting recesses 76 which are opposite each other and into which mounting pins 77 extend. These pins are part of a cylindrical sleeve of plastic which surrounds a permanent magnet 78. When the key is not introduced, the polarized end 78' of the permanent magnet 78 which faces the blocking plate 12 is pulled into a blocking-plate longitudinal-slot opening 80 lying in the direction of displacement of the pusher 74, up to the guide plate 9. The blocking-plate longitudinal-slot opening 80 widens in T-shape at the end opposite the insertion slot 4, forming a transverse slot 81.
If a successor key 82 is now inserted the supplementary region E of which causes the resetting has two adjacent zones 83, 84 which are of opposite magnetic polarity, permanent magnet 78 is acted on in repulsion by the zone 83. It thus passes into the position shown in FIG. 16 in which the end 78' facing the key still remains within the longitudinal slot 80. This is obtained in the manner that the mounting recesses 76 limit the movement of the permanent magnet 78. During the forward displacement, the end of the magnet pin which extends beyond the corresponding wide surface of the pusher can serve to control a control member which effects a recoding of a carrier-side coding pin. The permanent magnet 78 thus serves as control magnet. As soon as the permanent magnet or control magnet 78 reaches the transverse slot 81, it swings 180° since it is exposed to the force of attraction of the magnetic zone 84, and it is pulled up into the longitudinal slot 80. Further, use of the successor key 82 then does not lead to any controlling of the permanent magnet 78 and thus to any recoding. This must then again be effected by means of another key in which the magnetic regions are suitably polarized.
If the permanent magnet 78 is not used as control magnet and only one blocking-plate blocking-opening is provided for it, an alternate possibility of closing can be obtained by means of corresponding keys. This means that after locking by means of the one key, locking is possible only by means of another key. Repeated successive locking by means of one key can then no longer be effected
A variant could be obtained in the manner that the key is imparted an additional coding Upon the insertion of the key, the evaluation of this additional coding takes place. If the key has the correct coding then an obstacle by which a recoding is effected is brought into the position of action, whether it be a displacement of a permanent magnet or a displacement of a recoding magnet held by a carrier.
The locking-plate openings and locking-plate longitudinal slots may possibly also be provided in an additional plate. The force accumulator can be so coupled with the pusher that it is wound up to a certain amount by each displacement of the pusher. Since as a result of the more frequent normal key actuation, the pusher is actuated more frequently without a resetting displacement, it results statistically that it never completely discharged.
The structural form operating with a multi-bit key shows in
FIG. 18 a lock in elevation with bolt pushed forward and corresponding successor key,
FIG. 19 a top view of the lock, seen in the direction of the lock cover,
FIG. 20 a longitudinal section through the lock with the successor key inserted,
FIG. 21 a top view of the lock, with the lock cover omitted and with tumblers in locking position,
FIG. 22 a top view of the lock parts, with tumblers omitted and successor key inserted, corresponding to the forward-closed position of the bolt,
FIG. 23 a side view of the lock parts shown in FIG. 22,
FIG. 24 a showing corresponding to FIG. 22 but after a 180° locking rotation of the successor key, in which position the bolt is retracted over a part of the distance and the fixing-tooth carrier is in pushed-back position of release,
FIG. 25 also a showing corresponding to previous FIGS. 22 and 24 with multi-bit key turned more than 180° in the position in which the successor key lifts a swing bolt and also shifts the tumblers,
FIG. 26 a showing similar to the preceding Figures, in which the successor key is turned completely through 360° with bolt moved completely backward and fixing-tooth carrier assuming a locking position,
FIG. 27 a subsequent showing, after FIG. 26, during the forward closing of the bolt.
The lock shown in FIGS. 18 to 27 has a box-like lock housing 85 with a lock bottom 86 and lock-box sidewalls 87, 88, 89 and 90 extending from it. The lock parts mentioned below are covered by a lock cover 91. The latter contains in the center a key insertion opening 92 which extends in the longitudinal direction of the lock.
From the lock bottom 86 there extends centrally a centering mandrel 93 which extends up into the key insertion opening. Between said mandrel and the lock-box sidewall 88 there extends a pin 94 integral with and extending from the lock bottom 86, against which pin the lock cover 91 also rests and into which a lock cover fastening screw engages. The pin 94 serves in part for a longitudinal guiding of a plate-shaped carrier 95 which is provided in the region between the pin 94 and the lock-box sidewall 88 with a fixing tooth 96 This tooth extends up to the bottom of the lock cover 91. In the central region, the carrier 95 is provided with a key-engagement opening 97. Above the latter there is a recess 98 which by means of a lower flank forms a blocking shoulder 98'. A bent portion 99 of a blocking lever 101 mounted below the carrier 95 and spring-urged in direction of engagement by means a leaf spring 102 comes in front of said shoulder.
Flat alongside the carrier 95 there is a bolt 103. It forms a thicker bolt head 103' which passes through the lock-box sidewall 90 and adjoining which there is a thinner bolt tail 103". The end of the latter is slotted for the guiding engagement of the pin 94. The bolt tail 103" is provided at its center with a control opening 104. On the side facing away from the carrier 95 there is present on the bolt a recess 105 to receive a bolt rocker 106. The latter is mounted around a bolt-side bolt 107 and serves in part to form the closure engagement niche 108 of the bolt control opening 104. A leaf spring 106' acts on this bolt rocker 106 in clockwise direction, the rocker receiving support on the lower flank of the recess 105.
Adjoining the bolt head 103' there is a turn 109 which extends in the locking direction of the bolt up to the lock cover 91. In the region between the bolt tail 103" and the turn projection 109 there is a blocking opening 110 for a blocking tooth 111 of a tumbler plate 112 which rests on the bolt tail 103" and is swingable around the pin 94. Above that plate there extend seven tumblers 113 of identical development. In contradistinction to the tumbler plate 112, the point of swing of the tumblers 113 is variable. For this purpose, the region of each tumbler 113 facing the fixing tooth 96 forms an arcuate slot 114 which is passed through by the pin 94. The edge which extends concentrically to the slot 114 is provided with a toothing 115. Depending on the basic position of each tumbler 113, the fixing tooth 96 engages into a corresponding tooth gap. The end of each tumbler 113 and the tumbler plate 112 which is opposite the toothing 115 is provided with a stepped-down turn opening 116. All tumblers form a central control opening 117 and are so acted upon by leaf springs 118 in counterclockwise direction that with the bolt 103 closed they rest on the turn projection 109; see FIG. 21.
With respect to the key shown in the Figures, it is a successor key 119. It has a key shaft 120 and a key handle 121. From the lower end of the key shaft 20 there extends an opening 122 of circular cross section for the entrance of the centering mandrel 93.
In radial direction there protrudes from the key shaft 120 a closing-code bit-step region A. It comprises seven bit steps 123 which serve for the arranging of the tumblers 113. In the extension of the closure-code bit-step region there is a supplementation region E. The bit step 124 which directly adjoins the bit steps 123 serves for the control of the tumbler plate 112. The next, wider bit step 125 is intended for the controlling of the bolt 103. It is then adjoined by a bit step 126 by means of which the release position of the carrier 95 can be brought about. The lowermost bit step 127, on its part, serves for controlling the blocking lever 101. Diametrically opposite the bit steps 124 to 127 the supplementation region E has a drive wing 128 which extends exclusively in the plane of the tumbler plate 112 and of the bolt tail 103". It is adjoined, with the formation of a gap 129 which is arranged at the height of the bit steps 126 and 127, by an anti-pullout wing 130. Furthermore, diametrically opposite the closing-code bit steps 123 there is an additional bit-step region B the bit steps 123' of which incorporate the new closure code.
The manner of closing is as follows:
The key can be removed only when the bolt 103 is pushed forward. If the locking code used, for instance, by a prior user is to be changed, then a prescribed successor key 119 is issued to the following user. It comprises the bit-step regions A, E and B. The bit-step region A corresponds in its locking code to the locking code used for the predecessor key while the additional bit-step region B incorporates the new locking code. Since the anti-pullout wing 130 lies on the same side as the bit-step region B, the wing serves as aid in orientation upon the insertion of the successor key 119 into the lock. The insertion movement is limited by the lock bottom 86 so that the corresponding bit steps are then aligned with the corresponding lock ward parts, see FIG. 20. Upon the locking rotation which then commences, the tumblers 113 are so swung by the bit steps 123 of the region A associated with the locking code that the turn openings 116 thereof lie coinciding one above the other and thus permit the withdrawal of the bolt 103, the turn projection 109 moving into the turn openings 116. This is possible because the tumbler plate 112 is simultaneously brought out of engagement by the bit step 124. During the locking rotation from the position in FIG. 22 into the position in FIG. 24, along with the bit step 125 which strikes a control edge 104', the bolt 103 is pulled back approximately one-third of its total closure path. The step 125 therefore effects a partial displacement of the bolt in order to show the authorization for resetting. Furthermore, the blocking lever 101 is lifted by the bit step 127 of the supplementation region E, its angle part 99 moving away from the blocking shoulder 98'; see the dash-dot showing in FIG. 22. In this way, the carrier 95 is released for displacement. The corresponding displacement of the carrier takes place in the manner that the bit step 126 strikes against a drive shoulder 97' of the key engagement opening 97. The carrying along of the carrier 95 into the position shown in FIG. 24 has the result that the fixing tooth 96 leaves the toothing 115 of the tumblers 113 In this position, which is turned 180°, the anti-pullout wing 130 is also swung below the carrier 95, so that the key can not be withdrawn from this position. Furthermore, the key can no longer be turned back out of this position since the blocking lever 101 has again dropped back into its starting position and thus lies within the region of turn of the bit step 127. The turning of the key in clockwise direction must therefore be continued. In accordance with FIG. 25, the drive wing 128 of the successor key 119 strikes in this connection against the bolt rocker 106. Furthermore, by means of the bit steps 123' of the additional bit-step region B, the spring-actuated tumblers 113 are shifted into their new basic position, as is possible because the fixing pin 96 is still in release position. During the further turning of the successor key 119 into the position shown in FIG. 26 and therefore after movement through a total angle of turn of 360°, the bit-step 126 of the supplementation region E comes against another driver shoulder 97" of the key engagement opening 97 of the carrier 95 and shifts it thus in toward locking direction, the fixing tooth 96 dropping into the corresponding tooth space of the toothing 115 of the tumblers 113 with locking of the different basic positions of the tumblers. Thereupon, during this remaining turning path, the drive wing 128 has entered into the closure engagement niche 108 and has thus completely moved the bolt back. In this position the blocking tooth 11 of the tumbler plate 112 engages into the blocking opening 110 of the turn projection 109, which is not shown. The successor key 119 cannot be withdrawn from this position since the bit-step engages below the carrier 95.
The forward closing of the bolt 103 now requires an opposite closing rotation and therefore in counterclockwise direction. In this connection the drive wing 128 extends into the closure engagement niche 108 of the bolt 103 which is formed in part by the bolt rocker 106 and carries it along with it. The space 129 between the drive wing 128 and the anti-pullout wing 130 has the effect that the key cannot come into to contact with the carrier and the blocking lever. During this closing rotation, the tumblers 113 are also displaced by the additional bit-step region B. After the carrying out of a rearward closing rotation of 180°, the bolt 103 then assumes its forward closed position from which the successor key 119 can be withdrawn. For the reward closing of the bolt, the successor key must then be so inserted that the additional bit-step region B and therefore the new region, lies on the left-hand side. Upon the then following closing rotation, the blocking lever 101 and the carrier 95 are not displaced. Only the tumblers are arranged correctly, so that only the bolt is closed backward via the drive wing 128 of the successor key 119. The rearward closing rotation is completed after about 180° so that the position in accordance with FIG. 26 is then again present.
A key which follows the successor key 119 would then have the appearance that it is provided with the bit-step region B above the bit-steps 124, 125, 126, 127. A new additional bit-step region would then be provided in diametrically opposite position.
From the foregoing it is clear that the change does not affect the supplementation region E. The later remains the same at all times. A variation is effected solely on the first bit-step region associated with the closing code.
It is furthermore to be noted that the supplementation region E of the key enters into action only when the first region, bit-step region A, agrees with the closing code of the tumblers. If such agreement is absent, the tumblers prevent a closing rotation. The third category of structural form is now described. In detail,
FIG. 28 shows a longitudinal section through a lock developed in the form of a closure cylinder, with key of cross-shaped section,
FIG. 29 shows the closure cylinder with key introduced, partially in elevation and partially in a section turned 45°,
FIG. 30 shows in perspective the key used in accordance with FIGS. 28 and 29,
FIG. 31 shows in perspective a successor key of modified embodiment,
FIG. 32 shows the successor key inserted into the closure cylinder,
FIG. 33 is a section along the line XXXIII--XXXIII of FIG. 32,
FIG. 34 is a section along the line XXXIV--XXXIV of FIG. 33,
FIG. 35 is a section along the line XXXV--XXXV of FIG. 32,
FIG. 36 is a section corresponding to FIG. 35, the successor key being turned 90°,
FIG. 37 is a section corresponding to FIG. 36, with the successor key again inserted in a position shifted 90°,
FIG. 38 is a section along the line XXXVIII--XXXVIII of FIG. 32, and
FIG. 39 is a showing similar to FIG. 38, the key together with the cylinder core being turned 90°.
The lock which is developed as closure cylinder 131 has a housing 132 of circular shape in cross section. Within a central bore 133 it receives a cylinder core 134 which extends over somewhat more than half the length of the housing 132. Within the housing 132 and cylinder core 134 there are arranged four rows of housing pins 135 and core pins 136 at equal angles apart. Accordingly, the cylinder core has a key channel 137 of cross-shaped cross section into which the facing ends of the core pins 136 extend. Pin springs 138 act on the housing pins 135 which, in their turn, push the core pins in inward direction. In order that the pin springs 138 do not emerge from the bores that receive the housing pins 135, the housing 132 is covered by a shell 139.
From the side of the housing 132 opposite the cylinder core 134 a bore 140 of larger cross section than the core bore 133 is provided in it, a reset ring 141 being turnably housed therein. Said ring can be engaged in 90° positions. For this purpose, a blind hole 142 extends from the shell surface of the reset ring 141 in order to receive a detent pin 143 which is urged by spring in outward direction. The conical tip of said pin cooperates with four detent niches 144 lying in the same cross-sectional plane and distributed over the circumference. In each case, one of these detent niches 144 extends at the height of a row of tumbler pins.
Within a central bore 145 the diameter of which corresponds the core bore 133, a reset core 146 is mounted. The reset ring 141 and the reset core 146 serve to receive a single row of tumbler pins 147. They also consist of core pins and housing pins and are urged by spring in inward direction. The reset core 146 furthermore contains a cross-shaped channel 148 in the extension of the key channel 137. The cross arms 148' of said channel have the same arm width.
The bore 145 is continued on the other side of the reset ring 141 by a bore section 149 of larger cross section. A closure member 150 provided with an eccentrically arranged driver pin 151 extends in turnable manner into said section. The closure member 150 contains an arcuate slot 152 into which a stop 153 of the housing 132 which lies on the same cross sectional plane of the closure cylinder extends. The length of the bore slot 152 is so large that the closing rotation of the closure member of 150 is less than 90°.
A blind bore 154 extends from the end surface of the closure member 150 facing the reset core 146, in order to receive a coupling member 155 of pot shape. The bottom 156 of said pot faces the reset core 146 and bears an eccentrically arranged driver pin 157. The diameter of this pin is less than the width of the cross arms 148'. In the direction of its engagement the coupling member 155 is acted on by a compression spring 158. The coupling member 155 is made unturnable in the blind bore 154 by a radially aligned control wing 159 which lies at the height of the bottom 156 of the pot, for which wing longitudinal groove 160 extends from the blind bore 154.
The control wing 159 is provided with an oblique surface 161 which slopes down in the direction towards the rim of the pot. This surface cooperates with a conical tip of a control pin 162 which is arranged for displacement in radial direction within the closure member 150. A compression spring 163 arranged on its stepped-down shaft pushes the control pin 162 in the direction towards the oblique surface 161. The end of the control pin 162 which is towards the outside cooperates with a locking pawl 164 which is arranged in a longitudinal recess 165 extending from the shell side of the housing 132. The locking pawl 164 is a single-arm lever. Its mounting pin 166 lies close to the separation between reset ring 141 and housing 132. Approximately at the height of its center the locking pawl 164 forms a blocking projection 167 which points in the direction of the reset ring 141 and extends into one of four blocking niches 168 arranged spaced equally apart in circumferential direction. The engagement is brought about by a compression spring 169 which acts on the locking pawl 164. When the locking pawl 164 is engaged, the detent pin 143 also extends into one of the detent niches 144.
The control pin 162 then also serves for a further function. For this purpose it is provided near its conical tip with a control zone which is formed by a notch groove 170. The said control zone cooperates with a feeler pin 171 which is arranged crosswise to the direction of movement of the control pin. The control member 155 forms a suitable bore 172 for said pin. When the coupling member 155 is in engagement in the cross-shaped channel 148 the feeler pin 171 rests against the wall surface of the control pin 162. The feeler pin 171 extends in this connection beyond the separation surface between closure member 150 and reset core 146. In this connection it acts on one of four longitudinal pins 173 arranged equally apart on the circumference which are housed in corresponding longitudinal bores 174 which completely pass through the reset core 146. The longitudinal pin 173 which is acted on by the feeler pin 171 extends with its opposite end into one of four blocking openings 175 of the cylinder core 134 which are arranged spaced equally apart on the circumference. FIGS. 29 and 34 show that the longitudinal pins 173 are acted on in each case by a compression spring 176 in direction opposite their engagement.
The key channel 137 of the cylinder core 134 has its cross arms aligned with those of the cross-shaped channel 148 in the reset core 146. One of the cross arms 137' is narrower than the other cross arms; see in particular FIGS. 38 and 39.
The closure cylinder 131 shown in the drawing can be closed by means of a key 177 shown in FIGS. 28 and 30. The key is of cross-shape in cross section and forms two thinner sections 178 and 179 of the cross which are arranged at a right angle to each other They correspond in their thickness to the width of the cross arm 137'. The other sections 180, 181 of the cross correspond to the width of the other cross arms of the key channel 137 and also to the width of the cross arm 148' of the cross-shaped channel 148 present in the reset core 146.
The key 177 has a first region A which is associated with the closure code and which extends up to the place of separation between cylinder core 134 and reset core 146. The supplementation region E which causes a resetting joins it from that place on. According to FIG. 28, a resetting has already been effected. The sections 178 to 181 of the cross are provided at the height of region A with closure notches 182. They represent the closure-code notch region. With the key 177 inserted, therefore, all housing pins 135 and core pins 136 are so aligned that their place of separation lies at the height of the outer surface of the cylinder core; see FIG. 28.
The supplementation region E which adjoins the first region A has control notches 183 only at the cross-shaped section 181. The other cross sections are without closure notches in the region there. By means of the control notches 183 the spring actuated tumbler pins 147 are so aligned that their place of separation lies at the height of the outer surface of the reset core 146. A nose 184 then extends from the free front end of section 178. When the key 177 is inserted, however, this nose is shifted at an angle to the driver pin 157 and accordingly does not act on the driver pin. With the key 177 completely inserted, the nose 184 extends furthermore to the place of separation between reset core 146 and closure member 150. This means that the control pin 162 is then also not displaced The blocking engagement between locking pawl 164 and reset ring 141 is thus assured. Upon a closing turning of the key 177, the cylinder core 134, the reset core 146, and, via the coupling member 155, the closure member 150 are carried along. The connection between the two cores 134 and 146 is assured in this connection also by the one longitudinal pin 173; see FIG. 29. The reset ring 141 remains in its position upon this closing rotation, which amounts to less than 90°. This means that the key can not be withdrawn in the forward-closed position. The withdrawal thereof rather requires a turning back of the cores 134, 146 into their initial position.
To be sure, the key 177 could be inserted turned by an angle of 90°. However, no arranging of the tumbler pins 147 then takes place.
If the closing of the closure cylinder is to be changed, a successor key 185 is turned over to the new user. This key is developed similar to the predecessor key 177. The successor key 185 also consists of the two regions A and E. However the cross-shaped sections 179' and 181' are now thinner than the predecessor key 177. This means that their thickness corresponds to the width of the cross arm 137' of the cross-shaped channel 137. The other sections 178' and 180' are now developed with such a thickness that the width corresponds to the other cross arms of the key channel 137.
If this successor key 185 is inserted into the closure cylinder, then the position shown in FIGS. 32, 33, 34, 35, and 38 is obtained. Therefore only the housing pins 135 and core pins 136 are positioned by the first region A. The cross-shaped section 180', which is free of closure notches in the supplementation region E, does not adjust the tumbler pins 147. On the other hand, the nose 184 of the cross-shaped section 178' strikes the driver pin 157 and thus moves the coupling member 155 against spring action. In the end position of the coupling member 155, the driver pin 157 has then left the corresponding cross arm 148' of the cross-shaped channel 148. At the same time as the displacement of the coupling member 155, the control pin 162, via its control wing 159, is moved outward in radial direction. Its end swings the locking pawl 164 against spring action, its blocking projection 167 releasing the facing blocking niche 168. With the displacement of the blocking pin 162, the notch groove 170 also comes into alignment with the feeler pin 171, so that the longitudinal pin 173, via the compression spring 176, now assumes the position shown in FIG. 34 and thus eliminates the combination engagement between cylinder pawl 134 and reset pawl 146. Upon a closing rotation by means of the successor key 185 by 90°, the cylinder core 134 is thus carried along, together with reset core 146 and reset ring 141. The closing displacement is limited by the drive pin 157 which then engages into the next cross arm 148' of the key channel and therefore after a closing turn of 90°. The position shown in FIGS. 36 and 39 is then present. Further turning of the key forward or backward is then not possible. If the closure cylinder 131 is now to be actuated in the normal manner, the successor key 185 is to be withdrawn and inserted in an angular position shifted by 90° in order to bring the control notches 183 into engagement with the tumbler pins 147. In exactly the same way as in the case of the predecessor key, an incorrect insertion of the successor key 185 does not result in any closing action.
If necessary, a modified new successor key can be inserted which changes the closing of the closure cylinder and excludes the previously used successor key 185. Also in the case of this version there is a compulsory sequence in the use of the successor key. It is not possible to skip over the use of a successor key. | 4y
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TECHNICAL FIELD
[0001] The present invention relates to a negative electrode mixture or a gel electrolyte, and a battery including the negative electrode mixture or the gel electrolyte. The present invention specifically relates to a negative electrode mixture such as a zinc negative electrode mixture which contains zinc as a negative electrode active material and which is suitably used for forming negative electrodes of safe and economic batteries exhibiting excellent performance; a gel electrolyte suitably used as an electrolyte of batteries; and a battery including these.
BACKGROUND ART
[0002] Negative electrode mixtures are materials including a negative electrode active material for forming negative electrodes of batteries. In particular, zinc negative electrode mixtures containing zinc as a negative electrode active material have been studied for a long time accompanying the spread of batteries. Examples of batteries containing zinc in the negative electrode include primary batteries and secondary batteries (storage batteries). Specifically, the researchers have studied and developed zinc-air batteries utilizing oxygen in the air as a positive electrode active material, nickel-zinc batteries utilizing a nickel-containing compound as a positive electrode active material, manganese-zinc batteries and zinc ion batteries utilizing a manganese-containing compound as a positive electrode active material, silver-zinc batteries utilizing a silver-containing compound as the positive electrode active material, and the like. In particular, zinc-air primary batteries, manganese-zinc primary batteries, and silver-zinc primary batteries are put to practical use and are widely used all over the world. Currently, development and improvement of batteries have an importance in various industrial fields such as from mobile devices to automobiles, and novel batteries are developed and improved which are excellent mainly in battery performance and easiness of making the batteries into secondary batteries.
[0003] Examples of conventionally studied and developed batteries utilizing zinc in the negative electrode include: alkaline zinc storage batteries including a zinc electrode mainly containing zinc and zinc oxide and containing oxides or hydroxides of cadmium and tin (for example, see Patent Literature 1); alkaline zinc storage batteries including a zinc electrode mainly containing zinc and zinc oxide and containing oxide or hydroxide of tin and titanium oxide (for example, see Patent Literature 2); zinc electrodes for alkaline storage batteries including a zinc active material that contains fluororesin and polyvinyl alcohol, and at least one inorganic compound selected from the group consisting of calcium hydroxide, barium hydroxide, titanium oxide, zirconium oxide, and magnesium oxide added to the zinc active material (for example, see Patent Literature 3); alkaline zinc storage batteries including a zinc electrode mainly containing zinc and zinc oxide and containing an electrochemically inactive nonconductive inorganic compound at the periphery of an electrode containing an alkali-resistant water-repellent synthesized resin binding agent (for example, see Patent Literature 4); and alkaline zinc storage batteries including a zinc electrode mainly containing zinc or zinc oxide and containing as additives oxide or hydroxide of indium, oxide or hydroxide of thallium, and at least one oxide or hydroxide of gallium, cadmium, lead, tin, bismuth, and mercury, with the sum of the amounts of the additives being 1 to 15% by weight in the zinc electrode (for example, see Patent Literature 5). Further, a method of producing a zinc electrode for alkaline storage batteries is disclosed which includes kneading zinc, calcium hydroxide, thallium oxide, and water; drying the mixture and reducing the dried mixture to powder; mixing the powder with zinc powder, zinc oxide powder, an additive, and a binding agent to form an active material paste; and applying the active material paste to a collector (for example, see Patent Literature 6).
[0004] Background art documents disclose that addition of an oxide of metal other than zinc to a zinc electrode active material for the purpose of improving the discharge-and-charge cycle characteristic of a zinc electrode results in the fact that indium oxide and thallium oxide among various metal oxide additives have an effect of highly improving the cycle characteristic (for example, see Non-Patent Literature 1). Non-Patent Literature 2 outlines the history of studies and development of a zinc electrode for alkaline secondary batteries.
[0005] Other documents disclose a nickel-zinc Galvanic cell including a paste-type zinc oxide negative electrode, a paste-type nickel oxide positive electrode, and an alkaline electrolyte solution, the positive electrode containing a mixture of coprecipitated cobalt oxide and fractionated metal cobalt, and the negative electrode containing an oxide other than zinc oxide (for example, see Patent Literature 7); and an electrochemical battery including a zinc electrode containing zinc oxide, a binder, and a fluoride (for example, see Patent Literature 8). Still another document discloses an electrochemical cell that includes a zinc electrode containing a mixture of zinc oxide and inorganic fibers of silica and alumina and a buffer electrolyte solution (for example, see Patent Literature 9). The present inventors have performed studies to find that a zinc electrode containing silica and alumina suffers easy dissolution of these compounds into the system, resulting in rapid deterioration.
[0006] Still other documents disclose a zinc electrode containing zinc oxide, a metal oxide, hydroxyethyl cellulose, an oxide dispersant, and a liquid binder (for example, see Patent Literature 10); a rechargeable nickel-zinc battery including a negative electrode containing zinc or a zinc compound, a positive electrode containing nickel oxide, nickel hydroxide, and/or nickel oxide hydroxide, and an electrolyte containing a phosphoric acid salt, free alkali, and a boric acid salt (for example, see Patent Literature 11); and a method of producing a rechargeable battery including a zinc negative electrode material containing ZnO, zinc or a zinc alloy, bismuth oxide, and aluminum oxide, and a nickel positive electrode material containing nickel hydroxide and/or nickel oxide hydroxide, zinc oxide, cobalt oxide, and a binding agent (for example, see Patent Literature 12).
[0007] Another document discloses a rechargeable nickel-zinc battery including a zinc negative electrode containing electrochemically active zinc and surfactant-coated carbon fibers and a nickel positive electrode, and discloses that use of the surfactant-coated carbon fibers in the zinc negative electrode improves the charge and discharge characteristics of a nickel-zinc battery (for example, see Patent Literature 13). Alternative compounds to surfactant-coated carbon fibers used in the comparative examples are alumina fibers, which the present inventors have proved to cause marked deterioration of the zinc electrode because they are dissolved in a strong alkaline aqueous electrolyte solution, so that the document fails to prove the superiority of surfactant-coated carbon fibers in a true sense. Surfactant-coated carbon fibers are considered to suppress generation of hydrogen due to decomposition of an aqueous electrolyte solution, but the surfactant-coated carbon fibers contain Pb that has a high hydrogen overvoltage (for example, see Patent Literature 14). Thus, it is obvious that such carbon fibers can suppress generation of hydrogen, and this does not mean the superiority of surfactant-coated carbon fibers. In order to improve the capacitance density of a zinc electrode even slightly, there is still room for developing a conductive auxiliary agent without surfactant coating.
[0008] Batteries conventionally include a positive electrode, a negative electrode, and an electrolyte solution interposed between these electrodes. The electrolyte solution in batteries is a liquid in many cases. In particular, storage batteries suffer problems which make it difficult to use safely and stably for a long time, such as expansion of the storage batteries due to decomposition of an electrolyte solution. Especially, storage batteries having a negative electrode of a zinc-containing compound (aqueous electrolyte solution) or lithium metal (organic-solvent-type electrolyte solution) are superior to nickel-metal hydride batteries (aqueous electrolyte solution) and lithium ion batteries (organic-solvent-type electrolyte solution), which are used as storage batteries in various fields, in properties such as operating voltage and energy density in the case of comparison using the same electrolyte solution. In contrast, repeated charge and discharge of such batteries for a long time cause local dissolution and precipitation of the metal in the electrode and involving changes in form, such as shape change and formation of dendrite, of the electrode active material and progress of such changes. This results in capacity deterioration and life shortening of the storage batteries.
[0009] For general methods of solving issues about safety and stability of storage batteries, one conventional main approach is to use a gel-like electrolyte (gel electrolyte) which is high in ion conductivity and excellent in safety and mechanical properties instead of an electrolyte solution. Examples of the gel-like electrolyte for such an approach include: an inorganic hydrogel electrolyte for solid-state alkaline secondary batteries in which a layered hydrotalcite bears an alkali hydroxide aqueous solution (for example, see Patent Literature 15); and a polymer hydrogel electrolyte for alkaline batteries including a polymer composition of polyvinyl alcohol and an anionic cross-linked (co)polymer and an alkali hydroxide contained in the polymer composition (for example, see Patent Literature 16). Another document discloses a polymer gelling agent for electrolyte solutions obtained by saponifying a precursor of a polymer gelling agent for electrolyte solutions, the precursor being a copolymer of a hydrophobic monomer having a hydrophobic group that generates a carboxyl group by saponification and a hydrophobic polyfunctional monomer, and being capable of gelling an electrolyte solution (for example, see Patent Literature 17). Other examples of the gel-like electrolyte include an alkaline polymer gel electrolyte prepared by solution-polymerization of acrylic acid salt, potassium hydroxide, and water as starting materials (for example, see Non-Patent Literature 3); an inorganic hydrogel electrolyte containing hydrotalcite bearing a potassium hydroxide aqueous solution (for example, see Non-Patent Literature 4); a polyethylene oxide-based alkaline solid polymer electrolyte (for example, see Non-Patent Literature 5); a polymer electrolyte prepared from polyethylene oxide, polyvinyl alcohol, potassium hydroxide, and water (for example, see Non-Patent Literature 6); and an alkaline polymer electrolyte nanocomposite prepared from polyvinyl alcohol, nanoparticled zirconium oxide, potassium hydroxide, and water (for example, see Non-Patent Literature 7). Another document discloses a solid electrolyte which is a viscoelastic material containing a high molecular weight polymer that contains a non-aqueous electrolyte solution in an amount of 200% by weight or more for the amount of the high molecular weight polymer (for example, see Patent Literature 18).
[0010] Although not intended to suppress changes in form, such as shape change and formation of dendrite, of the electrode active material, one method of making an active material remain in an electrode is known in which an additive (e.g. binding agent, binder) is added to an electrode mixture for producing an electrode, thereby capturing the active material (metal). For example, a method of producing an electrode for batteries is disclosed which includes impregnating pores of particles of an active material or particles mainly of an active material with a polymerizable or copolymerizable monomer or a lower polymer compound, and then polymerizing or copolymerizing the monomer or the lower polymer compound in the pores (for example, see Patent Literature 19). Further, an additive (thickening agent) including a water-insoluble water-absorbing resin is disclosed as a polymer to be added to an electrode mixture, which is used in the step of producing an electrode paste for alkaline storage batteries (for example, see Patent Literature 20). Other documents disclose a binding agent for electrodes of electrochemical elements including a vinyl polymer-type thermoreversible thickening agent reversibly changing between hydrophilicity and hydrophobicity at a certain transition temperature, a water-dispersible binder resin, and a salt of metal in the groups 1 to 7 of the periodic table (for example, see Patent Literature 21); and an aqueous dispersion including an aqueous phase and a binding agent for electrodes dispersed in the aqueous phase, the binding agent including a synthetic resin having a glass transition temperature of lower than −40° C. (for example, see Patent Literature 22).
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: JP S58-163159 A
Patent Literature 2: JP S58-163162 A
Patent Literature 3: JP S60-208053 A
Patent Literature 4: JP S61-61366 A
Patent Literature 5: JP S61-96666 A
Patent Literature 6: JP H01-163967 A
Patent Literature 7: JP 2004-513501 T
Patent Literature 8: JP 2004-520683 T
Patent Literature 9: JP 2004-522256 T
Patent Literature 10: JP 2004-526286 T
Patent Literature 11: JP 2007-214125 A
Patent Literature 12: JP 2008-532249 T
Patent Literature 13: US 2011/0033747 A
Patent Literature 14: JP S51-32365 B
Patent Literature 15: JP 2007-227032 A
Patent Literature 16: JP 2005-322635 A
Patent Literature 17: JP 2003-178797 A
Patent Literature 18: JP H05-205515 A
Patent Literature 19: JP S60-37655 A
Patent Literature 20: JP H08-222225 A
Patent Literature 21: JP 2003-331848 A
Patent Literature 22: JP 2006-172992 A
Non-Patent Literature
[0000]
Non-Patent Literature 1: Mitsuzo Nogami, and four others, “Denki Kagaku”, 1989, Vol. 57, No. 8, p. 810-814
Non-patent Literature 2: F. R. McLamon, and one other, “Journal of The Electrochemical Society”, 1991, Vol. 138, No. 2, p. 645-664
Non-patent Literature 3: Xiaoming Zhu, and three others, “Electrochimica Acta”, 2004, Vol. 49, No. 16, p. 2533-2539
Non-patent Literature 4: Hiroshi Inoue, and four others, “Electrochemical and Solid-State Letters”, 2009, Vol. 12, No. 3, p. A58-A60
Non-patent Literature 5: J. F. Fauvarque, and four others, “Electrochimica Acta”, 1995, Vol. 40, No. 13-14, p. 2449-2453
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Non-patent Literature 7: Chun-Chen Yang, “Materials Science and Engineering B”, 2006, Vol. 131, p. 256-262
SUMMARY OF INVENTION
Technical Problem
[0040] Although various batteries using a zinc negative electrode have been studied as mentioned above, they are no more in the main stream of the battery development as novel batteries using other elements in negative electrodes are developed. Still, the present inventors have recognized that such batteries with zinc negative electrodes are inexpensive and highly safe, and have high energy density, so that they have focused on the possibility of these batteries for suitable uses in various applications from the above viewpoint. They have then studied the performance of zinc negative electrode batteries, and have found the batteries still have the following disadvantages to be solved so as to satisfy the performance required for current batteries; for example, repeated charge and discharge, which are essential for making a battery into a secondary battery, cause changes in form or passivation of a negative electrode active material including zinc, thereby deteriorating the charge-and-discharge cycle characteristics (battery life), as well as causing marked self-discharge in the charged state or during storage in the charged state. Solving such disadvantages possibly allows the zinc negative electrode batteries to be used as batteries satisfying the required economy and safety, as well as the required performance together in various industrial fields such as from mobile devices to automobiles.
[0041] In order to solve the disadvantages of storage batteries and to improve the performance thereof, various gel electrolytes and additives for electrode mixtures have been studied as mentioned above. From the viewpoint of the superiority of storage battery performance such as operating voltage and energy density, storage batteries using a zinc-containing compound or lithium metal as the negative electrode active material of an electrode instead of a hydrogen storage alloy or graphite are required to provide excellent battery performance such as a cycle characteristic, a rate characteristic, and coulombic efficiency while suppressing changes in form, such as shape change and formation of dendrite, dissolution, and corrosion, as well as passivation due to these factors, of the electrode active material so as to satisfy the performance required for such storage batteries. Thus, there is still a room for achieving storage batteries satisfying these requirements simultaneously. As is reported in Non-Patent Literature 3 and Non-Patent Literature 5, the above storage batteries also often use a gel electrolyte, but they fail to solve the disadvantages. Non-Patent Literature documents 4, 6, and 7 are limited to observe whether or not the characteristics of gel electrolytes are satisfactory to electrolytes of batteries, and they fail to solve the disadvantages. Thus, the gel electrolytes disclosed in these Non-Patent Literature documents are not used for suppressing changes in form of the electrode active material and for improving the battery performance such as a cycle characteristic, a rate characteristic, and coulombic efficiency. They still require improvement for sufficiently solving these disadvantages.
[0042] In each of the methods disclosed in Patent Literature documents 19 to 22, a polymer used as an additive is merely used as a thickening agent for paste electrodes of alkaline storage batteries. The polymer is not used for suppressing changes in form or passivation of the electrode active material and improving the battery performance such as a cycle characteristic, a rate characteristic, and coulombic efficiency, and it still requires improvement for sufficiently solving these disadvantages.
[0043] The present invention is devised in the aforementioned situation, and aims to provide a zinc negative electrode mixture for producing negative electrodes of batteries excellent in economy and safety, as well as battery performance, and to provide a gel electrolyte or a negative electrode mixture suitably used for producing storage batteries showing the battery performance such as a high cycle characteristic, rate characteristic, and coulombic efficiency, while suppressing changes in form, such as shape change and dendrite, dissolution, corrosion, and passivation of the electrode active material. The present invention also aims to provide a battery using such a zinc negative electrode mixture or gel electrolyte.
Solution to Problem
[0044] The present inventors have performed various studies on zinc negative electrode mixtures, especially those containing a zinc-containing compound as an active material and a conductive auxiliary agent, and have focused on the shapes of the zinc-containing compound and the conductive auxiliary agent. Then, they have found the following: with the zinc-containing compound and/or the conductive auxiliary agent containing particles having a small particle size that is smaller than a predetermined average particle size or long and narrow particles having a specific aspect ratio, the zinc negative electrode produced from such a zinc negative electrode mixture can better suppress generation of hydrogen, which is a side reaction, and better improve the cycle characteristic, rate characteristic, and coulombic efficiency of the battery than conventional zinc negative electrodes. They have further found that such a mixture can suppress changes in form and passivation of the zinc-containing negative electrode active material, and self-discharge in the charged state or during storage in the charged state. The zinc negative electrode having such features can be more suitably used as a negative electrode of batteries. Further, batteries including such a zinc negative electrode can use a water-containing electrolyte solution, and thus the resulting batteries are highly safe batteries. As mentioned here, the present inventors have arrived at solving the above disadvantages with the zinc negative electrode mixture that contains a zinc-containing compound and a conductive auxiliary agent in which the zinc-containing compound and/or the conductive auxiliary agent contain(s) particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher.
[0045] The present inventors have further performed various studies on disadvantages regarding changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material in batteries, and have focused on the gel electrolyte. Then, they have found that conventional gel electrolytes are still insufficient in performance as an electrolyte and, especially in the case of a concentrated alkaline solution, the solution gradually decomposes, and thus does not withstand the use in secondary batteries for industrial uses. The present inventors have also found that a gel electrolyte having a cross-linked structure formed by a multivalent ion and/or an inorganic compound can provide a storage battery that can effectively suppress changes in form, such as shape change and formation of dendrite, of the electrode active material, can have a high cycle characteristic, rate characteristic, and coulombic efficiency while maintaining a high ion conductivity of the gel electrolyte, and can have improved resistance to a concentrated alkaline solution. As mentioned here, the present inventors have arrived at solving the above disadvantages with the gel electrolyte having a cross-linked structure formed by a multivalent ion and/or an inorganic compound in storage batteries.
[0046] The present inventors have also focused on the negative electrode mixture regarding changes in form, such as shape change and formation of dendrite, of the electrode active material in storage batteries. Then, they have found that a negative electrode mixture containing a negative electrode active material and a polymer can provide a storage battery that can effectively suppress changes in form, such as shape change and formation of dendrite, and passivation of the electrode active material, and can have a high cycle characteristic, rate characteristic, and coulombic efficiency while maintaining a high electrical conductivity. As mentioned here, the present inventors have arrived at solving the above disadvantages with a negative electrode mixture for storage batteries containing a negative electrode active material and a polymer. Finally, the present inventors have completed the present invention. The present invention can be used not only for storage batteries (secondary batteries) but also for other electrochemical devices such as primary batteries, capacitors, and hybrid capacitors.
[0047] In other words, the present invention relates to a zinc negative electrode mixture including a zinc-containing compound and a conductive auxiliary agent, the zinc-containing compound and/or the conductive auxiliary agent containing particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher.
[0048] The zinc negative electrode mixture of the present invention further includes an additional component, and the additional component is at least one selected from the group consisting of compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds.
[0049] The present invention also relates to a zinc negative electrode formed from the zinc negative electrode mixture.
[0050] The present invention also relates to a battery including the zinc negative electrode.
[0051] The present invention also relates to a gel electrolyte intended to be used in batteries, and the gel electrolyte has a cross-linked structure formed by a multivalent ion and/or an inorganic compound.
[0052] The present invention also relates to a negative electrode mixture for batteries, and the negative electrode mixture includes a negative electrode active material and a polymer.
[0053] The present invention will be described in detail below.
[0054] Any combinations of two or more embodiments of the present invention to be mentioned below are also preferable embodiments of the present invention.
[0055] First of all, the following will describe a zinc negative electrode mixture (hereinafter, also referred to as the zinc negative electrode mixture of the first aspect of the present invention) including a zinc-containing compound and a conductive auxiliary agent, the zinc-containing compound and/or the conductive auxiliary agent containing particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher. Next, the following will describe a gel electrolyte (hereinafter, also referred to as the gel electrolyte of the second aspect of the present invention) of the present invention. Finally, the following will describe a negative electrode mixture (hereinafter, also referred to as the negative electrode mixture of the third aspect of the present invention) including a negative electrode active material and a polymer.
[0056] First, the zinc negative electrode mixture of the first aspect of the present invention is described below.
[0057] The zinc negative electrode mixture of the first aspect of the present invention includes a zinc-containing compound and a conductive auxiliary agent, and the zinc-containing compound and/or the conductive auxiliary agent contain(s) particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher.
[0058] The zinc negative electrode mixture of the present invention may contain an additional component as long as it contains the zinc-containing compound and the conductive auxiliary agent. For each of these components, one species thereof may be used, or two or more species thereof may be used.
[0059] The zinc-containing compound and/or the conductive auxiliary agent contain(s) particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher. A zinc negative electrode formed from the zinc negative electrode mixture containing such a conductive auxiliary agent and zinc-containing compound is capable of improving the cycle characteristic, rate characteristic, and coulombic efficiency of batteries. The reason of this is presumably as follows.
[0060] For the negative electrode of a battery formed from a zinc negative electrode mixture including a zinc-containing compound and a conductive auxiliary agent, the molecules of the zinc-containing compound, the zinc-containing compound and the conductive auxiliary agent, and the zinc-containing compound, the conductive auxiliary agent, and a collector are preferably bound to each other so as to allow the electrode to function as a negative electrode (allow a current to pass through the electrode). However, repeated charge and discharge or rapid charge and discharge may unavoidably cause dissociation between the zinc-containing compound molecules, between the zinc-containing compound and the conductive auxiliary agent, and among the zinc-containing compound, the conductive auxiliary agent, and the collector, or cause passivation of the zinc-containing compound, thereby deteriorating the battery performance. On the contrary, use of particles having an average particle size of 1000 μm or smaller as the zinc-containing compound and/or the conductive auxiliary agent enables effective contact between the zinc-containing compound molecules, between the zinc-containing compound and the conductive auxiliary agent, and among the zinc-containing compound, the conductive auxiliary agent, and the collector. This reduces the portions of complete dissociation between the zinc-containing compound molecules, between the zinc-containing compound and the conductive auxiliary agent, and among the zinc-containing compound, the conductive auxiliary agent, and the collector, resulting in suppression of deterioration of the battery performance. In the case where the zinc-containing compound and/or the conductive auxiliary agent contain(s) particles having an aspect ratio (vertical/lateral) of 1.1 or higher, each particle has a long and narrow shape, and thus dissociation is less likely to occur between the zinc-containing compound molecules, between the zinc-containing compound and the conductive auxiliary agent, and among the zinc-containing compound, the conductive auxiliary agent, and the collector. This results in suppression of deterioration of the battery performance. In addition, such particles can suppress changes in form of the zinc-containing compound which is an active material.
[0061] In the present invention, one of the zinc-containing compound and the conductive auxiliary agent may contain particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher, or both of the zinc-containing compound and the conductive auxiliary agent may contain particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher.
[0062] It is also one preferable embodiment of the present invention that the zinc-containing compound and the conductive auxiliary agent contain particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher.
[0063] The zinc-containing compound and/or the conductive auxiliary agent in the present invention at least contain(s) particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher, and may further contain particles having different shapes. The sum of the amounts of the particles having an average particle size of 1000 μm or smaller and the particles having an aspect ratio (vertical/lateral) of 1.1 or higher is preferably 10% by mass or more in 100% by mass of the whole of the zinc-containing compound and the conductive auxiliary agent. Such a total quantity of the particles having an average particle size of 1000 μm or smaller and/or the particles having an aspect ratio (vertical/lateral) of 1.1 or higher in the whole amount of the zinc-containing compound and the conductive auxiliary agent makes it possible to more sufficiently achieve the effects of the present invention. The sum of the amounts of the particles is more preferably 40% by mass or more, and still more preferably 80% by mass or more. The sum of the amounts of the particles is particularly preferably 100% by mass; in other words, the zinc-containing compound and the conductive auxiliary agent consist of the particles having an average particle size of 1000 μm or smaller and/or the particles having an aspect ratio (vertical/lateral) of 1.1 or higher.
[0064] The particles having a small particle size herein mean particles having an average particle size of 1000 μm or smaller, and the average particle size is preferably 500 μm or smaller, more preferably 200 μm or smaller, still more preferably 100 μm or smaller, particularly preferably 75 μm or smaller, and most preferably 20 μm or smaller. The lower limit of the average particle size is preferably 1 nm. The average particle size is more preferably 2 nm or greater, and still more preferably 5 nm or greater. The above average particle size is an average particle size of the zinc-containing compound and/or the conductive auxiliary agent in the state of raw material. Still, the average particle size preferably satisfies the above value in the analysis after dispersion by 1- to 20-minute ultrasonication or in the analysis of the zinc-containing compound and/or the conductive auxiliary agent contained in the zinc negative electrode mixture prepared through the steps to be mentioned later or contained in the electrode produced from the mixture.
[0065] The average particle size can be determined with a transmission electron microscope (TEM), a scanning electron microscope (SEM), or a particle size distribution analyzer, or by X-ray powder diffraction (XRD), for example.
[0066] Examples of the state of particles include fine powder, powder, particulates, granules, scales, polyhedrons, and rods. Particles having an average particle size within the aforementioned range can be produced by a method of grinding particles with, for example, a ball mill, dispersing the resulting coarse particles in a dispersant to give a predetermined particle size, and then dry-hardening the particles; a method of sieving the coarse particles to classify the particle sizes; a method of optimizing the conditions for producing the particles, thereby producing (nano)particles having a predetermined particle size; and the like methods.
[0067] For a group of particles having multiple uneven particle sizes, a typical particle size in this group of particles is defined as the average particle size of the group. The particle size is the length of a particle measured in conformity with a general rule. For example, (i) in the case of microscopy, two or more lengths of one particle, such as the major axis diameter, the minor axis diameter, and the Feret diameter, are measured and the average value thereof is defined as the particle size. Preferably at least 100 particles are measured. (ii) In the case of image analysis, light-shielding, or Coulter principle, the directly measured value (e.g. projected area, volume) as the size of a particle is converted into a systematic shape (e.g. circle, sphere, cube) of the particle based on a geometric formula, and the diameter of the systematic shape is defined as the particle size (equivalent size). (iii) In the case of sedimentation or laser diffraction scattering, the measured value is calculated into a particle size (effective size) based on the physical law (e.g. Mie theory) deduced by supposition of a specific particle shape and specific physical conditions. (iv) In the case of dynamic light scattering, the rate of diffusion (diffusion coefficient) of particles in a liquid owing to Brownian motion is measured to calculate the particle size. Analysis of the average particle size may be performed on particles as they are, or after dispersion by 1- to 20-minute ultrasonication. In either case, the average particle size preferably satisfies the above value. For the average particle size measured using a particle size distribution analyzer, the particle size at the peak of a frequency distribution graph (i.e. corresponding to the maximum frequency distribution value) is referred to as a mode diameter, and the particle size corresponding to a cumulative distribution value of 50% is referred to as a median size.
[0068] The particles having a small particle size preferably have a specific surface area of 0.01 m 2 /g or larger. The specific surface area is more preferably 0.1 m 2 /g or larger, and still more preferably 0.5 m 2 /g or larger. The upper limit of the specific surface area is preferably 1500 m 2 /g. The specific surface area is more preferably 500 m 2 /g or smaller, still more preferably 350 m 2 /g or smaller, and particularly preferably 250 m 2 /g or smaller.
[0069] The specific surface area can be measured by the nitrogen adsorption BET method using a specific surface area measurement device, for example.
[0070] Particles having a specific surface area within the above range can be produced by, for example, forming particles into nanoparticles or adjusting the conditions for particle production to make irregularities on the particle surface.
[0071] The long and narrow particles may mainly have a rectangular parallelepiped shape or a cylindrical shape (fibrous shape) with an aspect ratio (vertical/lateral) of 1.1 or higher. The aspect ratio (vertical/lateral) is preferably 20 or higher, more preferably 50 or higher, and still more preferably 60 or higher. The upper limit of the aspect ratio (vertical/lateral) is preferably 100000, and more preferably 50000.
[0072] For particles having a rectangular parallelepiped shape which are observed using a TEM or SEM, the aspect ratio (vertical/lateral) can be determined by, for example, dividing the vertical length by the lateral length, where the vertical means the longest side and the lateral means the second longest side. For particles having a cylindrical shape, a sphere shape, a shape with a curved surface, a polyhedral shape, and the like, a particle is placed such that a certain one point faces downward and the particle is projected from the direction that provides the maximum aspect ratio to form a two-dimensional shape; then, the distance between the certain one point and the farthest point therefrom is measured; and the aspect ratio is determined by dividing the vertical length by the lateral length, where the vertical means the longest side and the lateral means the longest side among the straight lines crossing the center of the vertical axis.
[0073] Particles having an aspect ratio (vertical/lateral) within the above range can be obtained by, for example, selecting particles having such an aspect ratio, or optimizing the conditions for producing particles to selectively produce such particles.
[0074] The aspect ratio is an average particle size of the zinc-containing compound and/or the conductive auxiliary agent in the state of raw material. Still, the aspect ratio preferably satisfies the above value in the analysis after dispersion by 1- to 20-minute ultrasonication or in the analysis of the zinc-containing compound and/or the conductive auxiliary agent contained in the zinc negative electrode mixture prepared through the steps to be mentioned later or contained in the electrode produced from the mixture.
[0075] Any zinc-containing compounds may be used as long as they are usable as the negative electrode active material. Examples thereof include zinc metal, zinc fibers, zinc oxide (#1, #2, #3), conductive zinc oxide, zinc hydroxide, zinc sulfide, tetrahydroxozincate ion salts, zinc halides, zinc carboxylate compounds (e.g. zinc acetate, zinc tartrate), magnesium zincate, calcium zincate, barium zincate, zinc borate, zinc silicate, zinc aluminate, zinc fluoride, zinc alloys, carbonate, hydrogen carbonate, nitrate, sulfate, and zinc used in alkaline batteries and zinc-air batteries. Preferable are zinc metal, zinc oxide (#1, #2, #3), conductive zinc oxide, zinc hydroxide, tetrahydroxozincate ion salts, zinc halides, zinc borate, zinc fluoride, zinc alloys, and zinc used in alkaline batteries and zinc-air batteries. More preferable are zinc metal, zinc oxide (#1, #2), conductive zinc oxide, zinc hydroxide, zinc borate, zinc fluoride, zinc alloys, and zinc used in alkaline batteries and zinc-air batteries. Still more preferable are zinc oxide, zinc hydroxide, zinc alloys, and zinc used in alkaline batteries and zinc-air batteries. Most preferred are zinc oxide and zinc hydroxide. One of the zinc-containing compounds may be used or two or more thereof may be used.
[0076] In the case of using zinc oxide, the zinc oxide preferably contains Pb in an amount of 0.03% by mass or less and Cd in an amount of 0.01% by mass or less. Pb and Cd are known as elements to suppress decomposition of the electrolyte solution (water) (generation of hydrogen) at the zinc electrode, but it is preferable to reduce their amounts as low as possible in view of current environmental issues. The zinc oxide used in the zinc electrode more preferably satisfies the JIS standards. The zinc oxide is preferably free from Hg.
[0077] The amount of the zinc-containing compound is preferably 50 to 99.9% by mass in 100% by mass of the whole zinc negative electrode mixture. With such a range of the amount of the zinc-containing compound, the zinc negative electrode formed from the zinc negative electrode mixture achieves better battery performance when it is used as the negative electrode of a battery. The amount is more preferably 55 to 99.5% by mass, and still more preferably 60 to 99% by mass.
[0078] The zinc-containing compound preferably contains particles satisfying the following average particle size and/or aspect ratio. More preferably, the zinc-containing compound itself satisfies the following average particle size and/or aspect ratio.
[0079] The average particle size of the zinc-containing compound is preferably 500 μm to 1 nm, more preferably 100 μm to 5 nm, still more preferably 20 μm to 10 nm, and particularly preferably 10 μm to 100 nm.
[0080] In the case of using, as the zinc compound, zinc oxide dispersed in ion exchange water by five-minute ultrasonication, the average particle size thereof measured using a particle size distribution analyzer is preferably 100 μm to 100 nm, more preferably 50 μm to 200 nm, and still more preferably 10 μm to 300 nm; the mode diameter thereof is preferably 20 μm to 50 nm, more preferably 10 μm to 70 nm, and still more preferably 5 μm to 100 nm; and the median size thereof is preferably 10 μm to 100 nm, more preferably 7 μm to 150 nm, and still more preferably 5 μm to 500 nm.
[0081] For zinc-containing compounds having a shape whose aspect ratio (vertical/lateral) is measurable, such as a rectangular parallelepiped shape, a cylindrical shape, a sphere shape, a shape with a curved surface, a polyhedral shape, a scaly shape, and a rod shape, the aspect ratio (vertical/lateral) is preferably 100000 to 1.1, more preferably 50000 to 1.2, and still more preferably 10000 to 1.5. If the zinc-containing compound contains no particles satisfying the above average particle size and aspect ratio, batteries may easily suffer deterioration of a cycle characteristics due to changes in form and passivation of the negative electrode active material, and self-discharge in a charged state or during storage in a charged state.
[0082] The average particle size and the aspect ratio can be measured by the same methods as mentioned above.
[0083] The phrase “in a charged state or during storage in a charged state” herein means that a battery is in the state where part or all of the zinc-containing compound as an active material is zinc metal during the charge and discharge operation or during storage of a battery which is a full cell with a zinc electrode used as the negative electrode (reduction of zinc oxide to zinc metal is charge, whereas oxidation of zinc metal to zinc oxide is discharge). The state where part or all of the zinc-containing compound as an active material is zinc metal in a full cell during the discharge operation or in a half cell including zinc metal as the counter electrode of the zinc electrode (reduction of zinc oxide to zinc metal is discharge, whereas oxidation of zinc metal to zinc oxide is charge) is also referred to as a charged state.
[0084] The zinc-containing compound preferably contains particles satisfying the following specific surface area. More preferably, the zinc-containing compound itself satisfies the following specific surface area.
[0085] The specific surface area of the zinc-containing compound is more preferably 0.01 m 2 /g or larger but 60 m 2 /g or smaller, and still more preferably 0.1 m 2 /g or larger but 50 m 2 /g or smaller. A zinc-containing compound containing no particles satisfying the above specific surface area may easily cause deterioration of the cycle characteristic and self-discharge in a charged state or during storage in a charged state.
[0086] The specific surface area can be measured in the same manner as mentioned above.
[0087] Zinc oxide used as the zinc-containing compound preferably has a true density of 5.50 to 6.50 g/cm 3 . The true density is more preferably 5.60 to 6.30 g/cm 3 , still more preferably 5.70 to 6.20 g/cm 3 , particularly preferably 5.89 to 6.20 g/cm 3 , and most preferably 5.95 to 6.15 g/cm 3 . Although zinc oxide particles not satisfying the above true density have no great influence on the capacity in charge and discharge, such particles with a certain average particle size may easily cause self-discharge in a charged state or during storage in a charged state. The true density can be measured using a density measurement device or the like device. In the cases where the zinc-containing compound is used in an electrode, for example, and thus it is difficult to measure the true density of the particle alone, the true density can be assumed by calculating the ratio between zinc and oxygen using an X-ray fluorescent (XRF) analyzer or the like device.
[0088] Examples of the conductive auxiliary agent include conductive carbon, conductive ceramics, and zinc metal.
[0089] Examples of the conductive carbon include graphite, natural graphite, artificial graphite, glassy carbon, amorphous carbon, graphitizable carbon, non-graphitizable carbon, carbon nanofoam, active carbon, graphene, nanographene, graphene nanoribbon, fullerene, carbon black, graphitized carbon black, Ketjenblack, vapor grown carbon fibers, pitch-based carbon fibers, mesocarbon microbeads, metal-coated carbon, carbon-coated metal, fibrous carbon, boron-containing carbon, nitrogen-containing carbon, multi-walled/single-walled carbon nanotubes, carbon nanohorn, VULCAN, acetylene black, carbon subjected to hydrophilic treatment by introducing an oxygen-containing functional group, SiC-coated carbon, carbon surface-treated by dispersion, emulsion, suspension, or microsuspension polymerization, and microencapsulated carbon.
[0090] Examples of the conductive ceramics include compounds containing at least one selected from Bi, Co, Nb, and Y sintered together with zinc oxide.
[0091] Preferable are graphite, natural graphite, artificial graphite, graphitizable carbon, non-graphitizable carbon, graphene, carbon black, graphitized carbon black, Ketjenblack, vapor grown carbon fibers, pitch-based carbon fibers, mesocarbon microbeads, fibrous carbon, multi-walled/single-walled carbon nanotubes, VULCAN, acetylene black, carbon subjected to hydrophilic treatment by introducing an oxygen-containing functional group, and zinc metal. The zinc metal may be any of those used in practical batteries such as alkaline batteries and air batteries, or may be any of those surface-coated by other elements or carbon.
[0092] One of these conductive auxiliary agents may be used or two or more thereof may be used. Conductive carbon is not coated with a low molecular weight surfactant so as to exert its conductivity at the maximum.
[0093] Zinc metal can also serve as an active material.
[0094] The zinc metal is added as a negative electrode mixture in the production of a negative electrode. The zinc metal generated from zinc oxide or zinc hydroxide, which is a zinc-containing compound, in the charge and discharge operation also serves as a conductive auxiliary agent. The zinc-containing compound in this case practically serves as a negative electrode active material and a conductive auxiliary agent in the charge and discharge operation.
[0095] The conductive auxiliary agent, used for producing a storage battery with a water-containing electrolyte solution, may promote a side reaction of decomposing water in charge and discharge. In order to suppress such a side reaction, a predetermined element may be introduced into the conductive auxiliary agent. Examples of such an element include B, Ba, Bi, Br, Ca, Cd, Ce, Cl, F, Ga, Hg, In, La, Mn, N, Nb, Nd, P, Pb, Sc, Sn, Sb, Sr, Ti, Tl, Y, and Zr. In the case where conductive carbon is used as one conductive auxiliary agent, examples of such an element include B, Bi, Br, Ca, Cd, Ce, Cl, F, In, La, Mn, N, Nb, Nd, P, Pb, Sc, Sn, Tl, Y, and Zr.
[0096] The phrase “a predetermined element is introduced into the conductive auxiliary agent” herein means that the conductive auxiliary agent is formed into a compound containing such an element as its constituent element.
[0097] The amount of the conductive auxiliary agent is preferably 0.0001 to 100% by mass for 100% by mass of the zinc-containing compound in the zinc negative electrode mixture. The conductive auxiliary agent in an amount within this range allows a battery including, as its negative electrode, a zinc negative electrode formed from the zinc negative electrode mixture to achieve better battery performance. The amount thereof is more preferably 0.0005 to 60% by mass, and still more preferably 0.001 to 40% by mass. As mentioned here, it is also one preferable embodiment of the present invention that the amount of the conductive auxiliary agent in the zinc negative electrode mixture of the present invention is 0.0001 to 100% by mass for 100% by mass of the zinc-containing compound in the zinc negative electrode mixture.
[0098] The zinc metal used as a conductive auxiliary agent in preparation of a negative electrode mixture is treated not as a zinc-containing compound but as a conductive auxiliary agent in calculation. The zinc metal generated from zinc oxide or zinc hydroxide, which is a zinc-containing compound, in charge and discharge also functions as a conductive auxiliary agent in the system, but it is not a zerovalent zinc metal in preparation of a zinc negative electrode mixture and a zinc negative electrode. Thus, the zinc metal is not considered as a conductive auxiliary agent in this case. Consequently, the preferred amount of the conductive auxiliary agent is the preferred amount of the conductive auxiliary agent mixed in preparation of a zinc negative electrode mixture and a zinc negative electrode.
[0099] The conductive auxiliary agent preferably contains particles satisfying the following average particle size and/or aspect ratio. More preferably, the conductive auxiliary agent itself satisfies the following average particle size and/or aspect ratio.
[0100] The average particle size of the conductive auxiliary agent is preferably 500 μm to 1 nm, more preferably 200 μm to 5 nm, and still more preferably 100 μm to 10 nm.
[0101] The aspect ratio (vertical/lateral) of the conductive auxiliary agent is preferably 100000 to 1.1, more preferably 80000 to 1.2, and still more preferably 50000 to 1.5.
[0102] The average particle size and the aspect ratio can be determined by the same methods as mentioned above.
[0103] The conductive auxiliary agent preferably contains particles satisfying the following specific surface area. More preferably, the conductive auxiliary agent itself satisfies the following specific surface area.
[0104] The specific surface area of the conductive auxiliary agent is more preferably 0.1 m 2 /g or larger but 1500 m 2 /g or smaller, still more preferably 1 m 2 /g or larger but 1200 m 2 /g or smaller, still further preferably 1 m 2 /g or larger but 900 m 2 /g or smaller, particularly preferably 1 m 2 /g or larger but 250 m 2 /g or smaller, and most preferably 1 m 2 /g or larger but 50 m 2 /g or smaller.
[0105] The conductive auxiliary agent having a specific surface area satisfying the above value suppresses passivation and changes in form of the zinc-containing compound, which is an active material in charge and discharge, and also suppresses self-discharge in a charged state or during storage in a charged state. The phrase “in a charged state or during storage in a charged state” herein means the state where part or all of the negative electrode active material is reduced during the charge and discharge operation or during storage of full cells or half cells.
[0106] With conductive carbon used as a conductive auxiliary agent, a side reaction of decomposing water presumably occurs also at an edge portion of the conductive carbon. Thus, the specific surface area of the conductive carbon is preferably 0.1 m 2 /g or larger but 1500 m 2 /g or smaller, more preferably 1 m 2 /g or larger but 1200 m 2 /g or smaller, still more preferably 1 m 2 /g or larger but 900 m 2 /g or smaller, particularly preferably 1 m 2 /g or larger but 250 m 2 /g or smaller, and most preferably 1 m 2 /g or larger but 50 m 2 /g or smaller. The average particle size of the conductive carbon is preferably 20 μm to 5 nm. It is more preferably 15 μm to 10 nm.
[0107] A zinc negative electrode including a zinc negative electrode mixture containing conductive carbon as a conductive auxiliary agent is expected to withstand high-rate charge-and-discharge conditions. In particular, such a zinc negative electrode is expected to give good performance when used in onboard storage batteries. It is also expected to suppress self-discharge in a charged state or during storage in a charged state and suppress changes in form of the zinc electrode active material due to precipitation of zinc into mesopores or micropores of the conductive carbon. Since water may possibly be decomposed at an edge portion of the conductive carbon in charge and discharge, the conductive carbon may be graphitized to have less edge portions for the expected purpose of achieving a high cycle characteristic, rate characteristic, and coulombic efficiency.
[0108] The zinc negative electrode mixture of the present invention may further include an additional component in addition to the zinc-containing compound and the conductive auxiliary agent. The additional component is different from the zinc-containing compound and the conductive auxiliary agent, and examples thereof include compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds.
[0109] From the viewpoint of safety, batteries using a water-containing electrolyte solution as its electrolyte solution are more preferred than those using an organic solvent-type electrolyte solution. From the thermodynamic viewpoint, however, side reactions may usually occur, such as electrochemical reactions involved in charge and discharge and self-discharge in a charged state or during storage in a charged state, thereby decomposing water to generate hydrogen. In contrast, the zinc negative electrode mixture of the present invention containing, as an additional component, at least one selected from compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds enables effective suppression of generation of hydrogen due to decomposition of water in charge and discharge even in batteries including a zinc electrode formed from the zinc negative electrode mixture of the present invention as its negative electrode and a water-containing electrolyte solution. It is also expected to suppress self-discharge during storage in a charged state, to suppress changes in form of an active material of the zinc electrode, to reduce the solubility of zinc species owing to salt formation with zinc species such as tetrahydroxozincate ions, to improve the affinity with water, to improve the anion conductivity, and to improve the electronic conductivity, thereby markedly improving the charge and discharge characteristics and the coulombic efficiency. In particular, the zinc negative electrode mixture of the present invention includes the zinc-containing compound and/or the conductive auxiliary agent containing particles having a small particle size equal to or smaller than the specific average particle size and/or long and narrow particles having the specific aspect ratio, as mentioned above. Thus, a zinc negative electrode formed from such a zinc negative electrode mixture allows batteries to have excellent performance. On the other hand, side reactions are difficult to thermodynamically completely stop, such as generation of hydrogen due to decomposition of water in charge and discharge or self-discharge in a charged state or during storage in a charged state, and dissolution of the zinc negative electrode active material. Thus, it is technically very important to combine the specific zinc-containing compound and/or conductive auxiliary agent as components of the zinc negative electrode mixture in the present invention with at least one selected from the group consisting of compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds as an additional component.
[0110] It is also one preferable embodiment of the present invention that the zinc negative electrode mixture of the present invention further includes an additional component and the additional component contains at least one selected from the group consisting of compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds.
[0111] For the zinc negative electrode mixture of the present invention further including such an additional component, the amount of the additional component is preferably 0.01 to 100% by mass for 100% by mass of the zinc-containing compound in the zinc negative electrode mixture. The amount thereof is more preferably 0.05 to 80% by mass, and still more preferably 0.1 to 60% by mass.
[0112] As mentioned here, it is also one preferable embodiment of the present invention that the zinc negative electrode mixture of the present invention further contains an additional component in an amount of 0.01 to 100% by mass for 100% by mass of the zinc-containing compound in the zinc negative electrode mixture.
[0113] With respect to at least one selected from the group consisting of compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds included in the additional component, the proportion of one species corresponding to the compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, the organic compounds, or the salts of organic compounds included in the additional component is preferably 0.1% by mass or more, more preferably 0.5% by mass or more, and still more preferably 1.0% by mass or more, for 100% by mass of the whole of the additional component. The upper limit thereof is preferably 100% by mass.
[0114] The element in the compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table is more preferably selected from those in the groups 1 to 7 and 12 to 17, more preferably those in the groups 2 to 7, 13 to 15, and 17, and most preferably those in the groups 2 to 7 and 13 to 15. Specifically, the element is preferably at least one selected from the group consisting of Al, B, Ba, Be, Bi, Ca, Ce, Cr, Cs, F, Ga, In, La, Mg, Mn, Nb, Nd, P, Pb, S, Sc, Se, Si, Sn, Sr, Sb, Te, Ti, Tl, V, Y, Yb, and Zr. The element is more preferably selected from the group consisting of Al, B, Ba, Bi, Ca, Ce, Cs, F, Ga, In, La, Mg, Nb, Nd, P, Pb, Sc, Se, Sn, Sr, Sb, Tl, Y, Yb, and Zr. The element is most preferably selected from the group consisting of Al, Ca, Ce, La, Nb, Nd, P, Sc, Y, and Zr.
[0115] The present inventors have found that the zinc negative electrode formed from the zinc negative electrode mixture containing the above element suppresses a side reaction of decomposing water in charge and discharge or dissolution of a zinc-containing negative electrode active material and improves a cycle characteristic, rate characteristic, and coulombic efficiency, and further suppresses self-discharge in a charged state or during storage in a charged state and markedly improves the storage stability. They have also found that such an electrode effectively suppresses changes in form and passivation of the zinc-containing negative electrode active material.
[0116] Examples of the compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table include: oxides; complex oxides; layered double hydroxides; hydroxides; clay compounds; solid solutions; halides; carboxylate compounds; carbonates; hydrogen carbonates; nitrates; sulfates; sulfonic acid salts; silicic acid salts; phosphoric acid salts; phosphorous acid salts; hypophosphorous acid salts; boric acid salts; ammonium salts; sulfides; onium compounds; and hydrogen storage compounds, of the element.
[0117] Specific examples of the compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table include aluminum oxide, barium oxide, bismuth oxide, bismuth-containing complex oxides, calcium oxide, calcium-containing complex oxides, cerium oxide, cerium-containing complex oxides, cesium oxide, gallium oxide, indium oxide, indium-containing complex oxides, lanthanum oxide, magnesium oxide, niobium oxide, neodymium oxide, lead oxide, phosphorus oxide, tin oxide, scandium oxide, antimony oxide, titanium oxide, manganese oxide, yttrium oxide, ytterbium oxide, zirconium oxide, zirconium oxide stabilized by scandium oxide, zirconium oxide stabilized by yttrium oxide, zirconium-containing complex oxides, barium hydroxide, calcium hydroxide, cerium hydroxide, cesium hydroxide, indium hydroxide, lanthanum hydroxide, magnesium hydroxide, tin hydroxide, antimony hydroxide, zirconium hydroxide, barium acetate, bismuth acetate, calcium acetate, calcium tartrate, calcium glutamate, cerium acetate, cesium acetate, gallium acetate, indium acetate, lanthanum acetate, magnesium acetate, niobium acetate, neodymium acetate, lead acetate, tin acetate, antimony acetate, tellurium acetate, bismuth sulfate, calcium sulfate, cerium sulfate, gallium sulfate, indium sulfate, lanthanum sulfate, lead sulfate, tin sulfate, antimony sulfate, tellurium sulfate, zirconium sulfate, calcium lignosulfonate, barium nitrate, bismuth nitrate, calcium nitrate, cerium nitrate, indium nitrate, lanthanum nitrate, magnesium nitrate, lead nitrate, tin nitrate, titanium nitrate, tellurium nitrate, zirconium nitrate, calcium phosphate, magnesium phosphate, barium phosphate, calcium borate, barium borate, layered double hydroxides (e.g. hydrotalcite), clay compounds, laponite, hydroxyapatite, solid solutions (e.g. cerium oxide-zirconium oxide), ettringite, and cement.
[0118] Compounds such as cerium hydroxide, zirconium hydroxide, layered double hydroxides (e.g. hydrotalcite), hydroxyapatite, and ettringite presumably not only suppress a side reaction of decomposing water in charge and discharge or during storage in a charged state in the zinc electrode and self-discharge, and dissolution of the zinc-containing negative electrode active material, but also improve the anion conductivity.
[0119] The compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table is preferably formed into nanoparticles having a small average particle size similarly to the zinc-containing compound and/or the conductive auxiliary agent because it more effectively suppresses side reactions occurring with the use of a water-containing electrolyte solution as an electrolyte solution. The compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table may be supported on, coprecipitated with, formed into an alloy with, formed into a solid solution with, or kneaded with at least one of the zinc-containing compound, the conductive auxiliary agent, the organic compounds, and the salts of organic compounds before or after preparation of the zinc negative electrode mixture or in preparation of the zinc negative electrode mixture. The compound may be prepared by the sol-gel process.
[0120] As mentioned here, the compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table preferably has an average particle size of 1000 μm or smaller, more preferably 200 μm or smaller, still more preferably 100 μm or smaller, particularly preferably 75 μm or smaller, and most preferably 20 μm or smaller. The lower limit of the average particle size is preferably 1 nm. The average particle size can be determined in the same manner as the average particle sizes of the zinc-containing compound and the conductive auxiliary agent.
[0121] Examples of the state of particles include fine powder, powder, particulates, granules, scales, polyhedrons, and rods. Particles having an average particle size within the aforementioned range can be produced by a method of grinding particles with, for example, a ball mill, dispersing the resulting coarse particles in a dispersant to give a predetermined particle size, and then dry-hardening the particles; a method of sieving the coarse particles to classify the particle sizes; a method of optimizing the conditions for producing the particles, thereby producing (nano)particles having a predetermined particle size; and the like methods.
[0122] The compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table preferably has a specific surface area of 0.01 m 2 /g or larger, more preferably 0.1 m 2 /g or larger, and still more preferably 0.5 m 2 /g or larger. The upper limit of the specific surface area is preferably 200 m 2 /g. The specific surface area can be determined in the same manner as the specific surface areas of the zinc-containing compound and the conductive auxiliary agent.
[0123] Examples of the organic compounds and the salts of organic compounds include poly(meth)acrylic acid moiety-containing polymers, poly(meth)acrylic acid salt moiety-containing polymers, poly(meth)acrylic acid ester moiety-containing polymers, poly(α-hydroxymethyl acrylic acid salt) moiety-containing polymers, poly(α-hydroxymethyl acrylic acid ester) moiety-containing polymers, polyacrylonitrile moiety-containing polymers, polyacrylamide moiety-containing polymers, polyvinyl alcohol moiety-containing polymers, polyethylene oxide moiety-containing polymers, polypropylene oxide moiety-containing polymers, polybutene oxide moiety-containing polymers, epoxy ring-opened moiety-containing polymers, polyethylene moiety-containing polymers, polypropylene moiety-containing polymers, polyisoprenol moiety-containing polymers, polymetallyl alcohol moiety-containing polymers, polyallyl alcohol moiety-containing polymers, polyisoprene moiety-containing polymers, aromatic ring moiety-containing polymers (e.g. polystyrene), polymaleimide moiety-containing polymers, polyvinylpyrrolidone moiety-containing polymers, polyacetylene moiety-containing polymers, ketone moiety-containing polymers, ether moiety-containing polymers, sulfide group-containing polymers, sulfone group-containing polymers, carbamate group-containing polymers, thiocarbamate group-containing polymers, carbamide group-containing polymers, thiocarbamide group-containing polymers, thiocarboxylic acid (salt) group-containing polymers, ester group-containing polymers, cyclopolymerized moiety-containing polymers, lignin, synthetic rubbers (e.g. styrene-butadiene rubber (SBR)), agar, betaine moiety-containing compounds (e.g. amino), cellulose, cellulose acetate, hydroxyalkyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, ethylene glycol, polyethylene glycol chain-containing compounds, polypropylene glycol chain-containing compounds, polybutene glycol chain-containing compounds, polyacetylene moiety-containing polymers, amino group-containing polymers (e.g. polyethylene imine), polyamide moiety-containing polymers, polypeptide moiety-containing polymers, polytetrafluoroethylene moiety-containing polymers, polyvinylidene fluoride moiety-containing polymers, poly(anhydrous) maleic acid moiety-containing polymers, polymaleic acid salt moiety-containing polymers, poly(anhydrous) itaconic acid moiety-containing polymers, polyitaconic acid salt moiety-containing polymers, polymethyleneglutaric acid moiety-containing polymers, polymethyleneglutaric acid salt moiety-containing polymers, ion-exchangeable polymers to be used for cation-anion exchange membranes, sulfonic acid salts, sulfonic acid salt moiety-containing polymers, quaternary ammonium salts, quaternary ammonium salt moiety-containing polymers, quaternary phosphonium salts, quaternary phosphonium salt moiety-containing polymers, isocyanic acid moiety-containing polymers, isocyanate group-containing polymers, thioisocyanate group-containing polymers, imide moiety-containing polymers, epoxy moiety-containing polymers, oxetane moiety-containing polymers, hydroxy moiety-containing polymers, heterocycle and/or ionized heterocycle moiety-containing polymers, polymer alloys, hetero atom-containing polymers, and low molecular weight surfactants. One of the organic compounds and the salts of organic compounds may be used, or two or more of them may be used. In the case where a polymer is used as the organic compound or the salt of an organic compound, the functional group of each polymer may exist at the main chain or at a side chain, and the main chain may be partially cross-linked.
[0124] In the case where a polymer is used as the organic compound or the salt of an organic compound, the polymer may be produced by polymerizing a monomer which corresponds to the structural unit of the polymer by, for example, radical polymerization, radical (alternating) copolymerization, anionic polymerization, anionic (alternating) copolymerization, cationic polymerization, cationic (alternating) copolymerization, graft polymerization, graft (alternating) copolymerization, living polymerization, living (alternating) copolymerization, dispersion polymerization, emulsion polymerization, suspension polymerization, ring-opening polymerization, cyclopolymerization, or light-, UV-, or electron beam-applying polymerization. In polymerization, particles of the zinc-containing compound, particles of the conductive auxiliary agent, and a compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table may be introduced into the polymer and/or on the surface of the polymer to form a single species of particles. The polymer may cause reactions such as hydrolysis in the electrolyte solution.
[0125] The organic compound and the salt of an organic compound are expected to serve as materials for achieving effects of improving the dispersibility of particles; of suppressing changes in form and passivation of binding agents which bind the particles or bind the particles and a collector, thickening agents, and the active material of the zinc electrode; of suppressing dissolution of the zinc electrode active material; of improving the hydrophilic-lipophilic balance; of improving the anion conductivity; and of improving the electronic conductivity, for example. With a water-containing electrolyte solution, the organic compound and the salt of an organic compound also have functions of suppressing a thermodynamically usually possible side reaction of decomposing water to generate hydrogen in charge and discharge, changes in form, passivation, and corrosion of the zinc electrode active material, and self-discharge in a charged state or during storage in a charged state; and of markedly improving the charge and discharge characteristics, the coulombic efficiency, and the storage stability of batteries. One factor of these effects is presumably derived from, for example, the fact that the organic compound and the salt of an organic compound suitably cover the surface of the zinc-containing compound or adsorb thereto, or they chemically interact with the zinc-containing compound. These effects of the organic compound and the salt of an organic compound are novel findings in the present invention.
[0126] The zinc negative electrode mixture of the present invention can be prepared by mixing, in addition to the zinc-containing compound and the conductive auxiliary agent, at least one selected from the group consisting of compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds as appropriate. The mixing may be performed using a device such as a mixer, a blender, a kneader, a bead mill, a ready mill, and a ball mill. In the mixing, water, an organic solvent such as methanol, ethanol, propanol, isopropanol, tetrahydrofuran, and N-methylpyrrolidone, or a solvent mixture of water and an organic solvent may be added. After the mixing, particles may be put through a sieve, for example, to make all the particles have a predetermined particle size. The mixing may be a wet process in which liquid components such as water and an organic solvent are added to solid components, or may be a dry process performed only using solid components without adding liquid components. In the case of the wet process, the mixture may be dried so that liquid components such as water or an organic solvent are removed. The wet process and the dry process may be combined. For example, the zinc-containing compound and the compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table are mixed through the wet process, then the mixture is dried so that liquid components are removed to provide a solid mixture, and finally the solid mixture and the conductive auxiliary agent are mixed through the dry process to prepare the zinc negative electrode mixture.
[0127] The zinc electrode of the present invention is formed from the zinc negative electrode mixture of the first aspect of the present invention. Such a zinc electrode formed from the zinc negative electrode mixture of the first aspect of the present invention is also one aspect of the present invention. The zinc electrode of the present invention is preferably used as a negative electrode. The zinc electrode of the present invention used as a negative electrode is also referred to as the zinc negative electrode of the present invention hereinbelow.
[0128] The zinc negative electrode of the present invention can improve the cycle characteristic, rate characteristic, and coulombic efficiency of batteries.
[0129] The zinc negative electrode may be produced as follows, for example.
[0130] The zinc negative electrode mixture of the present invention is prepared as a slurry or a paste mixture by the aforementioned preparation method. Then, the slurry or the paste mixture obtained is applied, press-applied, or bonded onto a collector so as to make the thickness as uniform as possible.
[0131] Examples of the collector include copper foil, electrolytic copper, copper foil combined with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl and carbon, copper foil plated with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, copper mesh, copper mesh combined with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, copper mesh plated with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, copper foam, copper foam combined with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, copper foam plated with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, copper alloy, nickel foil, nickel mesh, corrosion-resistant nickel, nickel mesh combined with an element such as Sn, Pb, Hg, Bi, In, Tl, and carbon, nickel mesh plated with an element such as Sn, Pb, Hg, Bi, In, Tl, and carbon, zinc metal, corrosion-resistant zinc metal, zinc metal combined with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, zinc metal plated with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, zinc foil, zinc foil combined with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, zinc foil plated with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, zinc mesh, zinc mesh combined with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, zinc mesh plated with an element such as Ni, Sn, Pb, Hg, Bi, In, Tl, and carbon, silver, and collector materials used for alkaline batteries and zinc-air batteries.
[0132] The slurry or the paste mixture may be applied or press-applied onto one face of the collector, or may be applied, press-applied, or bonded onto both faces. They are dried at 0° C. to 250° C. during the application and/or after the application. The drying temperature is more preferably 15° C. to 200° C. The drying may be performed in vacuo. The drying time is preferably 5 minutes to 48 hours. The application and the drying may be repeated. After the drying, the workpiece is preferably pressed at 0.01 to 20 t using, for example, a roll press. The pressure is more preferably 0.1 to 15 t. The temperature upon pressing may be 10° C. to 500° C.
[0133] Especially, in the case of using the zinc negative electrode (zinc mixture electrode) thus obtained as a negative electrode for a secondary battery, the electrode suppresses, at maximum, concentration of currents and decomposition of water in the zinc negative electrode, thereby suppressing deterioration of the electrode active material due to changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation, generation of hydrogen and oxygen in charge and discharge, and self-discharge in a charged state or during storage in a charged state.
[0134] The thickness of the zinc negative electrode is preferably 1 nm to 1000 μm from the viewpoints of battery structure and suppression of separation of the active material from the collector. The thickness is more preferably 10 nm to 100 μm, and still more preferably 20 nm to 50 μm.
[0135] A battery using the zinc electrode of the present invention can use a water-containing electrolyte solution as its electrolyte solution, and thus can have high safety.
[0136] A battery using the zinc electrode of the present invention as its negative electrode may be in the form of a primary battery; a secondary battery (storage battery) capable of charge and discharge; a battery utilizing mechanical charge (mechanical exchange of zinc negative electrodes); and a battery utilizing a third electrode (e.g. an electrode removing oxygen generated in charge and discharge) which is different from the zinc negative electrode of the present invention and a positive electrode formed from a positive electrode active material to be mentioned later. The battery is preferably in the form of a secondary battery (storage battery).
[0137] As mentioned here, the battery including the zinc electrode of the present invention is also one aspect of the present invention. The battery including the zinc electrode formed from the zinc negative electrode mixture of the first aspect of the present invention is also referred to as a first battery of the present invention.
[0138] A battery formed utilizing two or more of the first to third aspects of the present invention is also one aspect of the present invention.
[0139] The battery of the present invention may further include a positive electrode active material and an electrolyte solution in addition to the zinc negative electrode. The electrolyte solution is preferably a water-containing electrolyte solution to be mentioned later.
[0140] The battery including the zinc negative electrode of the present invention, a positive electrode active material, and a water-containing electrolyte solution is also one aspect of the present invention. The battery of the present invention may contain one species of each component or two or more species of each component.
[0141] The positive electrode active material may be any of those usually used as the positive electrode active material for primary batteries and secondary batteries. Examples thereof include oxygen (in the case where oxygen serves as a positive electrode active material, the positive electrode is an air electrode formed from a compound capable of reducing oxygen and oxidizing water, such as perovskite compounds, cobalt-containing compounds, iron-containing compounds, copper-containing compounds, manganese-containing compounds, vanadium-containing compounds, nickel-containing compounds, iridium-containing compounds, and platinum-containing compounds); nickel-containing compounds such as nickel oxide hydroxide, nickel hydroxide, and cobalt-containing nickel hydroxide; manganese-containing compounds such as manganese dioxide; silver oxide, lithium cobaltate, lithium manganate, and lithium iron phosphate.
[0142] Batteries using the zinc negative electrode mixture of the present invention in which the positive electrode active material is a nickel-containing compound are one preferable embodiment of the present invention.
[0143] Batteries using the zinc negative electrode mixture of the present invention in which the positive electrode active material is oxygen, such as air batteries and fuel batteries, are also one preferable embodiment of the present invention. In other words, the battery of the present invention which further satisfies that the positive electrode is an electrode capable of reducing oxygen is also one preferable embodiment of the present invention.
[0144] Any electrolyte solution usually used as an electrolyte solution of batteries may be used. Examples thereof include water-containing electrolyte solutions and organic-solvent-type electrolyte solutions, and water-containing electrolyte solutions are preferred. The water-containing electrolyte solution herein means an electrolyte solution (aqueous electrolyte solution) containing only water as the electrolyte solution material and an electrolyte solution containing a liquid mixture of water and an organic solvent as the electrolyte solution material.
[0145] Examples of the aqueous electrolyte solution include a potassium hydroxide aqueous solution, a sodium hydroxide aqueous solution, and a lithium hydroxide aqueous solution. As mentioned here, any electrolyte may be used. In the case of an aqueous electrolyte solution, it is preferably a compound generating hydroxide ions which provide ion conduction in the system. From the viewpoint of the ion conductivity, a potassium hydroxide aqueous solution is preferred. One aqueous electrolyte solution may be used, or two or more thereof may be used.
[0146] Examples of the organic solvent used in the organic-solvent-type electrolyte solution include ethylene carbonate, propylene carbonate, dimethyl carbonate, diethyl carbonate, γ-butyrolactone, dimethoxy methane, diethoxy methane, dimethoxy ethane, tetrahydrofuran, methyl tetrahydrofuran, diethoxy ethane, dimethyl sulfoxide, sulfolane, acetonitrile, benzonitrile, ionic liquid, fluorine-containing carbonates, fluorine-containing ethers, polyethylene glycols, and fluorine-containing polyethylene glycols. One organic-solvent-type electrolyte solution may be used, or two or more thereof may be used. Any electrolyte may be used in the organic-solvent-type electrolyte solution, and preferable examples thereof include LiPF 6 , LiBF 4 , LiB(CN) 4 , lithium bis(fluorosulfonyl)imide (LiFSI), and lithium bis(trifluoromethyl sulfonyl)imide (LiTFSI).
[0147] For a water-containing electrolyte solution containing an organic-solvent-type electrolyte solution, the amount of the aqueous electrolyte solution is preferably 10 to 99.9% by mass, and more preferably 20 to 99.9% by mass for 100% by mass of the sum of the amounts of the aqueous electrolyte solution and the organic-solvent-type electrolyte solution.
[0148] With respect to the concentration of the electrolyte solution, the concentration of the electrolyte (e.g. potassium hydroxide) is preferably 0.01 to 50 mol/L. The electrolyte solution having such a concentration allows for achievement of good battery performance. The concentration is more preferably 1 to 20 mol/L, and still more preferably 3 to 18 mol/L. In the case of using the following water-containing electrolyte solution in a primary battery or a secondary battery using the water-containing electrolyte solution with a zinc-containing compound used as its negative electrode, the electrolyte solution is preferably combined with at least one zinc compound selected from the group consisting of zinc oxide, zinc hydroxide, zinc phosphate, zinc pyrophosphite, zinc borate, zinc silicate, zinc aluminate, zinc metal, and tetrahydroxozincate ion salts. This makes it possible to further suppress generation and growth of changes in form, such as shape change and formation of dendrite, and passivation of the electrode active material involved in dissolution of the zinc electrode active material in charge and discharge, and self-discharge in a charged state or during storage in a charged state. In this case, the at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table is an element except for zinc. The zinc compound preferably exists in the electrolyte solution at a concentration of 0.0001 mol/L to saturated concentration.
[0149] The electrolyte solution may or may not be circulated.
[0150] The electrolyte solution may contain an additive. In the case of an aqueous electrolyte solution, the additive suppresses a thermodynamically usually possible side reaction of decomposing water to generate hydrogen in charge and discharge, changes in form, passivation, dissolution, and corrosion of the zinc electrode active material, and self-discharge in a charged state or during storage in a charged state, and also serves to markedly improve the charge and discharge characteristics and the coulombic efficiency. This is presumably because the additive suitably interacts with the surface of zinc oxide to suppress side reactions, changes in form, passivation, dissolution, and corrosion of the zinc electrode active material, and self-discharge.
[0151] In the case of an aqueous electrolyte solution using potassium hydroxide as its electrolyte, examples of the additive include lithium hydroxide, sodium hydroxide, rubidium hydroxide, cesium hydroxide, magnesium hydroxide, barium hydroxide, calcium hydroxide, strontium hydroxide, magnesium oxide, barium oxide, calcium oxide, strontium oxide, strontium acetate, magnesium acetate, barium acetate, calcium acetate, bismuth oxide, lithium fluoride, sodium fluoride, potassium fluoride, rubidium fluoride, cesium fluoride, beryllium fluoride, magnesium fluoride, calcium fluoride, strontium fluoride, barium fluoride, potassium acetate, boric acid, potassium metaborate, potassium borate, hydrogen potassium borate, calcium borate, fluoroboric acid, phosphoric acid, potassium phosphate, potassium pyrophosphate, potassium phosphite, potassium oxalate, potassium silicate, potassium sulfide, potassium sulfate, thiopotassium sulfate, titanium oxide, zirconium oxide, aluminum oxide, lead oxide, tellurium oxide, tin oxide, indium oxide, trialkyl phosphoric acid, quaternary ammonium salt-containing compounds, quaternary phosphonium salt-containing compounds, carboxylic acid salt-containing compounds, polyethylene glycol chain-containing compounds, chelating agents, polymers, gel compounds, low molecular weight organic compounds having a carboxylate group and/or a sulfonic acid base and/or a sulfinic acid base and/or a quaternary ammonium salt and/or a quaternary phosphonium salt and/or a polyethylene glycol chain and/or a halogen group such as fluorine, surfactants, and polymers and gel compounds containing the organic compounds and the salts of organic compounds.
[0152] The compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table may be added to the electrolyte solution. One additive may be used or two or more additives may be used.
[0153] In the case of using a water-containing electrolyte solution, including the case of making an organic-solvent-type electrolyte solution co-exist, the dissolved oxygen concentration (mg/L) (at 25° C.) of only the aqueous electrolyte solution is preferably not higher than the α value calculated by the formula α=−0.26375×β+8.11 (β is the hydroxide ion concentration <mol/L> in the aqueous electrolyte solution). More preferably, the dissolved oxygen concentration is as close to 0 mg/L as possible. A reduced dissolved oxygen concentration suppresses dissolution of the zinc electrode active material into the electrolyte solution, thereby suppressing changes in form, dissolution, corrosion, and passivation of the zinc electrode active material and lengthening the electrode life. The dissolved oxygen concentration can be reduced to a predetermined value or lower by operation such as deaeration of the electrolyte solution or a solvent used for the electrolyte solution, or bubbling of inert gas such as nitrogen or argon. In the case of a strongly alkaline aqueous solution-containing electrolyte solution, dissolved carbon dioxide is preferably removed simultaneously through the above operation because contamination of carbon dioxide causes generation of a large amount of carbonates, thereby reducing the conductivity and affecting the storage battery performance. The formula relating to the dissolved oxygen concentration is derived from the state of dissolved oxygen and the state of corrosion of zinc metal. The value 8.11 in the formula is the saturated solubility of oxygen in pure water (25° C.). Further, a predetermined concentration (25° C.) of oxygen is dissolved into 4M and 8M KOH aqueous solutions to prepare 4M and 8M KOH aqueous solutions (with a predetermined dissolved oxygen concentration), and zinc metal is immersed into these solutions. The presence of corrosion is observed using an SEM to lead to the formula. A dissolved oxygen concentration not higher than the α value suppresses the reaction represented by the formula Zn+1/2O 2 +H 2 O→Zn(OH) 2 , thereby presumably suppressing corrosion.
[0154] The battery of the present invention may further include a separator. The separator is a component for separating the positive electrode and the negative electrode and holding the electrolyte solution to secure the ion conductivity between the positive electrode and the negative electrode. In storage batteries using the zinc negative electrode, the separator also functions to suppress deformation of the zinc electrode active material and formation of dendrite, to wet the positive and negative electrodes, and to avoid lack of the liquid.
[0155] Any separator may be used, and examples thereof include nonwoven fabrics, filter paper, polyethylene, polypropylene, polytetrafluoroethylene, polyvinylidene fluoride, cellulose, fibrillar cellulose, viscose rayon, cellulose acetate, hydroxyalkyl cellulose, carboxymethyl cellulose, polyvinyl alcohol, cellophane, polystyrene, polyacrylonitrile, polyacrylamide, polyvinyl chloride, polyamide, polyimide, vinylon, nylon, macroporous polymers such as poly(meth)acrylic acid and copolymers thereof, agar, gel compounds, organic-inorganic hybrid (composite) compounds, ion-exchange membranous polymers and copolymers thereof, cyclopolymers and copolymers thereof, poly(meth)acrylic acid salt-containing polymers and copolymers thereof, sulfonic acid salt-containing polymers and copolymers thereof, quaternary ammonium salt-containing polymers and copolymers thereof, quaternary phosphonium salt polymers and copolymers thereof, and inorganic materials such as ceramics.
[0156] The separator may contain the compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table.
[0157] One separator may be used or two or more separators may be used. Without an increase in the resistance and deterioration in the battery performance, any number of separators may be used. The separator may have pores, micropores, or a gas diffusion layer.
[0158] As mentioned above, a battery including a zinc electrode prepared from the zinc negative electrode mixture is also one aspect of the present invention. The battery more preferably includes a zinc negative electrode prepared from the zinc negative electrode mixture. The positive electrode is preferably a nickel electrode or an air electrode. The following will exemplify a nickel electrode and describe the structure of a nickel-zinc storage battery.
[0159] The nickel-zinc battery includes the zinc negative electrode, a nickel positive electrode, a separator for separating the positive electrode and the negative electrode, an electrolyte or an electrolyte solution, an assembly including them, and a container.
[0160] Any nickel electrode may be used. For example, nickel electrodes used in nickel-hydrogen batteries, nickel-metal hydride batteries (Ni-hydrogen storage alloy batteries), and nickel-cadmium batteries may be used. The inner walls of the assembly and the container are formed from a material which is not deteriorated by corrosion or reactions in charge and discharge. Containers used for alkaline batteries and zinc-air batteries may be used. The storage battery may be of a cylindrical type such as D size, C size, AA size, AAA size, N size, AAAA size, R123A, and R-1/3N; a square type such as 9V size and 006P size; a button type; a coin type; a laminate type; a stacked type; a type in which rectangular positive and negative plates are alternately interposed between pleated separators; a closed type; an open type; or a vented cell type. The battery may have a portion for reserving gas generated in charge and discharge.
[0161] Next, the following will describe the gel electrolyte of the second aspect of the present invention and the negative electrode mixture of the third aspect of the present invention.
[0162] The aforementioned effects of the present invention of suppressing changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material and achieving good battery performance such as a high cycle characteristic, rate characteristic, and coulombic efficiency can be provided by making either of the gel electrolyte of the second aspect of the present invention or the negative electrode mixture of the third aspect of the present invention. Combination of the second aspect of the present invention and the third aspect of the present invention is also naturally one embodiment of the present invention.
[0163] The second aspect of the present invention is described at first, and then the third aspect of the present invention is described.
[0164] The gel electrolyte of the second aspect of the present invention has a cross-linked structure formed by a multivalent ion and/or an inorganic compound. In other words, the gel electrolyte has a cross-linked structure therein, and the cross-linked structure is cross-linked by a multivalent ion and/or an inorganic compound. For each of the multivalent ion and the inorganic compound, one species may be used or two or more species may be used.
[0165] The element of the multivalent ion is more preferably Mg, Ca, Sr, Ba, Sc, Y, La, Ce, Yb, Ti, Zr, Nb, Nd, Cr, Mo, W, Mn, Co, B, Al, Ga, In, Tl, Si, Ge, Sn, P, Sb, or Bi.
[0166] The multivalent ion is an anion or a cation generated by introducing any of substances containing a multivalent ion element, such as oxides; complex oxides; layered double hydroxides such as hydrotalcite; hydroxides; clay compounds; solid solutions; halides; carboxylate compounds; carbonic acid compounds; hydrogen carbonate compounds; nitric acid compounds; sulfuric acid compounds; sulfonic acid compounds; phosphoric acid compounds; phosphorus acid compounds; hypophosphorous acid compounds; boric acid compounds; silicic acid compounds; aluminic acid compounds; sulfides; onium compounds; and salts, into an electrolyte solution material, an electrolyte solution, a gel electrolyte, or the like. The anion or cation may be generated as a result of dissolution of part or the whole of a compound including the multivalent ion element into an electrolyte solution material, an electrolyte solution, a gel electrolyte, or the like. In the case where the compound including the multivalent ion element is insoluble, such a compound is introduced into an electrolyte solution material, an electrolyte solution, a gel electrolyte, or the like, and then the anion or cation may be generated on part of the compound, such as its surface. The multivalent ion may be generated in the gel electrolyte from the element-containing compound which serves as a precursor. In the case where the gel electrolyte of the present invention contains a polymer, the multivalent ion may be derived from the polymer.
[0167] As will be mentioned later, the gel electrolyte of the present invention containing a polymer may be produced by cross-linking resulting from an interaction, including covalent bond and coordination bond, and non-covalent interactions such as ionic bond, hydrogen bond, n bond, van der Waals bond, and agostic interaction, between the multivalent ion and a functional group existing mainly in the polymer.
[0168] The gel electrolyte of the present invention without a polymer may also be produced. This case only requires co-existence of the multivalent ion and an inorganic compound to be mentioned later in an electrolyte solution. Presumably, the multivalent ions as well as ions in the electrolyte solution more suitably cross-link the inorganic compound. In this case, the element of the multivalent ion and the element in the inorganic compound may be the same or different, and they each preferably contain at least one element different from those in the others.
[0169] The ratio by mass of the multivalent ion to the inorganic compound is preferably 50000/1 to 1/100000.
[0170] Examples of the inorganic compound include alkali metals and alkaline earth metals; and substances containing at least one element selected from the group consisting of Sc, Y, lanthanoids, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, Zn, Cd, B, Al, Ga, In, Tl, Si, Ge, Sn, Pb, P, As, Sb, Bi, S, Se, Te, F, Cl, Br, and I, such as oxides; complex oxides; layered double hydroxides such as hydrotalcite; hydroxides; clay compounds; solid solutions; zeolites; halides; carboxylate compounds; carbonic acid compounds; hydrogen carbonate compounds; nitric acid compounds; sulfuric acid compounds; sulfonic acid compounds; phosphoric acid compounds such as hydroxyapatite; phosphorus acid compounds; hypophosphorous acid compounds; boric acid compounds; silicic acid compounds; aluminic acid compounds; sulfides; onium compounds; and salts. Preferable are oxides; complex oxides; layered double hydroxides such as hydrotalcite; hydroxides; clay compounds; solid solutions; zeolites; fluorides; phosphoric acid compounds such as hydroxyapatite; boric acid compounds; silicic acid compounds; aluminic acid compounds; and salts, each containing at least one element selected from the group consisting of the above elements.
[0171] The hydrotalcite is a compound represented by the formula:
[0000] [M 1 1-x M 2 x (OH) 2 ](A n− ) x/n .m H 2 O
[0000] wherein M 1 represents an element such as Mg, Fe, Zn, Ca, Li, Ni, Co, and Cu; M 2 represents an element such as Al, Fe, and Mn; A represents, for example, CO 3 2− ; m is a positive number not smaller than 0; and n is approximately 0.20≦x 0.40. Any of compounds dehydrated by sintering at 150° C. to 900° C., compounds with interlayer anions decomposed, compounds with interlayer anions exchanged into ions such as hydroxide ions, natural minerals represented by Mg 6 Al 2 (OH) 16 CO 3 .mH 2 O, and the like may also be used as the inorganic compound. For a hydrotalcite-containing gel electrolyte without a polymer and an oligomer, it is preferable to co-exist a multivalent ion and/or an inorganic compound except the hydrotalcite, or to use hydrotalcite satisfying n=0.33.
[0172] The hydroxyapatite is a compound represented by Ca 10 (PO 4 ) 6 (OH) 2 . Any of compounds with a reduced Ca content owing to the preparation conditions and hydroxyapatite compounds with an element except Ca introduced therein may also be used as the inorganic compound.
[0173] The inorganic compound may be generated in the gel electrolyte with a compound containing the element used as a precursor. The inorganic compound introduced into an electrolyte solution material, an electrolyte solution, a gel electrolyte, or the like may be in the dissolved state, dispersed state (e.g. colloidal state), insoluble state, or the like. Preferably, part of the surface thereof is positively or negatively charged. The charged state of particles can be assumed by, for example, zeta potential measurement. As will be mentioned later, the gel electrolyte of the present invention containing a polymer may be produced by cross-linking resulting from an interaction, including covalent bond and coordination bond, and non-covalent interactions such as ionic bond, hydrogen bond, n bond, van der Waals bond, and agostic interaction, between the inorganic compound and a functional group existing mainly in the polymer. The gel electrolyte of the present invention without a polymer may also be produced. This case only requires existence of the inorganic compound in an electrolyte solution. Presumably, ions in the electrolyte solution and the inorganic compound are more suitably cross-linked. In this case, the multivalent ion may be contained. The element of the multivalent ion and the element in the inorganic compound may be the same or different, and they each preferably contain at least one element different from those in the others. With a layered compound such as hydrotalcite, a polymer is formed between the layers, resulting in a cross-linked state in some cases. The inorganic compound may be used such that part of the surface is not positively nor negatively charged (corresponding to an isoelectric point) when introduced into an electrolyte solution material, an electrolyte solution, a gel electrolyte, or the like. In this case, a preferable driving force for forming the gel electrolyte is not an electric interaction but a coordination bond, for example.
[0174] Specific examples of the inorganic compound include compounds containing elements of the multivalent ion. Whether such a compound generates ions and the ions serve as multivalent ions to form cross-linking or such a compound serves as an inorganic compound to form cross-linking as mentioned above depends on an electrolyte solution material, an electrolyte solution, a gel electrolyte, or the like to be used. In either case, the cross-linking structure is formed.
[0175] With the aforementioned water-containing electrolyte solution used as an electrolyte solution for preparing the gel electrolyte of the present invention, the compound generating the multivalent ion and the inorganic compound contribute to a high ion conductivity and permeability to gases generated in charge and discharge, suppress a thermodynamically usually possible side reaction of generating hydrogen and oxygen due to decomposition of water and changes in form, dissolution, and corrosion of the active material, and markedly improve the charge and discharge characteristics and the coulombic efficiency. This may presumably be attributed to suitable interactions of the multivalent ion and the inorganic compound with the surface of the negative electrode and suppression of diffusion of the zinc-containing compound.
[0176] The gel electrolyte may consist of a multivalent ion and/or an inorganic compound, and an electrolyte solution, or may further contain a polymer and/or an oligomer. The oligomer and/or the polymer contained in the gel electrolyte have/has a cross-linked structure formed by the multivalent ion and/or the inorganic compound. Presumably, use of such a gel electrolyte contributes to effective, physical and chemical suppression of diffusion of ions inside the electrode and/or its surface, thereby suppressing changes in form, such as shape change and formation of dendrite, dissolution, and corrosion of the electrode active material. Further, use of such a gel electrolyte provides an effect of suppressing passivation and self-discharge in a charged state or during storage in a charged state. Such an effect of suppressing passivation and self-discharge may also presumably be attributed to the functions of the above gel electrolyte. A storage battery produced using such a gel electrolyte is capable of achieving a high cycle characteristic, rate characteristic, and coulombic efficiency while maintaining a high electrical conductivity. Thus, the gel electrolyte of the present invention can be used in any of electrochemical devices such as primary batteries, secondary batteries (storage batteries), capacitors, and hybrid capacitors, and is preferably used in storage batteries.
[0177] The term “polymer” hereinbelow includes an oligomer.
[0178] It is one preferable embodiment of the present invention that the gel electrolyte contains a polymer. Preferably, the polymer used in the gel electrolyte is in a gel state and is formed into gel by covalent bond, coordination bond, or a non-covalent interaction such as ionic bond, hydrogen bond, n bond, and van der Waals bond. The polymer is more preferably one forming a cross-linking structure by functional groups in the polymer and the multivalent ion and/or the inorganic compound. Such a polymer is in a gel state, and the gel electrolyte contains an electrolyte solution as will be mentioned later. In conventional cases, the cross-linking moieties of the polymer are likely to be decomposed by the acidic condition or basic condition due to the electrolyte solution and/or the electrically loaded condition, and dissolved into the electrolyte solution, resulting in gradual deterioration of the gel electrolyte. In contrast, existence of a multivalent ion and/or an inorganic compound allows the functional groups in the polymer to serve as cross-link points owing to the multivalent ion and/or the inorganic compound, thereby suppressing the deterioration. In addition, the polymer is allowed to have a cross-linked structure formed by the multivalent ion and/or the inorganic compound, thereby forming a gel-like compound achieving good battery characteristics. This enables sufficient suppression of deterioration of the gel electrolyte, resulting in suppression of changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material; continuous, effective suppression of self-discharge in a charged state or during storage in a charged state; and keeping of high battery performance for a longer time.
[0179] Examples of the polymer used in the gel electrolyte include aromatic group-containing polymers such as polystyrene; ether group-containing polymers such as alkylene glycol; hydroxy group-containing polymers such as polyvinyl alcohol and poly(α-hydroxymethyl acrylic acid salts); amide bond-containing polymers such as polyamide, nylon, polyacrylamide, polyvinylpyrrolidone, and N-substituted polyacrylamide; imide bond-containing polymers such as polymaleimide; carboxyl group-containing polymers such as poly(meth)acrylic acid, polymaleic acid, polyitaconic acid, and polymethyleneglutaric acid; carboxylic acid salt-containing polymers such as poly(meth)acrylic acid salts, polymaleic acid salts, polyitaconic acid salts, and polymethyleneglutaric acid salts; halogen-containing polymers such as polyvinyl chloride, polyvinylidene fluoride, and polytetrafluoroethylene; polymers bonded by ring opening of epoxy groups such as epoxy resin; sulfonic acid salt moiety-containing polymers; quaternary ammonium salts and quaternary phosphonium salt-containing polymers such as polymers having a group represented by AR 1 R 2 R 3 B (wherein A is N or P; B is a halogen anion or an anion such as OH − ; R 1 , R 2 , and R 3 are the same or different, and each are a C1-C7 alkyl group, hydroxyalkyl group, alkyl carboxyl group, or aromatic ring; R 1 , R 2 , and R 3 may bond to form a ring structure) bonded thereto; ion-exchangeable polymers such as those used for cation-anion exchange membranes; natural rubber; synthetic rubber such as styrene-butadiene rubber (SBR); saccharides such as cellulose, cellulose acetate, hydroxyalkyl cellulose, carboxymethyl cellulose, and hydroxyethyl cellulose; amino group-containing polymers such as polyethylene imine; carbamate moiety-containing polymers; carbamide moiety-containing polymers; epoxy moiety-containing polymers, heterocycle and/or ionized heterocycle moiety-containing polymers, polymer alloys, and hetero atom-containing polymer. The polymer is obtainable from the monomer corresponding to the structural unit by radical polymerization, radical (alternating) copolymerization, anionic polymerization, anionic (alternating) copolymerization, cationic polymerization, cationic (alternating) copolymerization, graft polymerization, graft (alternating) copolymerization, living polymerization, living (alternating) copolymerization, dispersion polymerization, emulsion polymerization, suspension polymerization, ring-opening polymerization, cyclopolymerization, and polymerization by light, UV, or electron beam application. Such a polymer may have a functional group in its main chain and/or side chain, or may have a functional group as a bonding moiety with a cross-linker. One polymer may be used, or two or more polymers may be used. The polymer may be cross-linked by an organic cross-linker compound other than the multivalent ion and/or the inorganic compound via a bond such as ester bond, amide bond, ionic bond, van der Waals bond, agostic interaction, hydrogen bond, acetal bond, ketal bond, ether bond, peroxide bond, carbon-carbon bond, carbon-nitrogen bond, carbamate bond, thiocarbamate bond, carbamide bond, thiocarbamide bond, oxazoline moiety-containing bond, and triazine bond.
[0180] The polymer preferably has a weight average molecular weight of 200 to 7000000. The polymer with a weight average molecular weight within such a range sufficiently forms a gel electrolyte. The weight average molecular weight is more preferably 400 to 6500000, and still more preferably 500 to 50000000. Adjustment of the molecular weight of the polymer or use of multiple polymers having different molecular weights or different types of polymers enables adjustment of the strength of a gel electrolyte to be formed; in addition, this makes it possible to suppress changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material, to suppress self-discharge in a charged state or during storage in a charged state, and to achieve a high cycle characteristic, rate characteristic, and coulombic efficiency at best while maintaining a high ion conductivity. It is also possible to transport the hydrogen and oxygen generated by side reactions at the positive electrode or the negative electrode toward the counter electrode and to eliminate them.
[0181] The weight average molecular weight can be measured by gel permeation chromatography (GPC) or with a UV detector under the conditions mentioned in the section “EXAMPLES”.
[0182] With respect to the ratio between the polymer and the multivalent ion and/or the inorganic compound in the gel electrolyte, the ratio by mass of the polymer to a substance corresponding to at least one of the multivalent ion and the inorganic compound is preferably 5000000/1 to 1/100000. Such a ratio enables suppression of deterioration of the gel electrolyte, as well as suppression of changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation, sufficiently continuous effective suppression of self-discharge in a charged state or during storage in a charged state, and keeping of high battery performance for a longer time. The ratio is more preferably 2000000/1 to 1/10000, and still more preferably 1000000/1 to 1/1000.
[0183] The inorganic compound, the electrolyte solution, and the polymer used for preparation of the gel electrolyte are preferably deoxidized. The multivalent ion and/or the inorganic compound, the electrolyte solution, and the polymer are preferably mixed in an inert atmosphere. Use of deoxidized materials and mixing thereof under an inert atmosphere provide a gel electrolyte having good electric characteristics. The dissolved oxygen concentration of the gel electrolyte is more preferably as close to 0 mg/L as possible. Reduction in the dissolved oxygen concentration suppresses dissolution of the zinc electrode active material into an electrolyte solution, thereby suppressing changes in form, dissolution, and corrosion of the zinc electrode active material and lengthening the electrode life. In the case of a strongly alkaline aqueous solution-containing electrolyte solution, contamination of carbon dioxide may cause generation of a large amount of carbonates, deteriorating the conductivity, and affecting the storage battery performance. Thus, it is preferable to remove dissolved carbon dioxide simultaneously through the above operation.
[0184] The gel electrolyte of the present invention has a cross-linked structure formed by a multivalent ion and/or an inorganic compound, and a storage battery using such a gel electrolyte is capable of suppressing changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material, and self-discharge in a charged state or during storage in a charged state, and achieving a high cycle characteristic, rate characteristic, and coulombic efficiency while maintaining a high ion conductivity. The reason of this is as mentioned above. This gel electrolyte is also suitably used for primary batteries, suppressing changes in form of the electrode active material and achieving a high rate characteristic while maintaining a high ion conductivity.
[0185] As mentioned here, a battery including a positive electrode, a negative electrode, and an electrolyte interposed therebetween in which the electrolyte is formed essentially from the gel electrolyte of the present invention is also one aspect of the present invention. This battery of the present invention including the gel electrolyte of the present invention, which is the second aspect of the present invention, as an essential component of the electrolyte is also referred to as a second battery of the present invention. The second battery of the present invention may include one essential component, or may include two or more essential components of each of the parts.
[0186] As mentioned above, the gel electrolyte of the present invention is capable of improving various characteristics of storage batteries. Thus, it is one preferable embodiment of the present invention that the battery of the present invention (the second battery of the present invention) is a storage battery.
[0187] The whole electrolyte of the second battery of the present invention may be the gel electrolyte of the present invention, or the electrolyte may partially contain the gel electrolyte of the present invention. A battery in which the whole electrolyte is the gel electrolyte of the present invention include a gel electrolyte which is formed by swelling the electrolyte with an electrolyte solution, and such a battery has a structure where the swelled electrolyte is interposed between the positive electrode and the negative electrode. As mentioned here, it is also one preferable embodiment of the present invention that the whole electrolyte interposed between the positive electrode and the negative electrode in a battery is the gel electrolyte of the present invention.
[0188] A battery in which the electrolyte partially contains the gel electrolyte of the present invention includes an electrolyte containing the gel electrolyte of the present invention and (gel) electrolyte other than the above gel electrolyte and an electrolyte solution. For example, in the case where the gel electrolyte is used in a primary battery or a secondary battery having a zinc-containing compound as the negative electrode and a water-containing electrolyte solution to be mentioned later, the electrolyte contains the gel electrolyte of the present invention, as well as a gel electrolyte and a water-containing electrolyte solution containing no multivalent cation and/or no inorganic compound. Further, since the gel electrolyte of the present invention suppresses changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material and suppresses self-discharge in a charged state or during storage in a charged state, the electrolyte in contact with the negative electrode is preferably formed essentially using the gel electrolyte of the present invention. As mentioned here, it is also one preferable embodiment of the present invention that a battery contains the gel electrolyte of the present invention as part of the electrolyte interposed between the positive electrode and the negative electrode and the electrolyte in contact with the negative electrode is formed essentially using the gel electrolyte of the present invention. In this case, the electrolyte in contact with the negative electrode at least partially essentially contains the gel electrolyte of the present invention. The whole electrolyte in contact with the negative electrode is preferably formed essentially from the gel electrolyte of the present invention. The gel electrolyte may be preliminarily polymerized or prepared by an operation such as kneading of a polymer and an electrolyte solution before the use in batteries. Alternatively, the materials, such as a monomer, of the gel electrolyte may be put into a battery and the components are polymerized to form the gel electrolyte in the battery. An electrolyte coating may be formed on the surface of an electrode by applying a preliminarily prepared gel electrolyte to the surface of an electrode to a thickness of 1 nm or greater but 5 mm or smaller, or applying the materials of the gel electrolyte thereto and then polymerizing the materials. Used between the electrode and its counter electrode may be the same gel electrolyte as that in contact with the electrode, or may be a different gel electrolyte, or may be a liquid electrolyte solution. Optimization of the properties and the condition of the gel electrolyte between the positive and negative electrodes further improves the performance, stability, and life of the battery.
[0189] For the electrolyte containing the gel electrolyte of the present invention and a (gel) electrolyte other than the above gel electrolyte and an electrolyte solution, the proportion of the gel electrolyte of the present invention is preferably 0.001 to 100% by mass in 100% by mass of the whole electrolyte portion. The proportion is more preferably 0.01 to 100% by mass. Especially, in the case of an electrolyte containing the gel electrolyte of the present invention and a water-containing electrolyte solution, the proportion of the gel electrolyte of the present invention is preferably 0.01 to 100% by mass in 100% by mass of the whole electrolyte. The proportion is more preferably 0.02 to 100% by mass.
[0190] Examples of the positive electrode active material include the same positive electrode active materials as those mentioned in the aforementioned first battery of the present invention. In particular, a battery using a zinc negative electrode mixture with the positive electrode active material being a nickel-containing compound is also one preferable embodiment of the present invention. It is also one preferable embodiment of the present invention that the positive electrode active material is oxygen, such as air batteries and fuel batteries. In other words, the battery of the present invention whose positive electrode is an air electrode is also one preferable embodiment of the present invention.
[0191] A battery using the zinc negative electrode mixture of the present invention may be in the form of a primary battery; a secondary battery capable of charge and discharge; a battery utilizing mechanical charge (mechanical exchange of zinc negative electrodes); and a battery utilizing a third electrode (e.g. an electrode removing oxygen generated in charge and discharge) which is different from the zinc negative electrode of the present invention and a positive electrode formed from a positive electrode active material to be mentioned later.
[0192] The negative electrode may be any of those usually used as negative electrodes of batteries, and examples thereof include lithium-containing compounds and zinc-containing compounds. Negative electrodes containing lithium or zinc markedly show changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material. Thus, the effects of the present invention of effectively suppressing these disadvantages are more markedly exerted. This means that a negative electrode containing lithium and/or zinc in the first battery of the present invention is also one preferable embodiment of the present invention. The gel electrolyte of the present invention can be used as an electrolyte in lithium ion batteries whose negative electrode contains graphite, air batteries whose positive electrode is an air electrode, fuel batteries, and the like. In addition, the gel electrolyte can be used as a separator or an ion exchange membrane.
[0193] The electrolyte solution used in preparation of the gel electrolyte and the electrolyte solution may be any of electrolyte solutions for batteries usually used, and examples thereof include organic-solvent-type electrolyte solutions and water-containing electrolyte solutions. Examples of the organic solvents used in the organic-solvent-type electrolyte solutions and the water-containing electrolyte solutions include those used for the aforementioned first battery of the present invention, and preferable examples are the same. A preferable range of the ratio of an aqueous electrolyte solution in a water-containing electrolyte solution containing an organic-solvent-type electrolyte solution is the same as that in the first battery of the present invention.
[0194] The type of the electrolyte and the concentration of the electrolyte solution are also preferably the same as those in the first battery of the present invention.
[0195] In the case of using the gel electrolyte for primary batteries and secondary batteries in which a zinc-containing compound serves as the negative electrode and a water-containing electrolyte solution is used, it is preferable to add at least one zinc compound selected from the group consisting of zinc oxide, zinc hydroxide, zinc phosphate, zinc pyrophosphate, zinc borate, zinc silicate, zinc aluminate, zinc metal, and a tetrahydroxy zinc ion to the electrolyte solution serving as a material of the gel electrolyte. This further suppresses occurrence and growth of changes in form, such as shape change and formation of dendrite, and passivation of the electrode active material involved in dissolution of the zinc electrode active material in charge and discharge, and self-discharge in a charged state or during storage in a charged state. In this case, elements other than zinc are used for the multivalent ion and the inorganic compound. The zinc compound in the gel electrolyte is preferably 0.0001 mol/L to a saturated concentration.
[0196] With a water-containing electrolyte solution, the dissolved oxygen concentration in the aqueous electrolyte solution alone preferably satisfies a predetermined relationship with the hydroxide ion concentration in the aqueous electrolyte solution in the same manner as in the case of the aforementioned first battery of the present invention.
[0197] The (gel) electrolyte other than the gel electrolyte of the present invention may be any one that can be used as an electrolyte of batteries. Examples thereof include solid electrolytes capable of conducting cations (e.g. lithium) and anions (e.g. hydroxide ion) even without a liquid such as an electrolyte solution, and gel electrolytes containing no multivalent ion and/or no inorganic compound and cross-linked by other compounds (cross-linkers) via ester bond, amide bond, ionic bond, van der Waals bond, agostic interaction, hydrogen bond, acetal bond, ketal bond, ether bond, peroxide bond, carbon-carbon bond, carbon-nitrogen bond, carbamate bond, thiocarbamate bond, carbamide bond, thiocarbamide bond, oxazoline moiety-containing bond, triazine bond, or the like.
[0198] In the first battery of the present invention, the gel electrolyte may serve as a separator. Alternately, the battery may further include a separator. The definition and the function of the separator are the same as those in the aforementioned first battery of the present invention. The gel electrolyte and the separator each may have pores, micropores, and gas diffusion layers.
[0199] The separator may be the same separator as used in the first battery of the present invention, and the separator may contain the multivalent cation and/or the inorganic compound, a surfactant, an electrolyte solution, and the like. One separator may be used, or two or more separators may be used. Any number of separators may be used unless the resistance is increased and the battery performance is deteriorated. This is also the same as in the first battery of the present invention.
[0200] Next, the negative electrode mixture of the third aspect of the present invention is described. The negative electrode mixture of the present invention contains a negative electrode active material and a polymer, and contains a polymer in addition to the negative electrode active material. A negative electrode mixture having such a structure effectively suppresses changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material, and self-discharge in a charged state or during storage in a charged state. This is presumably because as follows: with a negative electrode mixture containing a polymer in addition to the negative electrode active material, a film of the polymer is formed on the whole or part of the surface of the particles of the negative electrode active material and it effectively physically and chemically suppresses diffusion of, for example, ions in the electrode and/or its surface, thereby effectively suppressing changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material, and self-discharge in a charged state or during storage in a charged state. Further, a storage battery produced using the negative electrode mixture of the present invention shows a high cycle characteristic, rate characteristic, and coulombic efficiency while maintaining a high electrical conductivity. This is presumably because such a battery shows effects of improving the hydrophilic-lipophilic balance, the ion conductivity, and the electronic conductivity, simultaneously with an effect of suppressing changes in form of the active material of the negative electrode. The negative electrode mixture of the present invention at least contains a negative electrode active material and a polymer, and may further contain an additional component such as a conductive auxiliary agent. For each of these components, one species thereof may be used, or two or more species thereof may be used. The negative electrode mixture of the present invention containing an additional component except the negative electrode active material and the polymer, the sum of the amounts of the negative electrode active material and the polymer in the negative electrode mixture of the present invention is preferably 20 to 99.99% by mass in 100% by mass of the whole negative electrode mixture. The sum of the amounts is more preferably 30 to 99.9% by mass.
[0201] An electrode formed using the negative electrode mixture of the present invention as mentioned above provides a battery showing excellent characteristics. Such an electrode formed using the negative electrode mixture of the present invention is also one aspect of the present invention. The electrode of the present invention is preferably used as a negative electrode, and a negative electrode formed using the negative electrode mixture of the present invention is also referred to as the negative electrode of the present invention.
[0202] The negative electrode mixture of the third aspect of the present invention preferably contains a zinc-containing compound as a negative electrode active material.
[0203] Examples of the zinc-containing compound may include the same zinc-containing compounds as in the aforementioned zinc negative electrode mixture of the first aspect of the present invention, and preferable examples thereof are also the same.
[0204] The average particle size and the specific surface area of the zinc-containing compound are also preferably the same as the average particle size and the specific surface area of the zinc-containing compound in the aforementioned zinc negative electrode mixture of the first aspect of the present invention.
[0205] The reason why the average particle size of the zinc-containing compound is preferably 500 μm to 1 nm is presumably as follows.
[0206] The negative electrode mixture containing a zinc-containing compound of a battery preferably further contains a conductive auxiliary agent. The negative electrode of a battery formed from a zinc negative electrode mixture containing a zinc-containing compound and a conductive auxiliary agent preferably satisfies that the zinc-containing compound molecules, the zinc-containing compound and the conductive auxiliary agent, and the zinc-containing compound, the conductive auxiliary agent, and the collector are bonded so that the negative electrode provides its function (a current is passed through the electrode). However, repeated charge and discharge or rapid charge and discharge may unavoidably promote dissociation between the zinc-containing compound molecules, between the zinc-containing compound and the conductive auxiliary agent, and among the zinc-containing compound, the conductive auxiliary agent, and the collector, or passivation of the zinc-containing compound, thereby deteriorating the battery performance. On the other hand, use of particles having the aforementioned average particle size as a zinc-containing compound allows the zinc-containing compound molecules, the zinc-containing compound and the conductive auxiliary agent, and the zinc-containing compound, the conductive auxiliary agent, and the collector to effectively contact with each other and reduces the portions where the zinc-containing compound molecules, the zinc-containing compound and the conductive auxiliary agent, and the zinc-containing compound, the conductive auxiliary agent, and the collector are completely dissociated, resulting in suppression of deterioration of the battery performance. The polymer in the negative electrode mixture further strengthens the effective contact between the zinc-containing compound molecules, between the zinc-containing compound and the conductive auxiliary agent, and among the zinc-containing compound, the conductive auxiliary agent, and the collector.
[0207] The method of measuring the average particle size and the method of producing particles having the aforementioned shape and an average particle size within the aforementioned range are the same as the method of measuring the average particle size of the zinc-containing compound and the method of producing particles having the aforementioned shape and an average particle size within the aforementioned range in the zinc negative electrode mixture of the first aspect of the present invention.
[0208] In the negative electrode mixture of the third aspect of the present invention, the amount of the negative electrode active material is preferably 50 to 99.9% by mass in 100% by mass of the whole negative electrode mixture. The negative electrode active material in an amount within the above range allows a battery including a negative electrode formed from the negative electrode mixture to achieve better battery performance. The amount is more preferably 55 to 99.5% by mass, and still more preferably 60 to 99% by mass.
[0209] The polymer in the negative electrode mixture may be the same polymer used in the above gel electrolyte, and one polymer may be used, or two or more polymers may be used.
[0210] The amount of the polymer is preferably 0.01 to 100% by mass for 100% by mass of the negative electrode active material in the negative electrode mixture. The polymer in an amount within the above range allows a battery including a negative electrode formed from the negative electrode mixture to achieve better battery performance. The amount is more preferably 0.01 to 60% by mass, and still more preferably 0.01 to 40% by mass.
[0211] The conductive auxiliary agent may be the same as the conductive auxiliary agent used in the aforementioned zinc negative electrode mixture of the first aspect of the present invention, and preferable examples thereof are also the same. Specific elements and preferable elements among them introduced into the conductive auxiliary agent are also the same as those for the conductive auxiliary agent used in the zinc negative electrode mixture of the first aspect of the present invention.
[0212] The specific surface area of the conductive auxiliary agent is preferably the same as the specific surface area of the conductive auxiliary agent used in the aforementioned zinc negative electrode mixture of the first aspect of the present invention.
[0213] The average particle size of the conductive auxiliary agent is 500 μm to 1 nm, more preferably 200 μm to 5 nm, and still more preferably 100 μm to 10 nm. The reason why the average particle size of the conductive auxiliary agent is preferably within such a range is the same as the reason why the zinc-containing compound preferably has an average particle size within the above range. Such an average particle size reduces portions where the zinc-containing compound and the conductive auxiliary agent, and the zinc-containing compound, the conductive auxiliary agent, and the collector are completely dissociated, resulting in suppression of deterioration of the battery performance.
[0214] The specific surface area and the average particle size of the conductive carbon can be measured in the same manners as for the aforementioned zinc-containing compound.
[0215] The specific surface area and the average particle size of the conductive carbon used as a conductive auxiliary agent are preferably the same as the average particle size of the conductive carbon in the aforementioned first aspect of the present invention. Similarly to the case of the first aspect of the present invention, edge portions of the conductive carbon may be reduced by graphitization, and the effects to be expected are the same.
[0216] The amount of the conductive auxiliary agent for 100% by mass of the negative electrode active material in the negative electrode mixture is preferably the same as the amount of the conductive auxiliary agent for 100% by mass of the zinc-containing compound in the zinc negative electrode mixture of the first aspect of the present invention. It is more preferably 0.0005 to 60% by mass, and still more preferably 0.001 to 40% by mass, for 100% by mass of the negative electrode active material in the negative electrode mixture.
[0217] The negative electrode mixture may further contain an additional component. Examples of the additional component include compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds.
[0218] The effects of containing these compounds are the same as the effects of containing these compounds in the zinc negative electrode mixture of the first aspect of the present invention, except the effects achieved by containing the zinc-containing compound and/or the conductive auxiliary agent which are particles having a particle size equal to or smaller than the specific average particle size and/or long and narrow particles having the specific aspect ratio.
[0219] Preferable examples of the element in the compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table are the same as those in the case of the aforementioned zinc negative electrode mixture of the first aspect of the present invention, and the effects to be achieved are the same.
[0220] Examples of the compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table are the same as those in the case of the aforementioned zinc negative electrode mixture of the first aspect of the present invention, and preferable examples thereof are the same.
[0221] The compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table is preferably formed into nanoparticles having a small average particle size similarly to the zinc-containing compound and/or the conductive auxiliary agent because they more effectively suppress side reactions occurring when a water-containing electrolyte solution is used as the electrolyte solution, and the average particle size of the compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table is preferably the same as that in the aforementioned zinc negative electrode mixture of the first aspect of the present invention. The compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table may be supported on, coprecipitated with, formed into an alloy with, formed into a solid solution with, or kneaded with at least one of the zinc-containing compound, the conductive auxiliary agent, the organic compounds, and the salts of organic compounds before or after preparation of the zinc negative electrode mixture or in preparation of the zinc negative electrode mixture. Such a compound may be prepared by the sol-gel process.
[0222] The method of producing particles having the aforementioned shape and an average particle size within the aforementioned range is also the same as in the case of the aforementioned zinc negative electrode mixture of the first aspect of the present invention.
[0223] The specific surface area of the compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table is also preferably the same as in the case of the aforementioned zinc negative electrode mixture of the first aspect of the present invention.
[0224] Examples of the organic compounds and the salts of organic compounds include the same polymers as those used in the aforementioned gel electrolyte, lignin, betaine moiety-containing compounds such as amino acids, trialkyl phosphoric acids, and low molecular weight surfactants.
[0225] In the case where the organic compounds and the salts of organic compounds are polymers, the polymerization method of producing a polymer from the monomer corresponding to the structural unit of the polymer and the effects expected from the organic compounds and the salts of organic compounds are the same as those in the case of the aforementioned zinc negative electrode mixture of the first aspect of the present invention.
[0226] Preferable examples of the organic compounds and the salts of organic compounds are the same as those preferable as the organic compounds and the salts of the organic compounds in the aforementioned zinc negative electrode mixture of the first aspect of the present invention.
[0227] The amount of the additional component is preferably 0.1 to 100% by mass for 100% by mass of the negative electrode active material in the negative electrode mixture. The amount is more preferably 0.5 to 80% by mass, and still more preferably 1.0 to 60% by mass.
[0228] The negative electrode mixture of the present invention may be prepared by mixing the negative electrode active material and the polymer, and the conductive auxiliary agent and the compound having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table as appropriate. The mixing method is the same as the method of preparing the zinc negative electrode mixture of the first aspect of the present invention.
[0229] The method of preparing the zinc negative electrode is the same as the method of producing the zinc negative electrode of the first aspect of the present invention.
[0230] Especially, use of the negative electrode (negative electrode mixture electrode) thus obtained as a negative electrode for secondary batteries suppresses concentration of currents and decomposition of water in the negative electrode, thereby suppressing deterioration due to changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the negative electrode active material, generation of hydrogen and oxygen in charge and discharge, and self-discharge in a charged state or during storage in a charged state, at maximum.
[0231] The thickness of the negative electrode is preferably 1 nm to 1000 μm from the viewpoints of battery structure and suppression of separation of the active material from the collector. The thickness is more preferably 10 nm to 100 μm, and still more preferably 20 nm to 50 μm.
[0232] The negative electrode mixture of the present invention contains a negative electrode active material and a polymer. A storage battery including a negative electrode formed from such a negative electrode mixture achieves a high cycle characteristic, rate characteristic, and coulombic efficiency while maintaining a high ion conductivity and electrical conductivity. A primary battery including a negative electrode formed from the negative electrode mixture of the present invention achieves a high rate characteristic while maintaining a high ion conductivity and electrical conductivity.
[0233] As mentioned here, a battery including a positive electrode, a negative electrode, and an electrolyte interposed therebetween, the negative electrode being formed essentially from the negative electrode mixture of the present invention is also one aspect of the present invention. This battery of the present invention including as an essential component a negative electrode formed from the negative electrode mixture of the present invention, which is the third aspect of the present invention, is also referred to as the third battery of the present invention. The third battery of the present invention may include one species of each of these essential components, or may include two or more thereof.
[0234] The negative electrode mixture of the present invention may be used in primary batteries and secondary batteries (storage batteries). Still, as mentioned above, the negative electrode mixture of the present invention enhances various characteristics of storage batteries, and thus it is preferably used in storage batteries. In other words, it is one preferable embodiment of the present invention that the third battery of the present invention is a storage battery.
[0235] In the third battery of the present invention, the polymer may also serve as a binding agent for binding particles of the negative electrode active material or the conductive auxiliary agent, or binding the particles and the collector, and/or a dispersant for dispersing the particles, and/or a thickening agent.
[0236] The negative electrode in the third battery of the present invention is formed essentially from the negative electrode mixture of the present invention. In the case where the negative electrode active material in the negative electrode mixture is a lithium-containing compound or a zinc-containing compound, the negative electrode to be formed contains lithium or zinc. Although the negative electrode containing lithium and/or zinc usually markedly causes changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material, and self-discharge in a charged state or during storage in a charged state, the negative electrode mixture of the present invention is capable of effectively suppress these disadvantages. In other words, the effects of the present invention are more markedly achieved for negative electrodes containing lithium and/or zinc. Thus, it is also one preferable embodiment of the present invention that the negative electrode contains lithium and/or zinc in the third battery of the present invention.
[0237] The positive electrode in the third battery of the present invention may be the same positive electrode in the second battery of the present invention. The electrolyte in the third battery of the present invention may be the gel electrolyte which is the second aspect of the present invention, or any electrolyte solution except for the gel electrolyte of the second aspect of the present invention to be used in the second battery of the present invention, in other words, any of organic-solvent-type electrolyte solutions, aqueous electrolyte solutions, and water-organic solvent-type electrolyte solution mixtures.
[0238] As mentioned above, combination of the second aspect of the present invention and the third aspect of the present invention is also included in the scope of the present invention, and such combination allows for more marked achievement of the effects of the present invention. In other words, a battery including a positive electrode, a negative electrode, and an electrolyte interposed therebetween, the electrolyte being formed essentially from the gel electrolyte of the present invention, and the negative electrode being formed essentially from the negative electrode mixture of the present invention is also one preferable embodiment of the present invention.
[0239] The batteries of the first to third aspects of the present invention may be produced through either a wet process or a dry process. In the wet process, for example, a positive electrode collector sheet and a negative electrode collector sheet are coated with a paste or a slurry of a positive electrode material and a paste or a slurry of a negative electrode material, respectively, and the coated electrode sheets are dried and compressed. The sheets are cut and cleaned, and the cut electrode sheets and separators are layered, thereby producing a battery assembly. The dry process is, for example, a process using a powder or granulated dry mixture of electrode components instead of a slurry or a paste. The dry process includes the steps of: (1) applying a negative electrode material to a conductive support; (2) applying a positive electrode material to a conductive support in a dried state; (3) disposing a separator between the sheets (1) and (2) to form a layered structure, thereby producing a battery assembly; and (4) winding or folding, for example, the battery assembly (3) to form a 3-dimensional structure. The electrodes may be wrapped in or coated with the separator or the gel electrolyte, for example. The positive electrode and the negative electrode may also serve as a container constituting the battery. Terminals may be attached by any conductive bonding technique such as spot welding, ultrasonic welding, laser beam welding, soldering, and other techniques suitable for the materials of terminals and collectors. The battery may be in the state of being charged or may be in the state of being discharged during the production or storage of the battery.
[0240] In the case where the batteries of the first to third aspects of the present invention are storage batteries, the charge and discharge rate of the storage battery is preferably 0.01 C or higher but 100 C or lower. The rate is more preferably 0.05 C or higher but 80 C or lower, still more preferably 0.1 C or higher but 60 C or lower, and particularly preferably 0.1 C or higher but 30 C or lower. The storage battery is preferably used in both cold districts and tropical districts on the earth, and is preferably used at a temperature of −50° C. to 100° C. With nickel zinc batteries, for example, the capacity of the zinc negative electrode may be higher or lower than, or may be equal to the capacity of the nickel positive electrode, and may suffer overcharge or overdischarge. In the case of using the storage battery of the present invention for onboard applications, the depth of charge and/or the depth of discharge are/is preferably set low. This lengthens the life of the storage battery and greatly suppresses generation of oxygen by side reactions. In the storage battery using a zinc electrode, the oxygen generated in the system is preferably consumed by (i) bonding with the zinc in the negative electrode, or (ii) the reaction in a third electrode which is different from the positive electrode and the negative electrode. Still, fundamental suppression of generation of oxygen by adjusting the charge and discharge conditions easily allows for long life and sealing of the storage battery. The nickel electrode may be a nickel electrode used in nickel-cadmium batteries and nickel-metal hydride batteries. Addition of carbon and lanthanoid compounds, for example, to the nickel electrode increases the overvoltage for oxygen generation, thereby suppressing generation of oxygen to the utmost. The additive contained in the electrolyte solution or the gel electrolyte improves the performance of the nickel electrode. The multivalent ion and/or inorganic compound and/or electrolyte contained in the gel electrolyte suppress(es) generation of oxygen to the utmost and the gel electrolyte has a more flexible skeleton than conventional gel electrolytes. Thus, the gas diffuses more rapidly, and the generated oxygen is expected to be rapidly transferred to the counter electrode and the third electrode.
Advantageous Effects of Invention
[0241] The zinc negative electrode mixture of the first aspect of the present invention has the aforementioned structure, and a zinc negative electrode formed therefrom more improves the cycle characteristic, rate characteristic, and coulombic efficiency of batteries and better suppresses self-discharge than conventional zinc negative electrodes. Further, use of a water-containing electrolyte solution provides a battery with high safety. Thus, the zinc negative electrode mixture of the first aspect of the present invention is excellent in economy, safety, stability, and storability, and is suitably used for producing a negative electrode of batteries with excellent battery performance. Even in the case of forming a battery with a water-containing electrolyte solution, mixing of the additional component in the zinc negative electrode mixture suppresses a side reaction of decomposing water to generate hydrogen in charge and discharge and changes in form, corrosion, and passivation of the zinc electrode active material, and self-discharge in a charged state or during storage in a charged state. Further, suppression of solubility of zinc species by salt formation with zinc species such as tetrahydroxy zinc ions, and improvement of hydrophilic-lipophilic balance, anion conductivity, and electronic conductivity are expected. In addition, the charge and discharge characteristics and the coulombic efficiency are markedly improved.
[0242] The gel electrolyte of the second aspect of the present invention has the aforementioned structure, and a battery formed using such a gel electrolyte suppresses changes in form, such as shape change and formation of dendrite, dissolution, corrosion, and passivation of the electrode active material and self-discharge in a charged state or during storage in a charged state, and achieves a high cycle characteristic, rate characteristic, and coulombic efficiency while maintaining a high ion conductivity of the gel electrolyte. Thus, the gel electrolyte of the second aspect of the present invention is suitably used for producing an electrolyte of a battery having excellent battery performance.
[0243] The negative electrode mixture of the third aspect of the present invention has the aforementioned structure, and a battery formed using such a negative electrode mixture suppresses changes in form, such as shape change and formation of dendrite, and passivation of the electrode active material and self-discharge in a charged state or during storage in a charged state, and achieves a high cycle characteristic, rate characteristic, and coulombic efficiency, while maintaining a high ion conductivity and electrical conductivity of the negative electrode mixture. Thus, the negative electrode mixture of the third aspect of the present invention is suitably used for producing a negative electrode of a battery having excellent battery performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0244] FIG. 1 is a graph showing the result of a charge and discharge test in Example 1, and indicating the discharging curve of the 1st cycle and the charging curves of the 20th cycle, 40th cycle, 60th cycle, 80th cycle, and 100th cycle.
[0245] FIG. 2 is a graph showing the result of a charge and discharge test in Example 2, and indicating the discharging curve of the 1st cycle and the charging curves of the 200th cycle and the 250th cycle.
[0246] FIG. 3 is a graph showing the result of a charge and discharge test in Example 3, and indicating the discharging curve of the 1st cycle and the charging curves of the 100th cycle, 200th cycle, 300th cycle, 400th cycle, and 500th cycle.
[0247] FIG. 4 is a graph showing the result of a charge and discharge test in Example 4, and indicating the discharging curve of the 1st cycle and the charging curves of the 20th cycle, 40th cycle, 60th cycle, and 100th cycle.
[0248] FIG. 5 is a graph showing the result of a charge and discharge test in Example 5, and indicating the discharging curve of the 1st cycle and the charging curves of the 1st cycle and 60th cycle.
[0249] FIG. 6 is a graph showing the result of a charge and discharge test in Example 6, and indicating the discharging curve of the 1st cycle and the charging curves of the 6th cycle, 100th cycle, 250th cycle, and 500th cycle.
[0250] FIG. 7 is a graph showing the result of a charge and discharge test in Example 7, and indicating the discharging curve of the 1st cycle and the charging curves of the 6th cycle, 30th cycle, and 60th cycle.
[0251] FIG. 8 is a graph showing the result of a charge and discharge test in Example 8, and indicating the discharging curve of the 1st cycle and the charging curves of the 5th cycle, 30th cycle, and 60th cycle.
[0252] FIG. 9 is a graph showing the result of a charge and discharge test in Example 9, and indicating the discharging curve of the 1st cycle and the charging curves of the 6th cycle, 30th cycle, and 60th cycle.
[0253] FIG. 10 is a graph showing the result of a charge and discharge test in Example 10, and indicating the discharging curve of the 1st cycle and the charging curves of the 6th cycle, 30th cycle, and 60th cycle.
[0254] FIG. 11 is a graph showing the result of a charge and discharge test in Example 11, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0255] FIG. 12 is a graph showing the result of a charge and discharge test in Example 12, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0256] FIG. 13 is a graph showing the result of a charge and discharge test in Example 13, and indicating the discharging curve of the 1st cycle and the charging curves of the 1st cycle, 30th cycle, and 60th cycle.
[0257] FIG. 14 is a graph showing the result of a charge and discharge test in Example 14, and indicating the discharging curve of the 1st cycle and the charging curves of the 4th cycle and the 30th cycle.
[0258] FIG. 15 is a graph showing the result of a charge and discharge test in Example 15, and indicating the discharging curve of the 1st cycle and the charging curves of the 8th cycle and the 30th cycle.
[0259] FIG. 16 is a graph showing the result of a charge and discharge test in Example 16, and indicating the discharging curve of the 1st cycle and the charging curves of the 4th cycle, 30th cycle, and 60th cycle.
[0260] FIG. 17 is a graph showing the result of a charge and discharge test in Example 17, and indicating the discharging curve of the 1st cycle and the charging curves of the 1st cycle, 30th cycle, and 60th cycle.
[0261] FIG. 18 is a graph showing the result of a charge and discharge test in Example 18, and indicating the discharging curve of the 1st cycle and the charging curves of the 6th cycle, 30th cycle, and 60th cycle.
[0262] FIG. 19 is a graph showing the result of a charge and discharge test in Example 19, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0263] FIG. 20 is a graph showing the result of a charge and discharge test in Example 20, and indicating the discharging curve of the 1st cycle and the charging curves of the 4th cycle, 30th cycle, and 60th cycle.
[0264] FIG. 21 is a graph showing the result of a charge and discharge test in Example 21, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0265] FIG. 22 is a graph showing the result of a charge and discharge test in Example 22, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0266] FIG. 23 is a graph showing the result of a charge and discharge test in Example 23, and indicating the discharging curve of the 1st cycle and the charging curves of the 2nd cycle, 30th cycle, and 60th cycle.
[0267] FIG. 24 is a graph showing the result of a charge and discharge test in Example 24, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0268] FIG. 25 is a graph showing the result of a charge and discharge test in Example 25, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0269] FIG. 26 is a graph showing the result of a charge and discharge test in Example 26, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0270] FIG. 27 is a graph showing the result of a charge and discharge test in Example 27, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0271] FIG. 28 is a graph showing the result of a charge and discharge test in Example 28, and indicating the discharging curve of the 1st cycle and the charging curves of the 4th cycle, 30th cycle, and 60th cycle.
[0272] FIG. 29 is a graph showing the result of a charge and discharge test in Example 29, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0273] FIG. 30 is a graph showing the result of a charge and discharge test in Example 30, and indicating the charging and discharging curves of the 20th cycle.
[0274] FIG. 31 is a graph showing the result of a charge and discharge test in Example 31, and indicating the charging and discharging curves of the 10th cycle.
[0275] FIG. 32 is a graph showing the result of a charge and discharge test in Example 32, and indicating the charging and discharging curves of the 6th cycle.
[0276] FIG. 33 shows photographs of the results of the corrosion test in Example 33, including SEM photographs of zinc metal before the test, zinc metal after immersed in an 8 M potassium hydroxide aqueous solution (oxygen concentration: 3.5 mg/L) for 5 hours, and zinc metal after immersed in an 8 M potassium hydroxide aqueous solution (oxygen concentration: 6.8 mg/L) for 5 hours.
[0277] FIG. 34 is a graph showing the result of a charge and discharge test in Example 43, and indicating the discharging curve of the 1st cycle and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0278] FIG. 35 is a graph showing the result of a charge and discharge test in Example 44, and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0279] FIG. 36 is a graph showing the result of a charge and discharge test in Example 45, and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0280] FIG. 37 is a graph showing the result of a charge and discharge test in Example 46, and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0281] FIG. 38 is a graph showing the result of a charge and discharge test in Example 47, and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0282] FIG. 39 is a graph showing the result of a charge and discharge test in Example 48, and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0283] FIG. 40 is a graph showing the result of a charge and discharge test in Example 49, and indicating the discharging curve of the 3rd cycle and the charging curves of the 30th cycle and the 60th cycle.
[0284] FIG. 41 is a graph showing the result of a charge and discharge test in Example 51, and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0285] FIG. 42 is a graph showing the result of a charge and discharge test in Example 53, and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0286] FIG. 43 is a graph showing the result of a charge and discharge test in Example 55, and the charging curves of the 3rd cycle, 30th cycle, and 60th cycle.
[0287] FIG. 44 is a graph showing the result of a charge and discharge test in Example 57, and the charging curves of the 5th cycle, 30th cycle, and 60th cycle.
[0288] FIG. 45 is a graph showing the result of a charge and discharge test in Example 58, and the charging curves of the 5th cycle, 30th cycle, and 60th cycle.
[0289] FIG. 46 is a graph showing the result of a charge and discharge test in Example 59, and the charging curves of the 5th cycle, 30th cycle, and 60th cycle.
[0290] FIG. 47 is a graph showing the result of a charge and discharge test in Example 60, and the charging curves of the 5th cycle, 30th cycle, and 60th cycle.
[0291] FIG. 48 is a graph showing the result of a charge and discharge test in Example 61, and the charging curves of the 5th cycle, 30th cycle, and 60th cycle.
[0292] FIG. 49 is a graph showing the result of a charge and discharge test in Example 62, and the charging curves of the 1st cycle, 3rd cycle, 30th cycle, and 60th cycle.
[0293] FIG. 50 is a graph showing the result of a charge and discharge test in Example 63, and indicating the charging and discharging curves of the 2nd cycle.
[0294] FIG. 51 is a graph showing the result of a charge and discharge test in Example 66, and indicating the charging and discharging curves of the 7th cycle.
[0295] FIG. 52 is a graph showing the result of a charge and discharge test in Example 67, and indicating the charging and discharging curves of the 20th cycle.
[0296] FIG. 53 is a graph showing the result of a charge and discharge test in Example 68, and indicating the charging and discharging curves of the 20th cycle.
[0297] FIG. 54 is a graph showing the result of a charge and discharge test in Example 69, and indicating the discharging curve of the 1st cycle and the charging curves of the 5th cycle, 30th cycle, and 60th cycle.
[0298] FIG. 55 is a graph showing the result of a charge and discharge test in Example 70, and indicating the discharging curve of the 1st cycle and the charging curves of the 5th cycle, 30th cycle, and 60th cycle.
DESCRIPTION OF EMBODIMENTS
[0299] The present invention will be described in more detail referring to, but not limited to, the following examples.
[0300] In the following examples, each of the physical properties is a measured value obtained as follows or, if the material is a product in the market, the official value shown in the catalog. Zinc oxide is zinc oxide #1 unless otherwise mentioned.
<Weight Average Molecular Weight>
[0301] The weight average molecular weight was measured using the following device under the following conditions.
[0302] Pump: L-7110 (Hitachi, Ltd.)
[0303] Detector: UV 214 nm (model 481 (Nihon Waters K.K.) or L-7400 (Hitachi, Ltd.))
[0304] Calibration curve: sodium polyacrylate standard sample (Sowa Science Corp.)
[0305] Eluent: aqueous solution prepared by adding pure water to disodium hydrogen phosphate dodecahydrate (34.5 g) and sodium dihydrogen phosphate dihydrate (46.2 g) to make up to 5,000 g, and filtering the mixture through a 0.45-micron membrane filter
[0306] Column: GF-7 MHQ (Showa Denko K.K.) or TSK-GEL G3000PWXL (TOSOH CORP.)
[0307] Flow rate of eluent: 0.5 mL/min
[0308] Column temperature: 35° C.
<Average Particle Size>
[0309] The average particle sizes and the aspect ratios of the zinc oxides, except for the average particle sizes in Examples 5, 6, 9 to 18, 21 to 32, 34 to 37, 39 to 63, and Examples 66 to 85, were each calculated as an average value of measured values on representative 200 particles using an S-3500 scanning electron microscope (SEM) (Hitachi High-Technologies Corp.).
<Average Particle Size, Mode Diameter, Median Diameter>
[0310] The average particle sizes, the mode diameters, and the median diameters of the zinc oxides in Examples 5, 6, 9 to 18, 21 to 32, 34 to 37, 39 to 63, and Examples 66 to 85 were measured using a laser analysis/scattering particle size distribution measurement device LA-950V2 Wet (HORIBA, Ltd.). The values described below were measured after dispersing the particles in ion exchange water and irradiating the particles with ultrasonic waves for five minutes.
<True Density>
[0311] The true density was measured using AccuPyc II-1340 (Shimadzu Corp.).
<Aspect Ratio>
[0312] Representative 200 particles were measured using an S-3500 series scanning electron microscope (SEM) (Hitachi High-Technologies Corp.), and the average value of the measured values was calculated.
<Specific Surface Area>
[0313] The specific surface area was measured using an automatic BET specific surface area measurement device (Mountech Co., Ltd.).
<Dissolved Oxygen Concentration>
[0314] The dissolved oxygen concentration was measured using an oxygen meter (UC-12-SOL series, electrode: UC-203 series) (Central Kagaku Corp.).
1. Examples of the First Aspect of the Present Invention
Example 1
[0315] Zinc oxide (10.6 g, average particle size: 20 nm, specific surface area: about 20 m 2 /g), vapor grown carbon fibers (multi-walled carbon nanotube) (0.35 g, aspect ratio (vertical/lateral): 100, specific surface area: about 10 m 2 /g, average fiber length: about 15 μm), and bismuth oxide (0.87 g, average particle size: about 50 μm) were put into a bottle, and the mixture was pulverized using a zirconia ball in a ball mill for 12 hours. The obtained solid was passed through a sieve to provide an average particle size of 25 μm or smaller. This solid (1.3 g), a solution of 12% polyvinylidene fluoride in N-methylpyrrolidone (2.2 g), and N-methylpyrrolidone (1.0 g) were put into a glass vial and stirred overnight using a stirrer with a stir bar. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours and dried in vacuo (at room temperature) for six hours. The copper foil coated with the zinc mixture was pressed at 1 t so that the thickness of the zinc mixture was 10 μm. The workpiece was punched using a punching device (diameter: 15.95 mm) to provide a zinc mixture electrode, and this was used as a working electrode (zinc mixture weight: 2.55 mg) having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L). Then, a charge and discharge test was performed using the three-electrode cell at a current of 1.38 mA (charge and discharge times: 1 hour, cut off at −0.2 V and 0.4 V).
Example 2
[0316] Zinc oxide (10.5 g, average particle size: 20 nm, specific surface area: about 20 m 2 /g), acetylene black (AB) (0.36 g, average particle size: about 40 nm, specific surface area: about 70 m 2 /g), and tin oxide (0.87 g, average particle size: about 5 μm, specific surface area: about 5 m 2 /g or smaller) were put into a bottle, and the mixture was pulverized using a zirconia ball in a ball mill for 12 hours. The obtained solid was passed through a sieve to provide an average particle size of 25 μm or smaller. This solid (1.29 g), a solution of 12% polyvinylidene fluoride in N-methylpyrrolidone (2.17 g), and N-methylpyrrolidone (1.2 g) were put into a glass vial and stirred overnight using a stirrer with a stir bar. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours and dried in vacuo (at room temperature) for six hours. The copper foil coated with the zinc mixture was pressed at 1 t so that the thickness of the zinc mixture was 10 μm. The workpiece was punched using a punching device (diameter: 15.95 mm) to provide a zinc mixture electrode, and this was used as a working electrode (zinc mixture weight: 2.88 mg) having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L). Then, a charge and discharge test was performed using the three-electrode cell at a current of 1.52 mA (charge and discharge times: 1 hour, cut off at −0.1 V and 0.4 V).
Example 3
[0317] A zinc mixture electrode was produced through the same steps as in Example 2. This zinc mixture electrode was used as a working electrode (zinc mixture weight: 2.64 mg) having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L). Then, a charge and discharge test was performed using the three-electrode cell at a current of 3.83 mA (charge and discharge times: 1 hour, cut off at −0.1 V and 0.4 V).
Example 4
[0318] Zinc oxide (10.5 g, average particle size: 1200 μm) and acetylene black (0.36 g, average particle size: about 40 nm, specific surface area: about 70 m 2 /g) were put into a bottle, and the mixture was stirred using a planetary centrifugal mixer for two hours. The obtained solid (1.2 g), a solution of 12% polyvinylidene fluoride in N-methylpyrrolidone (2.0 g), and N-methylpyrrolidone (1.1 g) were put into a glass vial and stirred overnight using a stirrer with a stir bar. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours and dried in vacuo (at room temperature) for six hours. The copper foil coated with the zinc mixture was pressed at 1 t so that the thickness of the zinc mixture was 10 μm. The workpiece was punched using a punching device (diameter: 15.95 mm) to provide a zinc mixture electrode, and this was used as a working electrode (zinc mixture weight: 2.67 mg) having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L). Then, a charge and discharge test was performed using the three-electrode cell at a current of 1.45 mA (charge and discharge times: 1 hour, cut off at −0.2 V and 0.4 V). The surface of the zinc mixture electrode after the charge and discharge test was observed using an SEM, and the observation revealed that the shape of the zinc electrode active material was changed.
Example 5
[0319] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 40 nm, specific surface area: about 70 m 2 /g), indium oxide (2.4 g, NACALAI TESQUE, INC.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, the mixture was dried using an evaporator under reduced pressure at 100° C. for two hours, and further dried using a stationary-type vacuum dryer under reduced pressure at 110° C. overnight. The dried solid was pulverized at 18000 rpm for 60 seconds using a pulverizer (WARING, X-TREME MX1200XTM). The obtained solid (1.1 g), a solution of 12% polyvinylidene fluoride in N-methylpyrrolidone (2.0 g), and N-methylpyrrolidone (0.90 g) were put into a glass vial and stirred overnight using a stirrer with a stir bar. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours. The copper foil coated with the zinc mixture was pressed at 3 t so that the thickness of the zinc mixture was 10 μm or smaller. The workpiece was punched using a punching device (diameter: 15.95 mm) to provide a zinc mixture electrode, and this was used as a working electrode (zinc mixture weight: 1.75 mg) having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L). Then, a charge and discharge test was performed using the three-electrode cell at a current of 0.834 mA (charge and discharge times: 1 hour, cut off at −0.1 V and 0.4 V).
Example 6
[0320] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), indium (III) oxide (2.4 g, NACALAI TESQUE, INC.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.24 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.590 mA (charge and discharge times: 1 hour).
Example 7
[0321] Zinc oxide (27.6 g, average particle size: 1.7 μm, true density: about 5.95 g/cm 3 ), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), indium (III) oxide (2.4 g, NACALAI TESQUE, INC.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 0.80 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.501 mA (charge and discharge times: 1 hour).
Example 8
[0322] Zinc oxide (27.6 g, average particle size: 5.5 μm, true density: about 5.75 g/cm 3 ), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), indium (III) oxide (2.4 g, NACALAI TESQUE, INC.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.16 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.554 mA (charge and discharge times: 1 hour).
Example 9
[0323] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), bismuth (III) oxide (2.4 g, 99.9%, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.32 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.675 mA (charge and discharge times: 1 hour).
Example 10
[0324] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), titanium (IV) oxide (2.4 g, anatase-type, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.09 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.519 mA (charge and discharge times: 1 hour).
Example 11
[0325] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), niobium (V) oxide (2.4 g, 99.9%, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.47 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.703 mA (charge and discharge times: 1 hour). The surface of the zinc mixture electrode after the charge and discharge test was observed using an SEM, showing neither shape change nor passivation of the zinc electrode active material.
Example 12
[0326] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.28 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.610 mA (charge and discharge times: 1 hour). The surface of the zinc mixture electrode after the charge and discharge test was observed using an SEM, showing neither shape change nor passivation of the zinc electrode active material.
Example 13
[0327] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), indium (III) oxide (2.4 g, NACALAI TESQUE, INC.), and water (180.0 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.46 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.699 mA (charge and discharge times: 1 hour).
Example 14
[0328] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), manganese (II) oxide (2.4 g, KISHIDA CHEMICAL Co., Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.47 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.701 mA (charge and discharge times: 1 hour).
Example 15
[0329] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), manganese (IV) oxide (2.4 g, 99.5%, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.15 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.547 mA (charge and discharge times: 1 hour).
Example 16
[0330] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), zirconium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.51 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.720 mA (charge and discharge times: 1 hour). The surface of the zinc mixture electrode after the charge and discharge test was observed using an SEM, showing neither shape change nor passivation of the zinc electrode active material.
Example 17
[0331] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), calcium hydroxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.38 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.658 mA (charge and discharge times: 1 hour/).
Example 18
[0332] Zinc oxide (27.6 g, zinc oxide #2, average particle size: about 1.9 μm, mode diameter: about 820 nm, median diameter: about 906 nm, true density: about 5.89 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), indium (III) oxide (2.4 g, NACALAI TESQUE, INC.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.59 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.759 mA (charge and discharge times: 1 hour).
Example 19
[0333] Needle-like zinc oxide (27.6 g, average major axis diameter: 100 nm, average minor axis diameter: 20 nm, average aspect ratio: 5, specific surface area: 30 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 3.71 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.77 mA (charge and discharge times: 1 hour, cut off at −0.1 V and 0.4 V).
Example 20
[0334] Needle-like zinc oxide (27.6 g, average major axis diameter: 900 nm, average minor axis diameter: 60 nm, average aspect ratio: 15, specific surface area: 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.64 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.784 mA (charge and discharge times: 1 hour).
Example 21
[0335] Zinc oxide (22.1 g, average particle size: about 2.0 μm, mode diameter: about 710 nm, median diameter: about 1.0 μm, true density: about 5.91 g/cm 3 , specific surface area: 3.3 m 2 /g), needle-like zinc oxide (5.5 g, average major axis diameter: 100 nm, average minor axis diameter: 20 nm, average aspect ratio: 5, specific surface area: 30 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.78 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.848 mA (charge and discharge times: 1 hour).
Example 22
[0336] Zinc oxide (22.1 g, average particle size: about 2.0 μm, mode diameter: about 710 nm, median diameter: about 1.0 μm, true density: about 5.91 g/cm 3 ), zinc oxide (5.5 g, average particle size: 5.5 μm, true density: about 5.75 g/cm 3 ), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.66 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.792 mA (charge and discharge times).
Example 23
[0337] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), conductive carbon black (0.9 g, average particle size: about 25 nm, specific surface area: about 225 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.55 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.739 mA (charge and discharge times: 1 hour).
Example 24
[0338] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), artificial graphite fine powder (0.9 g, average particle size: about 3 μm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.46 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.696 mA (charge and discharge times: 1 hour).
Example 25
[0339] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), artificial graphite fine powder (0.9 g, average particle size: about 10 μm, specific surface area: about 15 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.22 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.583 mA (charge and discharge times: 1 hour).
Preparation Example
[0340] A 5-L separable flask was charged with calcium hydroxide (88.9 g, Wako Pure Chemical Industries, Ltd.) and water (1930 g), and the substances were stir-mixed to provide an aqueous suspension. The aqueous suspension was warmed to 60° C. A 10% by mass aluminum sulfate aqueous solution (684.3 g) was put into the separable flask while the stirring was continued, and the stir-mixing was continued for four hours while the liquid temperature was kept at 60° C. Then, the stirring was stopped and the liquid was cooled down to room temperature, and the liquid mixture was left to stand overnight. Next, the precipitate was separated by filtration. The obtained precipitate was identified by X-ray diffraction, and this precipitate was proved to be ettringite (Ca 6 Al 2 (SO 4 ) 3 (OH) 12 .26H 2 O). The obtained precipitate was dried using a stationary-type dryer at 100° C. for one day, and then pulverized using a pulverizer (WARING, X-TREME MX1200XTM) at 18000 rpm for 60 seconds, thereby providing a dried, desiccated powder of ettringite.
Example 26
[0341] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), the dried, desiccated powder of ettringite obtained in the Preparation Example (2.4 g), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.13 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.540 mA (charge and discharge times: 1 hour). The surface of the zinc mixture electrode after the charge and discharge test was observed using an SEM, showing neither shape change nor passivation of the zinc electrode active material.
Example 27
[0342] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), graphitized carbon black (0.9 g, average particle size: about 70 nm, specific surface area: about 27 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.29 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.597 mA (charge and discharge times: 1 hour).
Example 28
[0343] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), Ketjenblack (0.9 g, average particle size: about 40 nm, specific surface area: about 800 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.21 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.580 mA (charge and discharge times: 1 hour).
Example 29
[0344] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), carbon black (0.9 g, average particle size: about 30 nm, specific surface area: about 250 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 0.875 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.418 mA (charge and discharge times: 1 hour).
Example 30
[0345] The zinc mixture electrode produced in Example 12 was used as a working electrode (zinc mixture weight: 1.82 mg) having an apparent area of 0.79 cm 2 . The counter electrode was a nickel electrode (active material: nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 7.3 mol/L potassium hydroxide and 1.0 mol/L potassium fluoride (dissolved oxygen concentration: 2.9 mg/L). A charge and discharge test was performed using the two-electrode cell at a current of 1.20 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). This charge and discharge test proved that the cell was stably used at least 300 cycles.
Example 31
[0346] The zinc mixture electrode produced in Example 12 was used as a working electrode (zinc mixture weight: 6.21 mg) having an apparent area of 2.0 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 7.3 mol/L potassium hydroxide (dissolved oxygen concentration: 3.2 mg/L). Nonwoven fabrics (two sheets) and a polypropylene macroporous membrane (one sheet) were interposed between the zinc electrode and the nickel electrode as separators to form a coin cell, and a charge and discharge test was performed using the coin cell at a current of 3.01 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V).
Example 32
[0347] The zinc mixture electrode produced in Example 12 was used as a working electrode (zinc mixture weight: 10.3 mg) having an apparent area of 2.0 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode) and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 7.3 mol/L potassium hydroxide (dissolved oxygen concentration: 3.2 mg/L). Nonwoven fabrics (two sheets) and a polypropylene microporous membrane (one sheet) were interposed between the zinc electrode and the nickel electrode as separators to form a coin cell, and a charge and discharge test was performed using the coin cell at a current of 1.49 mA (charge and discharge times: 3 hours 20 minutes, cut off at 1.9 V and 1.2 V).
Example 33
[0348] A zinc plate was immersed in an 8 M KOH aqueous solution (dissolved oxygen concentration: 3.5 mg/L or 6.8 mg/L) for five hours, and the surface of the zinc plate was observed using Miniscope TM3000 (Hitachi High-Technologies Corp.).
Example 34
[0349] A zinc mixture electrode was produced according to the composition in Example 11, and a charge and discharge test was performed using the same device under the same conditions as in Example 11 (10 cycles). The charging capacity at the 10th cycle was 657 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 657 mAh/g and no self-discharge occurred.
Example 35
[0350] A zinc mixture electrode was produced according to the composition in Example 12, and a charge and discharge test was performed using the same device under the same conditions as in Example 12 (10 cycles). The charging capacity at the 10th cycle was 655 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 630 mAh/g and self-discharge hardly occurred.
Example 36
[0351] A zinc mixture electrode was produced according to the composition in Example 16, and a charge and discharge test was performed using the same device under the same conditions as in Example 16 (10 cycles). The charging capacity at the 10th cycle was 658 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 658 mAh/g and no self-discharge occurred.
Example 37
[0352] A zinc mixture electrode was produced according to the composition in Example 24, and a charge and discharge test was performed using the same device under the same conditions as in Example 24 (10 cycles). The charging capacity at the 10th cycle was 650 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 574 mAh/g and self-discharge was effectively suppressed.
Example 38
[0353] A zinc mixture electrode was produced according to the composition in Example 4, and a charge and discharge test was performed using the same device under the same conditions as in Example 4 (10 cycles). The charging capacity at the 10th cycle was 380 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 0 mAh/g and self-discharge occurred.
Example 39
[0354] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), conductive carbon black (0.9 g, average particle size: about 25 nm, specific surface area: about 225 m 2 /g), zirconium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.57 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.762 mA (charge and discharge times: 1 hour). The charging capacity at the 10th cycle was 654 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 655 mAh/g and no self-discharge occurred.
Example 40
[0355] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), graphitized carbon black (0.9 g, average particle size: about 70 nm, specific surface area: about 27 m 2 /g), zirconium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.45 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.19 mA (charge and discharge times: 1 hour). The charging capacity at the 10th cycle was 658 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 638 mAh/g and self-discharge hardly occurred.
Example 41
[0356] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), artificial graphite fine powder (0.9 g, average particle size: about 3 μm, specific surface area: about 40 m 2 /g), zirconium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.85 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.38 mA (charge and discharge times: 1 hour). The charging capacity at the 10th cycle was 647 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 620 mAh/g and self-discharge hardly occurred.
Example 42
[0357] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), Ketjenblack (0.9 g, average particle size: about 40 nm, specific surface area: about 800 m 2 /g), zirconium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.59 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.769 mA (charge and discharge times: 1 hour). The charging capacity at the 10th cycle was 647 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 620 mAh/g and self-discharge hardly occurred.
Example 43
[0358] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), carbon black (0.9 g, average particle size: about 12 nm, specific surface area: about 1200 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.06 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.991 mA (charge and discharge times: 1 hour).
Example 44
[0359] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), scaly natural graphite (0.9 g, average particle size: about 6.5 μm), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.74 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.33 mA (charge and discharge times: 1 hour).
Example 45
[0360] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), bulk natural graphite (0.9 g, average particle size: about 7.8 μm), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.57 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.762 mA (charge and discharge times: 1 hour).
Example 46
[0361] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), pyrolytic graphite (0.9 g, average particle size: about 6.9 μm), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.80 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.872 mA (charge and discharge times: 1 hour).
Example 47
[0362] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), spherical graphite (0.9 g, average particle size: about 8.6 μm), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.00 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.968 mA (charge and discharge times: 1 hour).
Example 48
[0363] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), graphitized carbon microspheres (0.9 g, average particle size: about 270 nm), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.84 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.890 mA (charge and discharge times: 1 hour).
Example 49
[0364] Zinc oxide (30 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 40 nm, specific surface area: about 70 m 2 /g), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.74 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.33 mA (charge and discharge times: 1 hour). The surface of the zinc mixture electrode after the charge and discharge test was observed using an SEM, and the observation revealed that the shape of zinc electrode active material was changed.
Example 50
[0365] A zinc mixture electrode was produced according to the composition in Example 49, and a charge and discharge test was performed using the same device under the same conditions as in Example 49 (10 cycles). The charging capacity at the 10th cycle was 582 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 0 mAh/g and self-discharge occurred.
Example 51
[0366] Zinc oxide (27.6 g, zinc oxide #3, average particle size: about 800 nm, mode diameter: about 107 nm, median diameter: about 368 nm, true density: about 5.85 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.90 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.919 mA (charge and discharge times: 1 hour).
Example 52
[0367] A zinc mixture electrode was produced according to the composition in Example 51, and a charge and discharge test was performed using the same device under the same conditions as in Example 51 (10 cycles). The charging capacity at the 10th cycle was 470 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 0 mAh/g and self-discharge occurred.
Example 53
[0368] Zinc oxide (27.6 g, zinc oxide #2, average particle size: about 1.1 μm, mode diameter: about 930 nm, median diameter: about 810 nm, true density: about 5.70 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.19 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.06 mA (charge and discharge times: 1 hour).
Example 54
[0369] A zinc mixture electrode was produced according to the composition in Example 53, and a charge and discharge test was performed using the same device under the same conditions as in Example 53 (10 cycles). The charging capacity at the 10th cycle was 610 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 0 mAh/g and self-discharge occurred.
Example 55
[0370] Zinc oxide (27.6 g, zinc oxide #2, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 880 nm, true density: about 6.00 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.03 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.982 mA (charge and discharge times: 1 hour).
Example 56
[0371] A zinc mixture electrode was produced according to the composition in Example 55, and a charge and discharge test was performed using the same device under the same conditions as in Example 55 (10 cycles). The charging capacity at the 10th cycle was 658 mAh/g. Then, a discharge operation was performed under the same conditions, so that the whole zinc oxide in the zinc mixture electrode was converted into zinc metal. The cell was left to stand for 24 hours, and a charge operation was performed under the same conditions. The test proved that the discharging capacity at that time was 658 mAh/g and no self-discharge occurred.
Example 57
[0372] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), lanthanum oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.25 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.07 mA (charge and discharge times: 1 hour).
Example 58
[0373] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), hydroxyapatite (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.60 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.24 mA (charge and discharge times: 1 hour).
Example 59
[0374] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), yttrium oxide-stabilized zirconium oxide (2.4 g), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.34 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.11 mA (charge and discharge times: 1 hour).
Example 60
[0375] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), scandium oxide-stabilized zirconium oxide (2.4 g), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.71 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.81 mA (charge and discharge times: 1 hour).
Example 61
[0376] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium oxide-zirconium oxide solid solutions (2.4 g, CeO 2 /ZrO 2 /Y 2 O 3 =25/74/1), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.47 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 1.17 mA (charge and discharge times: 1 hour).
Example 62
[0377] A 2-L beaker was charged with zinc chloride (58.7 g, special grade, Wako Pure Chemical Industries, Ltd.) and water (900 g), and the zinc chloride was completely dissolved in water. Then, a solution of indium oxide (0.9, NACALAI TESQUE, INC.) dissolved in hydrochloric acid (53.1 g, special grade, Wako Pure Chemical Industries, Ltd.) was added to the beaker. The substances were stir-mixed to provide a uniform aqueous solution. Next, a 14% by mass ammonia water was gradually added to the aqueous solution until the pH of the aqueous solution reached 8 while stirred. The stirring was continued for 15 minutes after completion of the addition of the ammonia water. Then, the stirring was stopped and the mixture was left to stand for two hours, thereby providing generation of precipitate. The precipitate and the supernatant were separated by filtration. The obtained precipitate was sufficiently washed with water and ethanol, and the washed precipitate was dried overnight under reduced pressure at 60° C. The dried solid (powder) obtained was calcined for two hours under atmospheric pressure at 500° C., thereby providing an indium oxide-doped zinc oxide powder. The composition (ratio by weight) of this powder was ZnO/In 2 O 3 =97.5/2.5.
[0378] The indium oxide-doped zinc oxide powder (30.0 g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 1.80 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 5, a charge and discharge test was performed using the three-electrode cell at a current of 0.87 mA (charge and discharge times: 1 hour).
Example 63
[0379] The zinc mixture electrode produced in Example 12 was used as a working electrode (zinc mixture weight: 1.26 mg) having an apparent area of 0.50 cm 2 . The counter electrode was an air electrode with air holes (TOMOE ENGINEERING CO., LTD., QSI-Nano manganese gas diffusion electrode), and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (dissolved oxygen concentration: 2.9 mg/L). A charge and discharge test was performed using the two-electrode cell at a current of 0.829 mA (charge and discharge times: 20 minutes, cut off at 2.0 V and 0.5 V).
2. Examples of the Second and Third Aspects of the Present Invention
Example 64
[0380] To a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L) (10 mL) were added hydrotalcite (1.5 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and sodium polyacrylate (0.8 g, weight average molecular weight: 6500000) and the mixture was stirred for three days, thereby providing a hydrotalcite-cross-linked acrylic acid salt gel.
[0381] Zinc oxide (10.5 g, average particle size: 20 nm), acetylene black (AB) (0.36 g), and tin oxide (0.87 g, average particle size: about 50 μm) were put into a bottle, and the mixture was pulverized using a zirconia ball in a ball mill for 12 hours. The obtained solid was passed through a sieve to provide an average particle size of 25 μm or smaller. This solid (1.29 g), a solution of 12% polyvinylidene fluoride in N-methylpyrrolidone (2.17 g), and N-methylpyrrolidone (1.2 g) were put into a glass vial and stirred overnight using a stirrer with a stir bar. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours and dried in vacuo (at room temperature) for six hours. The copper foil coated with the zinc mixture was pressed at 1 t so that the thickness of the zinc mixture was 10 μm. The workpiece was punched using a punching device to provide a zinc mixture electrode, and this was used as a working electrode (zinc mixture weight: 11.8 mg) having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide. On the surface of the zinc negative electrode was placed the prepared hydrotalcite-cross-linked acrylic acid gel (thickness: 5 mm), and a charge and discharge test was performed using the three-electrode cell at a current of 1.52 mA (charge and discharge times: 1 hour, cut off at −0.1 V and 0.4 V). The charge and discharge operation was repeated 100 times, and then the cell was disassembled and the zinc electrode was visually observed. The observation found that changes in form and growth of dendrite of the active material in the zinc electrode mixture were suppressed.
Comparative Example 1
[0382] Zinc oxide (10.5 g, average particle size: 20 nm), acetylene black (AB) (0.36 g), and tin oxide (0.87 g, average particle size: about 50 μm) were put into a bottle, and the mixture was pulverized using a zirconia ball in a ball mill for 12 hours. The obtained solid was passed through a sieve to provide an average particle size of 25 μm or smaller. This solid (1.29 g), a solution of 12% polyvinylidene fluoride in N-methylpyrrolidone (2.17 g), and N-methylpyrrolidone (1.2 g) were put into a glass vial and stirred overnight using a stirrer with a stir bar. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours and dried in vacuo (at room temperature) for six hours. The copper foil coated with the zinc mixture was pressed at 1 t so that the thickness of the zinc mixture was 10 μm. The workpiece was punched using a punching device to provide a zinc mixture electrode, and this was used as a working electrode (zinc mixture weight: 12.0 mg) having an apparent area of 0.48 cm 2 . In the same manner as in Example 64, a charge and discharge test was performed using the three-electrode cell at a current of 1.53 mA (charge and discharge times: 1 hour, cut off at −0.1 V and 0.4 V). The charge and discharge operation was repeated 100 times, and then the cell was disassembled and the zinc electrode was visually observed. The observation found that the zinc electrode expanded due to changes in form and growth of dendrite of the active material in the zinc electrode mixture.
Example 65
[0383] Zinc oxide (10.5 g, average particle size: 20 nm) and acetylene black (AB) (1.5 g) were put into a bottle. Thereto were added a polymer having a moiety where a quaternary ammonium salt (counter anion: hydroxy group) was bonded to the aromatic ring of polystyrene and a solution of 12% polyvinylidene fluoride in N-methylpyrrolidone, and the mixture was pulverized using a ball mill for 12 hours. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours and dried in vacuo (at room temperature) for six hours. The copper foil coated with the zinc mixture was pressed at 1 t so that the thickness of the zinc mixture was 10 μm. The workpiece was punched using a punching device to provide a zinc mixture electrode, and this was used as a working electrode having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L). A charge and discharge test was performed using the three-electrode cell (charge and discharge times: 1 hour). The initial coulombic efficiency was about 70%. The zinc electrode was SEM-observed after the charge and discharge operation was repeated 60 times, and the observation revealed that changes in form of the active material were suppressed.
Comparative Example 2
[0384] Zinc oxide (10.5 g, average particle size: 20 nm) and acetylene black (AB) (1.5 g) were put into a bottle. Thereto was added a solution of 12% polyvinylidene fluoride in N-methylpyrrolidone, and the mixture was pulverized using a ball mill for 12 hours. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours and dried in vacuo (at room temperature) for six hours. The copper foil coated with the zinc mixture was pressed at 1 t so that the thickness of the zinc mixture was 10 μm. The workpiece was punched using a punching device to provide a zinc mixture electrode, and this was used as a working electrode having an apparent area of 0.48 cm 2 . In the same manner as in Example 64, a charge and discharge test was performed using the three-electrode cell (charge and discharge times: 1 hour). The initial coulombic efficiency was about 30%. The zinc electrode was SEM-observed after the charge and discharge operation was repeated 60 times, and the observation revealed that changes in form of the active material occurred.
Example 66
[0385] To a saturated solution of zinc oxide in an aqueous solution of 6 mol/L potassium hydroxide (10 mL, dissolved oxygen concentration: 4.8 mg/L) were added hydroxyapatite (1.6 g, Ca 10 (PO 4 ) 6 (OH) 2 ) and sodium polyacrylate (1.0 g, weight average molecular weight: 1500000), and the mixture was stirred for three days, thereby providing a hydroxyapatite-cross-linked acrylic acid salt gel.
[0386] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 5.4 mg) having an apparent area of 1.1 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydroxyapatite-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using the coin cell at a current of 0.79 mA (charge and discharge times: 3 hours 20 minutes, cut off at 1.9 V and 1.2 V). The battery endured at least 20 or more charge and discharge cycles. The zinc electrode was SEM-observed after the charge and discharge test, and the observation found neither changes in form nor passivation of the active material.
Example 67
[0387] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide (10 mL, dissolved oxygen concentration: 3.5 mg/L) were added hydrotalcite (1.5 g, [Mg 0.67 Al 0.33 (OH) 2 ](CO 3 2− ) 0.165 .mH 2 O) and sodium polyacrylate (1.0 g, weight average molecular weight: 1500000) and the mixture was stirred for three days, thereby providing a hydrotalcite-cross-linked acrylic acid salt gel.
[0388] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.3 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 1.1 mA (charge and discharge times: 1 hour). The battery endured at least 50 or more charge and discharge cycles. The zinc electrode was SEM-observed after the charge and discharge test, and the observation found neither changes in form nor passivation of the active material.
Example 68
[0389] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide (10 g, dissolved oxygen concentration: 3.5 mg/L) were added hydrotalcite (1.5 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and sodium polyacrylate (1.0 g, weight average molecular weight: 1500000) and the mixture was stirred for three days, thereby providing hydrotalcite-cross-linked acrylic acid gel.
[0390] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.9 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), zirconium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, a zinc mixture electrode was produced in the same manner as in Example 5 and was used as a working electrode (zinc mixture weight: 2.0 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked acrylic acid gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.98 mA (charge and discharge times: 1 hour). The battery endured at least 50 or more charge and discharge cycles. The zinc electrode was SEM-observed after the charge and discharge test, and the observation found neither changes in form nor passivation of the active material.
Example 69
[0391] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, the mixture was dried using an evaporator under reduced pressure at 100° C. for two hours, and further dried using a stationary-type vacuum dryer under reduced pressure at 110° C. overnight. The dried solid was pulverized at 18000 rpm for 60 seconds using a pulverizer (WARING, X-TREME MX1200XTM). The obtained solid (1.0 g), a 50% styrene butadiene rubber (SBR)-dispersed aqueous solution (0.080 g), an aqueous solution (0.033 g) containing a 45% copolymer (AQUALIC) of sodium acrylate and a sulfonic acid sodium salt-containing monomer, and water (0.43 g) were put into a glass vial and stirred for one hour using a stirrer with a stir bar. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours. The copper foil coated with the zinc mixture was pressed at 3 t, so that the thickness of the zinc mixture was 10 μm or smaller. The workpiece was punched using a punching device (diameter: 15.95 mm) to provide a zinc mixture electrode, and this was used as a working electrode (zinc mixture weight: 8.22 mg) having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L). Then, a charge and discharge test was performed using the three-electrode cell at a current of 4.63 mA (charge and discharge times: 1 hour, cut off at −0.1 V and 0.4 V). The test found that the battery endured at least 60 charge and discharge cycles stably.
Example 70
[0392] Zinc oxide (27.6 g, average particle size: about 1.1 μm, mode diameter: about 820 nm, median diameter: about 760 nm, true density: about 5.98 g/cm 3 , specific surface area: about 4 m 2 /g), acetylene black (0.90 g, average particle size: about 50 nm, specific surface area: about 40 m 2 /g), cerium (IV) oxide (2.4 g, Wako Pure Chemical Industries, Ltd.), ethanol (92.7 g, 99.5%, Wako Pure Chemical Industries, Ltd.), and water (92.7 g) were mixed in a ball mill. Then, the mixture was dried using an evaporator under reduced pressure at 100° C. for two hours, and further dried using a stationary-type vacuum dryer under reduced pressure at 110° C. overnight. The dried solid was pulverized at 18000 rpm for 60 seconds using a pulverizer (WARING, X-TREME MX1200XTM). The obtained solid (2.1 g), a polyvinylidene fluoride-dispersed aqueous solution (0.48 g), an aqueous solution (0.088 g) containing a 45% copolymer (HW-1) of sodium acrylate and a compound prepared by adding ethylene oxide to isoprenol, and water (0.80 g) were put into a glass vial and stirred for one hour using a stirrer with a stir bar. The obtained slurry was applied to a copper foil using an automatic coating device, and then dried at 80° C. for 12 hours. The copper foil coated with the zinc mixture was pressed at 3 t, so that the thickness of the zinc mixture was 10 μm or smaller. The workpiece was punched using a punching device (diameter: 15.95 mm) to provide a zinc mixture electrode, and this was used as a working electrode (zinc mixture weight: 7.71 mg) having an apparent area of 0.48 cm 2 . The counter electrode was a zinc plate, the reference electrode was a zinc wire, and the electrolyte solution was a saturated solution of zinc oxide in an aqueous solution of 4 mol/L potassium hydroxide (dissolved oxygen concentration: 5.2 mg/L). Then, a charge and discharge test was performed using the three-electrode cell at a current of 4.04 mA (charge and discharge times: 1 hour, cut off at −0.1 V and 0.4 V). The test found that the battery endured at least 60 charge and discharge cycles stably.
Example 71
[0393] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (8.0 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and polyvinylpyrrolidone (1.0 g), and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked vinylpyrrolidone gel.
[0394] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 2.3 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked polyvinylpyrrolidone gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 1.10 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The battery endured at least 50 or more charge and discharge cycles. The zinc electrode was SEM-observed after the charge and discharge test, and the observation found neither changes in form nor passivation of the active material. The discharging capacity at the 20th cycle was 550 mAh/g.
Example 72
[0395] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.8 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and an aqueous solution (0.5 g) containing a 45% copolymer (HW-1) of sodium acrylate and a compound prepared by adding ethylene oxide to isoprenol, and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked HW-1 gel.
[0396] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 2.8 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked HW-1 gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 1.34 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 6th cycle was 565 mAh/g.
Example 73
[0397] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.5 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and an aqueous solution (2.5 g) containing a 45% copolymer of sodium acrylate and sodium maleate, and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked polymer gel.
[0398] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 2.1 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked polymer gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 1.03 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 5th cycle was 533 mAh/g.
Example 74
[0399] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.8 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 . mH 2 O) and an aqueous solution (2.2 g) containing a 45% sodium acrylate polymer having a phosphoric acid group at an end, and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked polymer gel.
[0400] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.74 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked polymer gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.787 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 15th cycle was 496 mAh/g.
Example 75
[0401] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.8 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and an aqueous solution (0.3 g) containing 40% copolymer of sodium methacrylate and a compound prepared by adding ethylene oxide to methacrylic acid, and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked polymer gel.
[0402] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.67 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked polymer gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.793 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 10th cycle was 413 mAh/g.
Example 76
[0403] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.8 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and an aqueous solution (0.3 g) containing 20% copolymer of sodium methacrylate and a compound prepared by adding ethylene oxide to methacrylic acid and being partially cross-linked by a diepoxy compound, and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked polymer gel.
[0404] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.94 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked polymer gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.922 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 20th cycle was 422 mAh/g.
Example 77
[0405] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.8 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.2 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O), zirconium hydroxide hydrate (0.4 g), and sodium polyacrylate (1.0 g, weight average molecular weight: 1500000), and the mixture was stirred for one day, thereby providing a hydrotalcite/zirconium hydroxide-cross-linked acrylic acid salt gel.
[0406] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 2.64 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite/zirconium hydroxide-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 1.26 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 20th cycle was 517 mAh/g.
Example 78
[0407] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (2.3 g, dissolved oxygen concentration: 2.9 mg/L) were added zirconium hydroxide hydrate (1.6 g) and sodium polyacrylate (1.0 g, weight average molecular weight: 1500000), and the mixture was stirred for one day, thereby providing a zirconium hydroxide-cross-linked acrylic acid salt gel.
[0408] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.32 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared zirconium hydroxide-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.629 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 10th cycle was 424 mAh/g.
Example 79
[0409] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (9.2 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.2 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O), ettringite (0.4 g), and sodium polyacrylate (0.2 g, weight average molecular weight: 1500000), and the mixture was stirred for one day, thereby providing a hydrotalcite/ettringite-cross-linked acrylic acid salt gel.
[0410] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.49 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite/ettringite-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.709 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 10th cycle was 561 mAh/g.
Example 80
[0411] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (6.1 g, dissolved oxygen concentration: 2.9 mg/L) were added ettringite (1.6 g) and sodium polyacrylate (1.0 g, weight average molecular weight: 1500000), and the mixture was stirred for one day, thereby providing an ettringite-cross-linked acrylic acid salt gel.
[0412] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.03 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared ettringite-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.487 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 20th cycle was 495 mAh/g.
Example 81
[0413] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.8 g, dissolved oxygen concentration: 2.9 mg/L) was added hydrotalcite (1.6 g, [Mg 0.67 Al 0.33 (OH) 2 ](CO 3 2− ) 0.165 .mH 2 O), and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked gel.
[0414] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 2.56 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 1.24 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 3rd cycle was 513 mAh/g.
Example 82
[0415] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (5.8 g, dissolved oxygen concentration: 2.9 mg/L) was added ettringite (1.6 g), and the mixture was stirred for one day, thereby providing an ettringite-cross-linked gel.
[0416] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.02 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared ettringite-cross-linked gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.484 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 20th cycle was 495 mAh/g.
Example 83
[0417] To acrylic acid (1.1 g) was slowly added a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (10 g, dissolved oxygen concentration: 2.9 mg/L), and then hydrotalcite (0.5 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 . mH 2 O) was added and the mixture was stirred. Thereto was added a 4% ammonium persulfate aqueous solution (0.4 g), and the liquid was applied to the same zinc mixture electrode as in Example 12 and polymerized in nitrogen atmosphere, thereby forming a hydrotalcite-cross-linked acrylic acid gel film on the electrode.
[0418] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.8 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and a sodium acrylate polymer (1.0 g, weight average molecular weight: 1500000), and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked acrylic acid salt gel.
[0419] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.64 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.778 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 20th cycle was 590 mAh/g.
Example 84
[0420] N,N′-methylenebisacrylamide (10 mg) was dissolved in acrylic acid (1.1 g), and to the solution was slowly added a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (10 g, dissolved oxygen concentration: 2.9 mg/L), and then calcium nitrate (65 mg) was added and the mixture was stirred. Thereto was added a 4% ammonium persulfate aqueous solution (0.4 g), and the liquid was applied to the same zinc mixture electrode as in Example 12 and polymerized in nitrogen atmosphere, thereby forming a calcium- and amide bond-cross-linked acrylic acid salt gel on the electrode.
[0421] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (7.8 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O) and a sodium acrylate polymer (1.0 g, weight average molecular weight: 1500000), and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked acrylic acid salt gel.
[0422] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.90 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.903 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 10th cycle was 505 mAh/g.
Example 85
[0423] To a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide and 20 g/L lithium hydroxide (8.1 g, dissolved oxygen concentration: 2.9 mg/L) were added hydrotalcite (1.6 g, [Mg 0.8 Al 0.2 (OH) 2 ](CO 3 2− ) 0.1 .mH 2 O), sodium polyacrylate (0.2 g, weight average molecular weight: 1500000), and propylene carbonate (0.2 g), and the mixture was stirred for one day, thereby providing a hydrotalcite-cross-linked acrylic acid salt gel.
[0424] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.65 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared hydrotalcite/ettringite-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.784 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V). The discharging capacity at the 2nd cycle was 180 mAh/g.
Comparative Example 3
[0425] N,N′-methylenebisacrylamide (10 mg) was dissolved in acrylic acid (1.1 g), and to the solution was slowly added a saturated solution of zinc oxide in an aqueous solution of 8 mol/L potassium hydroxide (10 g), and thereto was added a 4% ammonium persulfate aqueous solution (0.4 g). The mixture was polymerized in nitrogen atmosphere, thereby forming an amide bond-cross-linked acrylic acid salt gel electrolyte.
[0426] The same zinc mixture electrode as in Example 67 was used as a working electrode (zinc mixture weight: 1.88 mg) having an apparent area of 0.50 cm 2 . The counter electrode was a nickel electrode (active material: cobalt-coated nickel hydroxide, the capacity was set three times or more as high as that of the zinc electrode), and the gel electrolyte was the prepared amide bond-cross-linked acrylic acid salt gel (thickness: 1 mm). A charge and discharge test was performed using a coin cell at a current of 0.891 mA (charge and discharge times: 1 hour, cut off at 1.9 V and 1.2 V), but the cell was not charged and discharged at all.
[0000] (1) The results of Examples 1 to 63 show the following.
[0427] For storage batteries including a zinc negative electrode which is formed from a zinc negative electrode mixture containing a zinc-containing compound and/or an electric conduction which contain(s) particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher, deterioration of the battery performance even after repeated charge and discharge was suppressed, and the batteries had an excellent cycle characteristic, as well as an excellent rate characteristic and coulombic efficiency.
[0428] Especially with a zinc negative electrode mixture in which the zinc-containing compound and the conductive auxiliary agent contain particles having an average particle size of 1000 μm or smaller and/or particles having an aspect ratio (vertical/lateral) of 1.1 or higher, storage batteries including a zinc negative electrode formed from such a zinc negative electrode mixture had a markedly excellent cycle characteristic.
[0429] Further, addition of an additional component (at least one selected from the group consisting of compounds having at least one element selected from the group consisting of elements in the groups 1 to 17 of the periodic table, organic compounds, and salts of organic compounds) in the zinc negative electrode mixture allowed batteries containing a water-containing electrolyte solution to effectively suppress a side reaction of decomposing water to generate hydrogen and corrosion, to markedly improve the charge and discharge characteristics and coulombic efficiency, and to suppress changes in form and passivation of the zinc electrode active material.
[0430] In addition, use of a zinc-containing compound having a specific median diameter or a specific true density suppressed self-discharge in a charged state or during storage in a charged state.
[0431] In the above examples, the zinc negative electrodes were each formed from a zinc negative electrode mixture containing a specific zinc-containing compound and a specific conductive auxiliary agent. Use of the zinc negative electrode mixture of the present invention as a zinc negative electrode mixture for forming a zinc negative electrode and use of such a zinc negative electrode in storage batteries allow the storage batteries to have excellent battery performance such as a cycle characteristic, rate characteristic, and coulombic efficiency, and to suppress self-discharge. This applies to all the cases of using the zinc negative electrode mixture of the present invention. Therefore, the results of the examples show that the present invention can be applied in the general technical scope of the present invention and in the various forms disclosed herein, and can achieve advantageous effects.
[0000] (2) Examples 64 to 85 and Comparative Examples 1 to 3 show the following.
[0432] In batteries formed using the gel electrolyte of the second aspect of the present invention or the negative electrode mixture of the third aspect of the present invention, use of such a gel electrolyte or negative electrode mixture suppressed growth of dendrite even after repeated charge and discharge.
[0433] Further, the batteries formed using the gel electrolyte of the second aspect of the present invention or the negative electrode mixture of the third aspect of the present invention suffered neither changes in form nor passivation of the active material even after repeated charge and discharge. Thus, such batteries can stably endure repeated charge and discharge, and had an excellent cycle characteristic, rate characteristic, and coulombic efficiency.
[0434] In the examples, the gel electrolyte and the negative electrode mixture were formed using, for example, a specific polymer. Use of the gel electrolyte or the negative electrode mixture of the present invention in storage batteries allow the storage batteries to have excellent battery performance such as a cycle characteristic, rate characteristic, and coulombic efficiency. This applies to all the cases of using the gel electrolyte or the negative electrode mixture of the present invention. Therefore, the results of the examples show that the present invention can be applied in the general technical scope of the present invention and in the various forms disclosed herein, and can achieve advantageous effects. | 4y
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation of Ser. No. 07/885,124, filed May 18, 1992, entitled "CHEMICAL VAPOR DEPOSITION SYSTEM," now abandoned, which is a continuation of Ser. No. 720,750, now U.S. Pat. No. 5,156,521, filed Jun. 25, 1991, entitled "METHOD FOR LOADING A SUBSTRATE INTO A CVD APPARATUS," which is a continuation of Ser. No. 07/468,572, filed Jan. 23, 1990, now abandoned, which is a divisional of Ser. No. 315,332, now U.S. Pat. No. 5,092,728, filed Feb. 24, 1989, entitled "SUBSTRATE LOADING APPARATUS FOR A CVD PROCESS," which is a divisional Ser. No. 108,771, now U.S. Pat. No. 4,828,224, filed Oct. 15, 1987, entitled "CHEMICAL VAPOR DEPOSITION SYSTEM."
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to systems for chemical vapor deposition of materials on substrates, and more particularly to a chemical vapor deposition system having improved substrate loading, off-loading, and handling sub-systems which interact with at least one especially configured processing subsystem having a reaction chamber, susceptor and heating sub-assemblies for precision control of the deposition process.
2. Discussion of the Related Art
In the electronics art, it has long been a practice to employ chemical vapor deposition techniques for depositing various materials on substrates or wafers, as part of the process for manufacturing semiconductor devices. Chemical vapor deposition processes includes passing of a reactant gas, which contains the material to be deposited, over the substrates for forming, or growing a compound on the substrates as a result of thermal reaction or decomposition of the various gaseous materials.
The equipment used to accomplish such a process is of various configurations but will include the basic components of a reaction chamber, a heating system and a gas flow system. Of course these various components are configured in accordance with the tasks to be accomplished. For example, when the number of substrates to be processed is small, the reaction chamber may be in the form of a bell jar, but in high quantity production work considerably more sophisticated equipment is needed.
For some time now, batch processing equipment has been used for accomplishing the chemical vapor deposition processes in production environments and batch processing equipment may be categorized as being of two basic types, namely horizontal gas flow systems and vertical gas flow systems. A horizontal gas flow system generally includes a platform, or susceptor as it is referred to in the art, which is located in a horizontally disposed reaction chamber with the reactant gas flowing in a horizontal path across the susceptor. In a vertical gas flow system, a horizontally disposed susceptor, or an upstanding multi-surface barrier shaped susceptor, is located in a vertically disposed reaction chamber with the reactant gas being caused to flow in a substantially vertical path and around the susceptor. In either case, these susceptors are configured to support a multiplicity of relatively small substrates, i.e. in the neighborhood of 2 to 5 inches in diameter, for simultaneously depositing, materials on the multiplicity of substrates. While simultaneous deposition of materials on a multiplicity of substrates is desirable from a manufacturing standpoint, it has some drawbacks from a quality standpoint.
The first problem associated with batch, or multi-substrate processing relates to the reactant gas, which contains the atoms of the deposition materials. As the gas flows over the surfaces of the substrates and the susceptor, deposition of the materials results in changes in the concentration of the deposition materials in the reactant gas. Consequently, as the reactant gas flows across or over the length of these relatively large susceptors, across each individual substrate and across a multiplicity of such substrates, different rates of growth of the deposited layer of material have been found. A second problem is that of temperature control which is critical at the elevated temperatures needed for proper deposition. It is difficult, if not impossible, to control the temperature within the critical tolerances at all the desired locations within the relatively large reaction chambers. This results in different deposition layer thickness from one substrate to another, and can even produce varying thickness within the individual substrates. Still another problem is contamination which can result from various factors such as the handling techniques used to load and unload the substrates, the introduction of the reactant gas into the reaction chamber, and the like.
These problems and drawbacks, as well as other factors, all contribute to significant problems as the semiconductor devices and the uses to which they are put become more sophisticated. As a result, many changes and improvements have been made in the equipment that is used to simultaneously process a multiplicity of substrates. For example, some equipment manufacturers are now using automated loading and off-loading devices, as opposed to hand-loading techniques, to eliminate, or at least substantially reduce contamination resulting from human handling. Further, the second type of susceptor discussed above, i.e. the upstanding barrel shaped structure, is being rotated in some instances about its vertical axis to rotate the multiplicity of substrates about that same axis within the reaction chamber. Such barrel rotation is being done for averaging purposes, that is, temperature averaging and reactant gas flow averaging. Obviously these and other things which are being done to improve the simultaneous multi-substrate processing techniques have helped. However, there are practical limits which many feel will ultimately make the batch processing techniques unacceptable or at least undesirable. One of the limitations is that of the equipment not being very well suited for handling larger diameter substrates. The economics of larger diameter substrates are causing many manufactures of semiconductor devices to use larger substrates. However, increasing the size of the substrate is causing some problems with regard to temperature differentials across the substrate, decreasing concentrations of the deposition material as it is carried across the substrate, and the like.
Therefore, steps are being taken now by some equipment manufacturers to make suitable single substrate processing equipment which is significantly simpler in so far as controlling the various factors involved in chemical vapor deposition. Single substrate chemical vapor deposition equipment becomes inherently more desirable than multi-substrate equipment as the manufacturers of semiconductor devices change to larger substrates, i.e. 6 to 8 inches in diameter or even larger. One important consideration is the cost at risk when processing one substrate as opposed to the simultaneous multi-substrate processing. That is, if something goes wrong, the monetary loss is far less with one substrate than it is with a plurality of substrates.
Various prior art components and sub-systems have been devised for use in building single substrate processing chemical vapor deposition systems. For example, loading and unloading of substrates into such systems may be handled in various ways with the most pertinent prior art structure being a cassette elevator available from the Brooks Automation Co., a division of Aeronca Electronics, Inc., One Executive Park Drive, North Billerica, Miss. 01862. The cassette elevator, which is identified as Product No. 6200, includes a vacuum chamber for receiving a plurality of substrates that are carried in a cassette with the cassette being supported on a platform. The platform is vertically movable by means of an elevating mechanism which brings the substrates one at a time into alignment with an access port. An isolation valve such as that available as Product No. 3003 from the above identified Brooks Automation Co., is located at the access port of the elevating mechanism for closing the vacuum chamber except during extraction of the individual substrates. Both the elevating mechanism and the isolation valve provide a controllable environment for receiving and loading the substrates into a processing system.
The Brooks Automation Co. also markets a vacuum transport station under the name Vacu-Tran™ for extracting the substrates one at a time from the elevating mechanism described above. The transport station includes a housing which is coupled to the isolation valve described above, and a robot arm structure is located in the housing. The robot arm structure includes a rotatable plate having an extensible and retractable arm arrangement thereon, with a pallet or spatula on the distal end of the arms. With the plate and arms rotated so as to align with the access port of the elevating mechanism and the isolation valve open, the arms are extended to move the pallet into position below a substrate, and then the entire arm structure is raised to lift the substrate so that it is carried on the pallet out of the cassette. The arms are then retracted to extract the substrate from the elevating mechanism, and then the arm assembly is rotated to another position and extended once again so as to pass through another isolation valve into a suitable reaction chamber. This particular handling system relies on the weight of the substrate to hold it in place on the pallet and another prior art structure includes a similar arm arrangement which further includes a vacuum outlet on the pallet for a more positive attachment to the underside of the substrates.
The operation of the above described prior art loading system can be reversed for extracting a processed substrate from the reaction chamber and returning it to the same cassette from which it was extracted, or alternatively, to another cassette provided in a second elevating mechanism provided solely for off-loading of processed substrates.
While the above described loading, handling and off-loading structures are significantly better than hand operations, and other prior art loading and handling mechanism which are not relevant to the present invention, they are less than completely satisfactory. One of the prime considerations in modern chemical vapor deposition systems is to hold contamination to an absolute minimum, and prevent it entirely, if possible. In that the vacuum chamber of the elevating mechanism must be opened from time to time for insertion and extraction of cassettes, environmental contamination will enter the vacuum chamber. The isolation valve located at the access port of the elevating mechanism is needed to prevent contaminants from passing through the vacuum chamber of the elevating mechanism into the housing of the transport system during the time when the vacuum chamber is open to the environment, and such an isolation valve is expensive. However, the main problem with this prior art system is in the robot arm structure which slides under and carries the substrates on the pallet from the elevating mechanism to the reaction chamber and back again when processing is completed. First of all, such a substrate handling technique cannot possibly place a substrate on a flat continuous surface, such as an ideally configured susceptor, which is used in the reaction chamber, due to the pallet of the robot arms being in supporting engagement with the bottom surface of the substrate. Therefore, some sort of less than ideal susceptor configuration must be provided in the reaction chamber if is it is to be used with the prior art robot arm handling mechanisms. Secondly, damage often results from the pallet coming into mechanical contact with the substrate. Also, contaminants in the form of airborne particles can settle on the top surface of the substrate and this reduces the yield of the substrates and destroys circuit integrity.
As was the case with the above discussed batch processing chemical vapor deposition systems, the reaction chambers used in single substrate processing systems may be categorized as either a horizontal gas flow system or a vertical gas flow system. However, the susceptors being used in the single substrate reaction chambers consist essentially of a planar platform or base upon which the substrate rests during the deposition process, and those susceptors contribute nothing further to the deposition process with regard to improving the problems of depletion of the material carried by the reactant gas as it flows past and around the substrate, and with regard to improved temperature sensing and control.
Therefore, a need exists for a new and improved single substrate chemical vapor deposition system which enhances the process and thereby helps in eliminating, or at least reducing, the problems and shortcomings of the prior art systems.
SUMMARY OF THE INVENTION
In accordance with the present invention, a new and improved chemical vapor deposition system is disclosed for depositing various materials on substrates as part of the process for manufacturing semiconductor devices. The present system is broadly categorized as a horizontal gas flow system in that the reactant gas which carries the materials to be deposited, is directed in a horizontal flow path through the reaction chamber in which the substrates are processed. Also, the system is further categorized as a single substrate processing system as opposed to a batch processing system, in that one relatively large substrate is processed per cycle of the system. However, as will be seen, the system of the present invention is configured so that a plurality of independent single substrate processing cycles can be simultaneously accomplished.
The chemical vapor deposition system of the present invention includes the following major sub-systems. A special substrate loading sub-system is provided for receiving cassettes which carry a multiplicity of substrates to be processed, and an identical off-loading sub-system is provided for receiving processed substrates that are to be removed in cassettes from the system. Both the loading and off-loading sub-systems include a unique built-in isolation valve which closes off the rest of the system from environment contamination whenever these sub-systems are opened for insertion for removal of the cassettes.
A special substrate handling sub-system, as fully disclosed in U.S. Pat. No. 5,080,549, issued Jan. 14, 1992, entitled WAFER HANDLING SYSTEM WITH BERNOULLI PICK-UP, which is hereby expressly incorporated herein by reference, includes a housing having a loading port to which the substrate loading sub-system is coupled and an unloading port to which the off-loading sub-system is coupled. A special robot arm assembly is mounted in the housing for rotary and extensible movements for substrate handling purposes. A pick-up wand is mounted on the distal end of the robot arms for positioning above the substrates to be handled, and a special gas flow arrangement is provided in the robot arm assembly so that the pick-up wand operates in accordance with Bernoulli's principle for moving the substrates within the system without any mechanical contact being made with the top or bottom planar surfaces of the substrates. In addition to the loading and unloading ports, the housing of the substrate handling sub-system is provided with a delivery port through which substrates are supplied to and retrieved from a processing sub-system which is coupled to the delivery port. The housing may be provided with a plurality of such delivery ports to which an equal number of processing sub-systems are coupled.
In any event, a special isolation valve assembly having a ported gate valve is mounted proximate delivery port of the housing for closing that delivery port whenever a chemical vapor deposition cycle is being accomplished in the processing sub-system. Also, a gas injection structure, as fully disclosed in U.S. Pat. No. 5,221,556, issued Jun. 22, 1993, entitled GAS INJECTORS FOR REACTION CHAMBERS IN CVD SYSTEMS, which is hereby expressly incorporated by reference, is interposed between the isolation valve assembly and the inlet of the processing sub-system. The gas injector is configured to provide a reactant gas flow of special character through the reaction chamber.
The processing sub-system in which the chemical vapor deposition process takes place, includes a reaction chamber which is fully disclosed in U.S. Pat. No. 4,846,102, issued Jul. 11, 1989, entitled REACTION CHAMBERS FOR CVD SYSTEMS, which is expressly incorporated herein by reference. The reaction chamber is especially configured to provide desirable gas flow characteristics for accomplishing the deposition process in a precisely controllable environment. The reaction chamber housing is also configured for mounting of a special substrate supporting mechanism with temperature sensing devices therein.
U.S. Pat. No. 4,821,674, issued Apr. 18, 1989, entitled ROTATABLE SUBSTRATE SUPPORTING MECHANISM WITH TEMPERATURE SENSING DEVICES FOR USE IN CHEMICAL VAPOR DEPOSITION EQUIPMENT, is hereby expressly incorporated herein by reference. This sub-system is designed for optimum temperature averaging and control, and for reactant gas flow averaging, and includes a circular susceptor for supporting a single substrate, with the susceptor being disposed within the reaction chamber on a driveshaft assembly which axially depends from the susceptor through a depending tubular shaft of the reaction chamber housing. The driveshaft assembly is rotatably drivable for rotation of the susceptor and thus the single substrate supportable thereon. The critical temperatures at various points of the susceptor are sensed by a special temperature sensing arrangement which includes a master temperature sensor that is located in the vicinity of the center of the susceptor. A special fixed ring, is located in concentric relationship with the rotatable susceptor, and plurality of, slave temperature sensors are located in the fixed ring for sensing the temperatures at various points near the periphery of the susceptor. The master and slave temperature sensors produce signals indicative of the temperatures sensed thereby, and the signals are transmitted to a suitable temperature control means.
The processing sub-system of the chemical vapor deposition system of this invention further includes a heating system that is fully disclosed in U.S. Pat. No. 4,836,138, issued Jun. 6, 1989, entitled HEATING SYSTEM FOR REACTION CHAMBER OF CHEMICAL VAPOR DEPOSITION EQUIPMENT, that is hereby expressly incorporated herein by reference. The heating system includes an upper radiant heat assembly which is disposed atop the reaction chamber for directing radiant heat downwardly into the chamber a lower radiant heat assembly is located below the reaction chamber for directing heat upwardly into the chamber. A heat concentrator structure which is part of the lower heating assembly, is provided for directing concentrated radiant heat into the vicinity of the center of the susceptor where the master temperature sensor is located, with the heat concentrator providing optimum temperature control. The upper and lower heating structures have individually controllable banks of discrete heating elements for precision heat control of the various regions in and about the rotatable susceptor.
In addition to the above, the system of the present invention is provided with various purging sub-systems for controlling the gas flow within the system and maintaining a contaminant free environment therein.
Accordingly, it is an object of the present invention to provide a new and improved chemical vapor deposition system for continuous and sequential handling and processing single substrates for depositing various materials thereon as part of a semiconductor manufacturing process.
Another object of the present invention is to provide a new and improved chemical vapor deposition system which includes special substrate loading and unloading sub-systems wherein cassettes containing multiplicities of substrates are inserted into the system for processing and retrieved from the system subsequent to processing with the loading and unloading sub-systems eliminating, or at least substantially reducing, system contamination resulting from the insertion and retrieval of the cassettes.
Another object of the present invention is to provide a new and improved chemical vapor deposition system having a special substrate handling system including a special robot arm structure which moves the substrates in the system without coming into physical contact with the top and bottom planar surfaces of the substrates.
Another object of the present invention is to provide a new and improved chemical vapor deposition system of the above described character wherein the substrate handling sub-system is operable for moving individual substrates from the loading sub-system into a desired one of a plurality of processing sub-systems for processing and retrieving the substrates after processing and delivering the processed substrates to the unloading sub-system.
Another object of the present invention is to provide a chemical vapor deposition system which includes ported gate valves which isolates the substrate handling sub-system from the processing sub-systems at all times except when substrates are being inserted into or retrieved from the processing sub-systems.
Another object of the present invention is to provide a new and improved chemical vapor deposition system which further includes special gas injectors for inducing special flow characteristics in the gas that is supplied to the processing sub-systems.
Another object of the present invention is to provide each of the processing sub-systems of the system with a reaction chamber housing that induces desired gas flow characteristics through the reaction chamber and is configured to accommodate a special susceptor and heat sensing sub-system.
Another object of the present invention is to provide a new and improved chemical vapor deposition system of the above described character wherein a circular susceptor is mounted in the reaction chamber for supporting a single substrate, with the susceptor being rotatably driven to rotate the substrate about an axis which is normal with respect to the center thereof for optimum averaging of temperature differences and material concentration differences in the reactant gas to eliminate, or at least substantially reduce, the undesirable effects of those variables on the deposition process.
Another object of the present invention is to provide a new and improved chemical vapor deposition system wherein a special temperature sensing arrangement is provided to sense the temperatures in and about the rotatable susceptor and producing signals which are used for controlling the heat input to the various regions in and about the susceptor.
Another object of the present invention is to provide a new and improved chemical vapor deposition system of the above described character which further includes a special heating sub-system which is controllable to direct variable amounts of radiant heat energy into the reaction chamber for optimized heating of the various regions in and about the rotatable susceptor.
Another object of the present invention is to provide a new and improved chemical vapor deposition system of the above described type wherein purging sub-systems are provided at various points in the system for controlling gas flow within the system and for maintaining a contaminant free environment within the system.
Still another object of the present invention is to provide a new and improved mechanism for loading various articles into a processing system, or retrieving various articles from a processing system, with the mechanism including a built-in isolation valve which prevents environmental contamination of the processing system.
Yet another object of the present invention is to provide a new and improved isolation valve for use between various sub-systems of a processing system for selective isolation of the sub-systems.
The foregoing and other objects of the present invention as well as the invention itself, will be more fully understood from the following description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the chemical vapor deposition system of the present invention which shows some of the various features thereof.
FIG. 2 is an enlarged fragmentary sectional view taken along the line 2--2 of FIG. 1.
FIG. 3 is an enlarged fragmentary sectional view taken along the line 3--3 of FIG. 1.
FIG. 4 is a fragmentary sectional view taken along the line 4--4 of FIG. 3.
FIG. 5 is a fragmentary sectional view taken along the line 5--5 of FIG. 3.
FIG. 6 is a fragmentary sectional view taken along the line 6--6 of FIG. 1.
FIG. 7 is an enlarged fragmentary sectional view taken along the line 7--7 of FIG. 6.
FIG. 8 is a schematic plan view of the system of the present invention which is partially broken away to show the various relationships and features of the sub-systems and components thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to the drawings, FIGS. 1 and 8 best show the chemical vapor deposition system of the present invention which is indicated in its entirety by the reference numeral 10. As will hereinafter be described in detail, the system 10 is formed of several sub-systems which includes a substrate loading sub-system 12, an identical substrate unloading sub-system 14, a substrate handling sub-system 16. In the illustrated embodiment, three identical processing sub-systems 18 are shown, but it will be understood that the deposition system 10 is completely operational with a single processing sub-system 18, and additional processing sub-systems 18 are employed, if desired, for production purposes.
As mentioned above, the loading and unloading sub-systems 12 and 14 respectively, are identical with the difference being in the way that they are operated. Since the sub-systems 12 and 14 are identical, it will be understood that the following detailed description of the loading sub-system 12 will also apply to the unloading sub-system 14.
As seen best in FIGS. 1, 2, 3, 4 and 5, the substrate loading sub-system 12 includes an upper housing 20 which defines a hermetically sealable cassette receiving interior chamber 22. The upper housing 20 has a hatch 24 which is hingedly mounted on the housing 20 with a suitable latch 25 being provided for opening the hatch so that a cassette 26, which is shown in dashed lines in FIG. 2, may be placed in and retrieved from the interior cassette receiving chamber 22. The cassette 26, as is well known in the art, is a case-like structure having an open side 27 with a plurality of shelf-like supports (not shown) therein for containing and providing lateral access to a plurality of substrates 28 that are carried in vertically spaced stacked relationship with the cassette 26. The upper housing 20 includes a floor 29 having a large central opening 30 formed therethrough with that opening being closed by a cassette support platform 32 whenever a cassette 26 is being loaded into or unloaded from the receiving chamber 22, as will hereinafter be described.
The loading sub-system 12 further includes an intermediate housing 34 which is bolted or otherwise attached so as to be immediately below the upper housing 20, and is configured to define an interior feed chamber 36. The intermediate housing 34 is open at its top end so that the floor 29 of the upper housing 20 forms the top wall of the intermediate housing 34, with the central opening 30 of the floor 29 being located so as to open into the feed chamber 36. The intermediate housing 34 further includes a sidewall 38 having a lateral feed port 40 formed therein, and a bottom wall 42 which is provided with a central opening 44 that is in axial alignment with the central opening 30 of the upper housing 20.
The cassette support platform 32 is mounted on the upper end of an elevator shaft 46 for vertical movement between an elevated position shown in solid lines in FIG. 2, and a fully lowered position shown in phantom lines in the same figure. The support platform 32 has a seal means 48 such as an O-ring mounted thereon to extend upwardly from its top surface 49. Therefore, when the support platform 32 is fully elevated, the seal means 48 engages the lower surface of the floor 29 about the central opening 30 thereof so that the receiving chamber 22 of the upper housing 20 is hermetically sealed from the feed chamber 36 of the intermediate housing 34 when the cassette support platform 32 is in the elevated position.
Therefore, the floor 29 with its central opening 30 and the vertically movable cassette support platform 32 cooperate to provide the loading sub-system 12 with a built-in isolation valve which isolates the feed chamber 36 of the intermediate housing 34 from the cassette receiving chamber 22 of the upper housing 20. Such isolation is provided so that whenever the hatch 24 is opened for loading or retrieval of a cassette 26, environmental contamination will be kept out of the feed chamber 36 of the intermediate housing 34 and thus out of the rest of the system 10 as will become apparent as this description progresses.
However, environmental contamination will enter the cassette receiving chamber 22 of the upper housing 20 during loading and unloading operations. Therefore, the upper housing 20 is provided with a purge gas inlet port 50 in its top wall 51 and a purge gas outlet port 52 in one of its sidewalls 53. As seen in FIG. 2, the purge gas outlet port 52 is coupled to a suitable gas disposal location (not shown) by an exhaust tube 54 which is welded or otherwise fixedly attached to a mounting plate 55 that is bolted to the housing 20 and has a suitable O-ring seal 56. The purge gas inlet port 50 is similarly coupled to a remote source of pressurized purge gas (not shown) by a supply tube 57 with a similar mounting plate 58.
As will hereinafter be described in detail, an elevator means 60 is mounted below the intermediate housing 34 with the above mentioned elevator shaft 46 extending therefrom so as to pass axially through the opening 44 provided in the bottom wall 42 of the intermediate housing 34. In addition to passing axially through the opening 44, the top end of the elevator shaft 46 is axially disposed in a bellows seal assembly 62 of the type well known in the art. The bellows seal assembly 62 includes an axially extensible bellows 64 having an upper mounting plate 65 which is attached to the lower surface of the cassette support platform 32 and a lower mounting plate 66 which is attached in the manner shown to the bottom wall 42 of the intermediate housing 34. In this manner, the feed chamber 36 is isolated from the elevator means 60 to prevent any contamination from entering the feed chamber 36 from the elevator means 60.
The elevator means 60 includes an elongated housing 68 that is bolted or otherwise attached so as to be supported and depend from the intermediate housing 34, with the housing 68 defining an internal chamber 70. An elongated guide rail 72 is mounted within the elevator housing 68 with a pair of tracks 74 being formed on its opposed longitudinal edges, and an elevator carriage 76 is mounted for vertical reciprocal movement on the guide rail. The carriage 76 includes a housing 78 with suitable wheels 79 mounted thereon which engage the tracks 74 of the guide rail 72. The elevator shaft 46 is fixedly carried in a bore 80 formed in the carriage such as by the illustrated set screws 81 and the elevator shaft defines an axial bore 82 with an open lower end. An elongated lead screw 84 is journaled for rotation in a bearing assembly 86 that is suitably mounted in the bottom wall 87 of the elevator housing 68 so that the lower end 88 of the lead screw 84 depends axially from the housing 68, and the upper threaded end 90 extends axially upwardly through the bore 80 of the carriage housing 78 so as to be axially disposed in the bore 82 of the elevator shaft 46. A follower nut 92 is bolted or otherwise affixed to the lower end of the carriage housing 78 so that it's internally threaded bore 94 is in threaded engagement with the lead screw 84.
A plate 96 is mounted on the lower surface of the bottom wall of the elevator housing 68 and the plate 96 has a laterally extending portion 97 upon which a drive motor 98 is mounted. The drive motor 98 is an electrically and reversibly operated digital stepping motor of the type well known in the art, and has a drive pulley 100 mounted for rotation with its output shaft 102. A suitable drive belt 104 is employed for coupling the drive pulley 100 of the motor 98 to a driven pulley 106 that is mounted fast on the depending lower end 88 of the lead screw 84.
When the drive motor 98 is operated, the lead screw 84 will be rotated about its longitudinal axis with the follower nut 92 causing the carriage 76 to move along the guide rail 72 either upwardly or downwardly as determined by the rotational direction of the drive motor 98. When the carriage 76 is in its lowered position as shown in FIG. 3, the cassette support platform 32 will be lowered, and the carriage is upwardly movable to raise the cassette support plate 32 to its upper position wherein it performs the above described isolation valve function.
As seen in FIG. 3, a lower limit switch 108 is mounted in the elevator housing 68 for engaging a suitable switch actuator arm 110 that is mounted on the carriage housing 78. The lower limit switch 108 is used as an emergency stopping device which prevents the carriage from moving below a desired lower limit. An upper limit switch 112 is similarly mounted in the elevator housing 68 for contact by the same switch actuator arm 110 when the carriage 76 reaches its upper position. In addition to limiting the upward movement of the carriage 76, the upper limit switch 112 produces a signal indicative of the up-position of the substrate support platform 32 and that signal is used by a suitable control means (not shown) to actuate a latching means 114 which is shown in FIG. 4. The illustrated latching mechanism 114 is a commercially available power clamp that is marketed by the DE-STA-CO division of Dover Resources, Inc., 250 Park Street, Troy, Mich. 48007-2800. The latching mechanism 114, which is identified as Model No. 807-L, is mounted on the exterior of the elevator housing 68 by being bolted to a mounting bracket 115 that is provided on the housing for that purpose. The latching mechanism 114 includes a pneumatic (or hydraulic) cylinder 116 having the usual reciprocally extensible rod 117 which operates an over-center linkage 118 for moving a clamping arm 119 back and forth through an opening 120 formed in the housing 68 and an aligned opening 121 formed through the guide rail 72. The clamping arm 119 is movable from a carriage latching position shown in solid lines in FIG. 4 to a carriage releasing position shown in dashed lines in the same figure. The clamping arm 119 is especially configured to provide a first indicator lug 122 which interacts with a first detector switch 124, such as an optical sensor, to produce a control signal indicative of a latched position of the arm 119. A second indicator lug 126 is also provided on the arm 119 to interact with a second detector switch 128, that is mounted on the cylinder 116 by means of a suitable bracket 130, to provide a control signal that is indicative of the unlatched position of the clamping arm 119.
The latching mechanism 114 is operable to clamp and hold the cassette support platform 32 in sealed engagement with the floor 29 of the upper housing 20 by bearing engagement of the adjustable bolt 132 that is mounted on the distal end of the clamping arm 119 with the lower end of the carriage 76, as indicated in FIG. 4. By virtue of the over-center linkage 118, the power clamp 114 will maintain the latched position of the arm 119 despite power failures, equipment shut-down and the like to prevent system contamination during such periods as well as during operation.
As seen best in FIGS. 3 and 5, another position indicator is provided in the elevator means 60, and includes a mounting assembly 134 for adjustably carrying a lug 136. A sensor device 138, such as an optical sensor, is mounted in the housing 68 so as to interact with the lug 138 to produce a control signal indicative of the alignment of the lowermost substrate 28 in the cassette 26 with the feed port 40 of the intermediate housing 34.
When a cassette 26 containing substrates 28 to be sequentially processed in the system 10, has been loaded into the receiving chamber 22 of the upper housing 20, and that chamber has been subjected to a purging operation, the latching mechanism 114 is operated to move the latching arm 119 to its unlatched position. Then, the drive motor 98 is operated in a stepping manner to lower the carriage 76 and support platform 32. When the position indicator lug 136 is aligned with the sensing switch 138, the resulting control signal is supplied to a control system (not shown) which sequentially lowers the support platform 32, and therefore the cassette 26, to sequentially move the substrates into the desired position relative to the feed port 40 of the intermediate housing 34.
As shown, the loading sub-system 12 is mounted on the substrate handling sub-system 16 which, as will hereinafter be described, is operated to extract the substrates 28 from the loading sub-system 12 for sequential processing in the system 10. The substrate unloading sub-system 14 is similarly mounted on the handling sub-system 16 for receiving the processed substrates from the system for unloading therefore, the unloading sub-system 14 which is identical to the loading sub-system 12, is operated in a reversed manner to accomplish the processed substrate unloading operation.
The substrate handling sub-system 16, as hereinbefore stated, is fully disclosed in U.S. patent application Ser. No. 048,630, filed May 11, 1987, which is expressly incorporated herein by reference. However, to insure a complete understanding of the chemical vapor deposition system 10 of the present invention, a brief description of the handling sub-system 16 will now be presented.
With special reference to FIGS. 1, 2 and 8, the substrate handling sub-system 16 is shown as including a housing 140 which defines an internal chamber 142. The housing 140 includes a suitable substrate input port 143 which is aligned with the feed port 40 of the substrate loading sub-system 12, and a substrate output port 144 that is aligned with the feed port 40 of the substrate unloading sub-system 14. As will hereinafter be described in detail, the housing 140 is also provided with at least one substrate delivery port 146 through which substrates to be processed are passed into the processing sub-system(s) 18. The moving of the substrates from the loading sub-system 12 into the processing sub-system 18, and movement of processed substrates from the sub-system 18 into the unloading sub-system 14, is accomplished by a special wafer handling mechanism 148 having a pair of articulated robot arms 150 and 152 each having a proximal end mounted for rotational movement about drive shafts 153 and 154, respectively. Each of the arms 150 and 152 also have an intermediate joint 156 with a special pick-up wand 158 being mounted on the distal ends of the arms. The arm drive-shafts 153 and 154 are driven in opposite rotational directions for extending and retracted folding movements of the robot arms 150 and 152 to move the pick-up wand toward and away from the uppermost end of a robot arm drive assembly 160 upon which the proximal ends of the arms are mounted and which drives the robot arms. The drive assembly 160, as seen in FIG. 2, includes a first drive motor 161 which rotatably drives a center shaft (not shown) that extends upwardly from the motor 161 through the center of a coaxial bearing and seal mechanism 164 and drives the internal gears (not shown) of a gear box 166 for rotational driving of the drive shafts 153 and 154. A second motor 170 is provided which rotatably drives a tubular shaft (not shown), that is concentrically disposed about the above-described center shaft, and also extends through the mechanism 164 for rotation of the entire gear head 168. The gear head 168 is therefore rotatable for selected positioning of the robot arms 150 and 152 in alignment with the various ports 143, 144 and 146 of the housing 140 by operation of the motor 170. When in any of these aligned positions, the other drive motor 160 is operated for foldingly extending and retracting the robot arms 150 and 152 to move the pick-up wand 158 to the desired locations for picking up and delivering the substrates 28.
The pick-up wand 158 operates in accordance with the Bernoulli principle to produce an area of relatively low pressure between the downwardly facing surface of the wand 158 and the upwardly facing surface of the substrate to be moved. In this manner, the pick-up wand 158 can lift and move the substrates 28 without ever touching the top or bottom planar surfaces of the substrate. The only physical contact between the wand 158 and the substrates is an edge contact which is made so that the substrates will move along with the wand. The pick-up wand 158 is provided with a special array of gas outlet apertures (not shown) which open onto the lower surface of the pick-up wand with those apertures being coupled to a remote source of gas under pressure (not shown). The connection of the wand to a remote source of gas is made via passages formed through the robot arms 150 and 152 and downwardly through the drive assembly 160.
In addition to the gas which enters the housing 140 of the substrate handling sub-system 16 from the pick-up wand 158, the housing is provided with a purge gas inlet 172 and a purge gas outlet 174 which may be coupled to the same sources and disposal location as the drive assembly 160 and the loading and unloading sub-systems 12 and 14.
As will hereinafter be described, the substrate handling sub-system 16 moves the substrates to be processed through a special isolation valve 176 and gas injector 178, as seen in FIG. 6, into the processing sub-system 18. It also, of course retrieves the processed substrates by moving the back through the gas injector 178 and isolation valve 176 when processing is completed.
The housing 140 of the substrate handling sub-system 16, as shown in FIGS. 6 and 7, is provided with an opening 179 in it's bottom surface 180 adjacent it's delivery port 146, and the isolation valve 176 is mounted in that opening so as to be disposed in the housing 140 proximate the delivery port 146. The isolation valve 176 includes a mounting plate 182 that is bolted or otherwise attached to the bottom surface 180 of the housing 140 so as to hermetically seal the opening 179 and support the various components of the isolation valve. A pair of actuator support arms 184 depend from the mounting plate 182 in spaced apart relationship with respect to each other, and a rock shaft 186 is transversely journaled for rotation in bushing blocks 188 that are mounted on the lower ends of the actuator support arms 184. A pneumatic actuator means 190 is mounted such as by the cap screws 191 to the rock shaft 186 for movement herewith, and the reciprocally extensible rod 192 of the actuator 190 extends upwardly through an opening 193 formed in the mounting plate 182. A bellows seal 194 of the type well known in the art is concentrically disposed about the extensible rod 192 of the actuator 190 to hermetically seal the opening 193 through which the extensible rod 192 extends. The bellows seal 194 has the usual lower mounting flange 195 that is sealingly attached to the upper surface of the mounting plate 182 about the opening 193 thereof, and an extensible bellows 196 that extends upwardly about the actuator rod 192. An upper mounting flange 197 of the bellows seal 194 is suitably attached to the actuator rod 192 proximate it's upper end 198 which is connected to a clevis 199 of a valve body 200 by a pivot pin 202.
A plurality (four shown) of valve body support arms 204 are mounted so as to extend upwardly from the mounting plate 182 in spaced apart relationship with respect to each other. Suitable bearings 206 (one shown) are mounted in the top end of each of the support arms 204 for journaling of a pivot axis 208 which is mounted in the valve body 200. The valve body 200 is of elongated configuration having opposed planar surfaces 209 and 210 with an elongated open port 212 extending transversely through the body so as to open onto both of the opposed planar surfaces 209 and 210. The pivot axis 208 extends longitudinally through the valve body 200 proximate the side edge 214 thereof with the opposite longitudinal side edge forming a valve closing surface 216. As shown best in FIG. 6, the valve closing surface 216 is disposed to form an acute angle of approximately 30-40 degrees with respect to open port 212 thereof. An O-ring type sealing gasket 218 is provided on the valve closing surface 216 of the valve body 200.
When the actuator 190 is in it's retracted state, the valve body 200 will be in the solid line position as shown in FIG. 6, with this position being referred to as the open position of the isolation valve 176. When in this open position, the open port 212 will be disposed in parallel relationship with the mounting plate 182 so that the distal ends of the robot arms 150 and 152 and the wand 158, along with the substrates carried thereby, can be moved through the port 212 of the valve body 200. When the actuator 190 is opened to move the extensible rod 192 to its extended state, the valve body 200 will be pivotably moved through less than 90° of rotation to the closed dashed line position shown in FIG. 6, to bring the valve closing surface 216 into seated sealing engagement with the gas injector structure 178 which is adjacent thereto.
The gas injecting structure 178, as hereinbefore stated, is fully disclosed in U.S. Pat. No. 5,221,556, which is incorporated herein by reference. To insure a complete understanding of the present invention, the gas injector structure 178 will be briefly described.
The gas injector structure 178 as seen best in FIG. 6, includes an elongated injector housing 220 which is interposed between the substrate delivery port 146 of the handling sub-system housing 140 and the input to the processing sub-system 18. The injector housing 220 is provided with an elongated through port 222 which extends transversely therethrough so as to open onto both of the opposite planar surfaces 224 and 226 of the injector housing. The hereinbefore described isolation valve 176 is operable to selectively open and close the through port 222 of the injector housing 220 with the gas outlet side 227 of the port 222 remaining open to the processing sub-system 18 at all times. In otherwords, the valve closing surface 216 of the valve body 200 of the isolation valve 176, is movable into sealing engagement with the surface 224 of the injector housing 220 to close the end of the through port 222 which faces into the housing 140 of the substrate handling sub-system 16.
The injector housing 220 is further provided with a gas flow passage 228 that is normal with respect to the through port 222 and extends upwardly therefrom so as to open onto the top edge surface of the housing 220. An elongated flow control plate 230 having a plurality of variously sized apertures 232 (one shown) formed in spaced increments along its length, is mounted on the top edge of the injector housing 220 so that the apertures 232 open into the gas flow passage 228 of the housing 220. A gas inlet body 234 is mounted atop the flow control plate 230 and is configured to define a plenum chamber 36 having a bottom which opens onto the upper surface of the flow control plate. A gas inlet conduit 238 is mounted on the top end of the inlet body 234 for supplying gas under pressure from a remote source (not shown) to the plenum chamber 236. The plenum chamber distributes the gas pressure equally to all points in the chamber so that equal gas pressures will be applied to the open top end of each of the apertures 232. The gas will therefore flow into the gas flow passage 228 at various velocities as determined by the apertures of the flow control plate 230. The gas passes downwardly into the through port 222 with a predetermined velocity profile through the gas outlet side 227 thereof into the processing sub-system 18.
As hereinbefore mentioned, a single one of the processing sub-systems 18 may be coupled to the substrate handling sub-system 16 to form a complete chemical vapor deposition system 10, but the system 10 may be expanded to include a plurality of processing sub-systems 18 if desired. Each of the processing sub-systems 18 are preferably identical to each other, and the following description is intended to cover each such sub-system.
The processing sub-system 18, as seen best in FIGS. 6 and 7, includes a reaction chamber 240 which, as hereinbefore stated, is fully disclosed in U.S. Pat. No. 4,846,102 which is incorporated herein by reference. The reaction chamber 240 is an especially configured horizontal flow low-profile housing designed for producing desired gas flow characteristics from it's inlet end 242 to it's outlet end 244. The reaction chamber is formed of a material which is transparent to radiant heat energy, such as quartz, and is configured to work in conjunction with a special substrate supporting susceptor and temperature sensing sub-system 246.
The substrate supporting susceptor and temperature sensing sub-system 246 is fully disclosed in U.S. Pat. No. 4,821,674, which is expressly incorporated by reference. However, a brief description of the mechanism 246 will now be presented to provide a complete understanding of the system 10 of the present invention.
The substrate supporting and temperature sensing sub-system 246 includes a circular susceptor 248 which is configured to support a single substrate for rotation about an axis which is normal with respect to the center of the substrate. The circular susceptor 248 is mounted in the reaction chamber 240 on the upper end of a driveshaft assembly 250 which axially extends from the susceptor through a tubular shaft 252 that depends from the floor of the reaction chamber 240, as shown in FIG. 6. The driveshaft assembly 250 is coupled to a drive means 254 which rotates the driveshaft 250 and thus the susceptor 248. The tubular shaft 252 is sealingly coupled as at 256 to the drive means 254 and a purge gas inlet conduit 258 is provided for supplying purge gas from a remote source of gas under pressure (not shown). The purge gas is directed into the drive means 254 and is supplied through the tubular shaft 252 of the reaction chamber 240 and the driveshaft assembly 250 so as to enter the reaction chamber 240 below the rotatable susceptor 248. The susceptor 248, and therefore the substrates supportable thereon, are rotated for temperature averaging purposes and for averaging the thickness of the deposition layer resulting from the passage of reactant gas across the substrate.
A fixed, i.e. non-rotating ring 260 is supported in concentric relationship with respect to the rotatable susceptor 248 on a stand means 262 (FIG. 6) and a plurality of temperature sensors 266 (FIG. 8) are mounted at various points in the annular chamber 264 for sensing the temperatures at various points about the periphery of the rotatable susceptor. The temperature sensor 266 interact with a central temperature sensor 268 provided at the upper end of the driveshaft assembly 250 proximate the center of the rotatable susceptor, to produce control signals for operating a heating sub-system 270.
As hereinbefore stated, the heating sub-system 270 is fully disclosed in U.S. Pat. No. 4,836,138, which is expressly incorporated herein by reference. To insure a complete understanding of the system 10 of the present invention, a brief description of the heating sub-system 270 will now be presented.
The heating sub-system 270 includes an upper radiant heat assembly 272 which is disposed in overlaying relationship with respect to the reaction chamber 240, for directing radiant heat energy downwardly onto the rotating susceptor 248, the temperature sensing ring 260 and adjacent areas. A lower heat assembly 274 is disposed in underlying relationship with respect to the reaction chamber 240 for directing radiant heat energy upwardly into the reaction chamber onto the rotating susceptor 248 and the ring 260 and adjacent areas. The heating sub-system 270 also includes a heat concentrator structure 276 which is employed to direct concentrated radiant heat energy upwardly into the vicinity of the center of the rotatable susceptor 248, for temperature control purposes. The upper and lower heat assemblies 272 and 274 have individually controllable banks of discrete heating elements (not shown) for heating of the various regions on and about the rotatable susceptor 248 and the temperature ring 260, and those banks of elements in conjunction with the concentrator structure 276, which is also separately controlled, provided optimum temperature controlling capabilities.
The outlet end 244 of the reaction chamber 240 has a suitable flange 278 formed thereon and a spent gas collector means 280 is suitably coupled to that flange. The collector means includes a suitable housing 282 defining a collection chamber 284 into which spent reactant gas, purge gas and the like are received after passing through the reaction chamber 240. The spent gas is directed via a suitable hose 286 to a disposal location (not shown). A suitable motor 290, such as pneumatic, is mounted on the housing 282 and has a linearly extensible output shaft 292 (FIG. 1 and 8) for extending engagement with any fixed structural means (not shown). When operated to extend the shaft 292, the entire gas collector means 280 reacts by moving toward the reaction chamber 240 to load its inlet end 242 into sealed engagement with the gas injector structure 178, and to load the housing 282 into sealed engagement with the outlet end 244 of the reaction chamber.
While the principles of the invention have now been made clear in the illustrated embodiments, there will be immediately obvious to those skilled in the art, many modifications of structure, arrangements, proportions, the elements, materials and components used in the practice of the invention and otherwise, which are particularly adapted for specific environments and operation requirements without departing from those principles. The appended claims are therefore intended to cover and embrace any such modifications within the limits only of the true spirit and scope of the invention. | 4y
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. §119(e) of U.S. Application No. 60/018,647 filed May 30, 1996.
BACKGROUND OF THE INVENTION
Active power factor correction (PFC) is being increasingly employed in switching power converters for various applications. This trend is driven by the regulatory requirements of low input harmonic distortions as well as the need to get maximum real power from a given AC outlet. Another significant trend in the power conversion industry in recent years has been the advent of distributed power systems and the standardization around 48V as the distribution bus. A 48V distribution bus provides a ready interface to battery backup systems as well as the highest "safe" voltage for minimizing the currents flowing in the distribution bus. The telecommunication industry has been the driving force behind this standardization as it has been using 48V systems for a number of years.
The major outcome of these recent trends has been that many power conversion systems are compartmentalized into two distinct stages. Referring to FIG. 1, there is shown a power conversion system 10 having first stage converters 12 for accomplishing the tasks of power factor correction along with the generation of an isolated voltage for a distribution bus 14. A second stage 16 consists of local DC-DC converters 18 working off the distribution bus voltage which address local load requirements.
Traditional first stage converters for a distributed power bus (e.g., 48V) have involved 2-step power conversion comprising a PFC boost converter 20 and a step-down converter with isolation 22. While this approach is accepted because it provides functional optimization and good energy storage, it involves two power processing steps and associated complexity and loss in efficiency.
Alternatively, an isolated boost converter 24, first introduced by P. W. Clarke in U.S. Pat. No. 3,938,024, issued Feb. 10, 1976, and entitled "Converter Regulation by Controlled Conduction Overlap", simplifies the converter design by eliminating one process step while still offering isolation and voltage step-down by the use of transformer turns ratio. There is also the potential for efficiency improvement presented due to reduced component count in the power path. Flyback and SEPIC converters can also offer single stage power factor correction with isolation, but their applications are limited to low power levels for the reasons of high peak current and voltage stresses.
Most active PFC converters, including the Clarke, flyback, and SEPIC converters mentioned above, convert a full bridge rectified AC input line voltage to a regulated and isolated DC output voltage. The primary goal of these converters is to reduce the harmonic content of the AC line current. This goal is accomplished by forcing the line current to track the line voltage, thereby causing the input impedance of the converter to appear purely resistive.
Optimal total harmonic distortion (THD) reduction requires that a controller, either discrete or monolithic, maintain the gain of a voltage feedback loop constant as the RMS value of the input line voltage changes. Otherwise, a gain variation of approximately 10 to 1 can occur over the full range of international AC line voltages and cause line current distortion.
Prior art techniques of line voltage compensation have employed an external two pole filter, in conjunction with an analog squaring function, the result of which is divided into the product of the instantaneous line voltage and a DC power command. This technique has an inherent trade off between THD reduction and response time to line voltage variations. A faster response time through the filter, which is desirable, increases the 120 Hz ripple riding on the average DC level. This is an error term that is subsequently squared and input as the divider term in a multiplier. The result is a 3rd harmonic distortion in the input current waveform. Accordingly, it would be desirable to provide a power factor correction controller which overcomes the shortcomings of these prior art techniques while providing other key enhancements.
BRIEF SUMMARY OF THE INVENTION
The present invention contemplates a power factor correction controller which extracts RMS information from a rectified AC input line voltage signal using a novel sample and hold analog to digital conversion approach. The controller then processes a digital word representing the RMS information through the application of a programmable mathematical function. The result is converted to analog form and provided as an input to an analog multiplier. This technique improves the response time of the feed forward gain path of an isolated boost converter circuit by approximately 6 times (e.g., 60 Hz vs. 10 Hz), in addition to eliminating an external two pole passive filter. The mathematical function performed on the RMS information is mask selectable, and can be optimized for different line conditions.
When the present invention controller is used to control an isolated boost converter, commonly referred to as a "Clarke" converter, the controller is configured to drive two IGBT power transistors as main power switches, and one MOSFET switch which is used to ensure zero current transition switching for the IGBT power transistors. The IGET power transistors are favored for high power applications because of their lower conduction losses and lower cost (higher power density) compared to MOSFET's. Overlapping conduction phases of the IGBT power transistors define the charging phase of the isolated boost converter. The drawback of IGBT power transistors is a long turn-off current tail. This limits the usable operating frequency generally to below 20 kHz, in order to keep switching losses low. Thus, a technique which employs a MOSFET switch that is shunted across the IGBT power transistors can be employed. This technique increases the usable frequency range of IGBT power transistors to as high as 100 kHz. Higher switching frequencies allow the size of the magnetic components in the boost converter to be reduced, thereby reducing required area and cost. Applying this technique to an active PFC circuit results in an efficient single stage PFC and step down voltage converter.
A drawback of previous isolated boost converters is a fixed MOSFET conduction overlap delay, generally on the order of 1 to 2 usec. While this is beneficial when the input line current is high (i.e., heavy load, low line), it introduces significant distortion to the AC line current during moderate and light load conditions when the input RMS voltage is high. This is because the conduction delay of the MOSFET switch extends the effective duty ratio of the converter beyond the overlap conduction period of the IGBT power transistors. This becomes a problem when the control loop wants to command a duty ratio lower than the conduction delay of the MOSFET switch. When this occurs, the control loop overshoots trying to correct, thus causing a discontinuity in the input line current.
The present invention controller monitors the output load power and linearly reduces the overlap delay time when the load power decreases. By reducing the overlap time of the MOSFET switch under these conditions, reduction of the turn off losses of the IGBT power transistors is not compromised because the input line current is low, and the distortion is greatly reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features of this invention, as well as the invention itself, may be more fully understood from the following detailed description of the drawings in which:
FIG. 1 is a prior art power conversion system having first stage converters for accomplishing the tasks of power factor correction along with the generation of an isolated voltage for a distribution bus;
FIG. 2 is a prior art isolated boost converter circuit;
FIG. 3 is an isolated boost converter circuit having a controller for providing isolated boost power factor correction with zero current transition switching in accordance with the present invention;
FIG. 4 shows the operating waveforms for the isolated boost converter circuit shown in FIG. 3;
FIG. 5 is a detailed block diagram of the controller shown in FIG. 3;
FIG. 6 is a prior art two stage low pass filter for averaging incoming rectified AC line voltage;
FIG. 7 is a schematic representation of an RMS detector for the controller shown in FIG. 5;
FIG. 8 is a schematic representation of a trailing edge delay circuit for the controller shown in FIG. 5;
FIG. 9 is an equivalent circuit showing the coupling from the primary to the secondary for the isolated boost converter circuit shown in FIG. 3; and
FIG. 10 shows representative voltage waveforms for the power stage of the isolated boost converter circuit shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 2, there is shown a conventional implementation of an isolated boost converter circuit 30. This boost converter circuit 30 has a front-end inductor L, similar to a boost inductor, which is "charged" when both of switches Q1 and Q2 are on simultaneously. When one of the switches Q1 or Q2 is turned off, a corresponding output rectifier D1 or D2 turns on enabling the energy from the inductor L to be transferred to the output V OUT . The two switches Q1 and Q2 are alternately turned off to provide push-pull action and automatic core flux balance. It can be easily seen that while the basic operation of this circuit 30 closely resembles the operation of a boost converter, it provides the added versatility of being able to program the output voltage independently of the input voltage range by scaling the turns ratio of a transformer T. The presence of the input inductor L yields the opportunity to program the input current I L to follow the shape of the input voltage and achieve a high power factor, while the isolation transformer T allows the output voltage level to be programmed at a distributed bus voltage level. These features make this circuit 30 an ideal candidate for a single stage front-end converter with PFC for distributed power applications.
However, certain practical limitations of this circuit 30 have to be addressed to ensure its usefulness in such applications. Like all other PFC converters, the output voltage regulation of the isolated boost converter circuit 30 is generally not as good as what can be achieved with 2-stage conversion. However, it is generally acceptable to have loose regulation for the distributed bus voltage (i.e., 48V) as the downstream point of load converters are expected to tolerate variations in voltage. This approach also requires a higher voltage rating on the two switching elements Q1 and Q2. The voltage stress seen by the switches Q1 and Q2 is greater than twice the maximum line voltage, and can be above 800V for a universal input voltage range. While power MOSFET's are generally acknowledged to be better switching devices for power conversion applications, their price to performance ratio deteriorates quickly at such high voltage levels. With the recent advances in power device technology, IGBT's prove to be ideal components for such high voltage applications. One limiting factor for IGBT's is their slow turn-off characteristics. It has been shown by E. X. Yang, Y. M. Jiang, G. C. Hua, and F. C. Lee in "Isolated Boost Circuit for Power Factor Correction", VPEC 1992, pp. 97-104, that with the addition of a faster MOSFET (of lower current and voltage rating) and appropriate timing control, the turn-off of IGBT's can be carried out with zero voltage thereacross, thereby eliminating turn-off losses and allowing the IGBT's to be operated at higher switching frequencies. The MOSFET carries current only during the transition period and can be sized to be much smaller than the IGBT's. This technique improved the converter efficiency by approximately 2-5% for a 400 W DC-DC application. The critical issue of timing control for the switches Q1 and Q2 can be addressed with certain novel control techniques.
Referring to FIG. 3, there is shown a modified converter circuit 40 depicting the use of the present invention soft-switching isolated boost approach with power factor correction. A novel controller 42 provides all of the control functions needed for the implementation. Operating waveforms for the converter circuit 40 are shown in FIG. 4.
Both of the switches Q3 and Q4 are IGBT's, and switch QA is a MOSFET. When switches Q3 and Q4 are both on, an input inductor LF is charged. When one of the switches Q3 or Q4 is off (along with QA), energy stored in the input inductor LF is transferred through transformer T1 to the output V OUT through output diode 44 or output diode 46, respectively. The two switches Q3 and Q4 are alternately turned off to achieve transformer reset every cycle. The timing of the MOSFET switch QA is adjusted so that it turns on with each IGBT and stays on for a programmed delay (td) after an IGBT has been turned off. During the delay, the current transfers from the IGBT's to the MOSFET as shown in FIG. 4 (while the inductor LF continues to charge up). The current in both IGBT's reduces slowly due to the inherent current tail as shown, but keeping the MOSFET on during this period allows lossless IGBT turn-off.
The converter circuit 40 also includes a bias supply 48, a coupling resistor 50, a coupling capacitor 52, an opto-coupler 54, a feedback circuit 56, a soft start capacitor 58, a feedback impedance 60, a feedback impedance 62, a coupling resistor 64, a coupling capacitor 66, an RC low pass filter 68, a coupling resistor 70, a coupling capacitor 72, a coupling resistor 76, a transformer winding 78, and a diode 80. The function of these devices will be described in detail below.
The controller 42 is a monolithic control solution for isolated boost PFC with Zero Current Transition switching (ZCT). Referring to FIG. 5, there is shown a detailed block diagram of the controller 42. The controller 42 is preferably fabricated with a combination of dense CMOS logic, precision bipolar elements, and power DMOS output drivers. It employs a fixed frequency average current inner control loop for accurate tracking of the input line current with a generated reference signal. An outer low bandwidth voltage loop regulates the output V OUT . While similar in function to previous PFC controllers, several distinct features of this controller 42 allow for greater power system integration, improved performance, and higher efficiency over other approaches.
The controller 42 has multiple inputs and outputs for performing its necessary functions. For instance, the VIN input provides a supply voltage to the controller 42 from the bias supply 48. The supply voltage level is preferably limited to less than 18 VDC. The controller 42 is enabled when the supply voltage level at the VIN input exceeds 13.75V (nominal).
The IAC input is typically resistor coupled to the rectified AC input line voltage through resistor 50. The IAC input provides an internal analog multiply and divide circuit 82 and an internal RMS detect and conditioning circuit 84 with instantaneous line voltage information. The RMS value detected by the RMS detect and conditioning circuit 84 may be multiplied by an internal multiplying DAC (see FIG. 7).
The CRMS input is capacitor coupled to ground through capacitor 52 to average the AC line voltage over a half cycle. The CRMS input is internally connected to the RMS detector 84.
The SNS input is a feedback input for the outer voltage control loop. The external opto-coupler 54 and feedback circuit 56 provide output voltage regulation information to the SNS input across an isolation barrier.
The SS input is capacitor coupled to ground through soft start capacitor 58 to provide the controller 42 with a soft start feature. The voltage on the COMP input, discussed below, is clamped to approximately the same voltage as the SS input. An internal 10 uA (nominal) current source is provided by the controller 42 to charge the soft start capacitor 58.
The COMP output is the output of an internal voltage loop error amplifier 86. The COMP output is internally clamped to approximately 5.6V by the controller 42 and can swing as low as approximately 0.1V. Voltages below 0.5V on COMP output will disable the MOSDRV output and force the IGDRV1 and IGDRV2 outputs to a zero overlap condition. The COMP output is coupled to the SNS input through a feedback impedance 60.
The CA- input is the inverting input of an internal inner current loop error amplifier 88. The CA- input is coupled to the CAO output, discussed below, through a feedback impedance 62.
The PKLMT input is the inverting input to an internal peak current limit comparator 90. The threshold for the peak current limit comparator 90 is nominally set to 0 volts. The peak current limit comparator 90 terminates the MOSDRV, IGDRV1, and IGDRV2 outputs when tripped.
The RT input is resistor coupled to ground through resistor 64 to set the charging current for an internal ramp generator 92. The controller 42 provides a temperature compensated 3.0V at RT. The oscillator charging current of the ramp generator 92 is therefore 3.0V divided by the value of resistor 64. The current out of the RT input should be limited to 250 uA for best performance.
The CT input is capacitor coupled to ground through capacitor 66 to set the switching frequency of the ramp generator 92 in conjunction with the RT input. Capacitor 66 is preferably a low ESR, ESL capacitor. The frequency of the ramp generator 92 is approximately equal to 0.67 divided by the value of the product of the value of resistor 64 and the value of capacitor 66.
The AGND input provides a reference point for an internal voltage reference 94 and all thresholds, as well as the return for the remainder of the controller 42, except for several internal output drivers 96, 98, 100.
The PGND input provides a return for all high level currents internally tied to the output driver stages of the controller 42.
The IGDRV1 output is the driver output for the external IGBT power switch Q3. The IGDRV2 output is the driver output for the external IGBT power switch Q4. The MOSDRV output is the driver output for the external MOSFET power switch QA. The VD input provides a positive supply rail for the three output driver stages. The voltage applied to the VD input should be limited to less than 18VDC. The VD input should be bypassed to the PGND input with a 0.1 to 1.0 uF low ESR, ESL capacitor for best results. The VD input and the VIN input can be isolated from each other with an RC low pass filter 68 for better supply noise rejection.
The DELAY input is resistor coupled to the VREF output through resistor 70, and is capacitor coupled the AGND input through capacitor 72. The resultant RC filter 74 provides an overlap delay time for a trailing edge delay circuit 102 and for the MOSDRV output stage. The overlap delay function can be disabled by disconnecting capacitor 72 from the AGND input.
The CAO output provides the output of the inner current loop error amplifier 88. This output can swing between approximately 0.1V and the value at the VREF output. It is one of the inputs to an internal PWM comparator 104.
The MOUT output provides the output of the internal analog multiply and divide circuit 82. The MOUT output is resistor coupled to the return leg of the input bridge through resistor 76. The resultant waveform on the MOUT output forms a sine reference for the current error amplifier 88.
The VREF output provides a precision 7.5V reference voltage. A 0.01 to 0.1 uF low ESR, ESL bypass capacitor is recommended between the VREF output and the AGND input for best performance.
Traditional PFC controllers employ an analog RMS voltage feed forward function as part of an analog computation unit (ACU) to maintain a constant gain in the outer voltage regulation loop (see L. Dixon, "High Power Factor Preregulators for Off-line Power Supplies", Unitrode Seminar (SEM-600)). The RMS term must be squared by the ACU in order to provide optimal gain linearity. Without this function, the voltage loop gain would vary with the square of the input line RMS voltage, or approximately 10:1 over a universal input voltage range of 85 to 265VAC. The ACU transfer function typically employed is: ##EQU1## I mult =ACU output current (current loop reference). V err =voltage amplifier output (load current command, input to ACU).
I AC =rectified AC input voltage reference (input to ACU).
K=ACU gain constant.
V rms =averaged value of the rectified input line voltage (input to ACU).
The input line voltage is averaged to extract a DC voltage which is proportional to its RMS value for a sinusoidal input. This is traditionally accomplished with a two stage low pass filter 120 off of the incoming rectified AC line, as shown in FIG. 6. The filter output has a 120 Hz ripple imposed on its average DC level which is out of phase with the AC input. Since this voltage will be squared by the internal circuitry of the controller 42, attenuation of the 120 Hz ripple is crucial in order to reduce the third harmonic distortion in the resultant line current waveform. The limitation with the low pass filter technique is its inherent trade-off between reduction in ripple and providing adequate response time to changes in the input line RMS value. Typical implementations place a cut-off frequency for the filter around 10 Hz. Lower cutoff frequencies can reduce the THD at the expense of a slower responding feed forward path.
Referring to FIG. 7, there is shown a schematic representation of the internal RMS detector 84 in accordance with the present invention. The RMS detector 84 employs an RMS voltage sensing technique which takes advantage of the mixed signal capabilities allowed by a BiCMOS fabrication process. It combines an integrate and hold function with a 6 bit A-D converter 122 to extract the RMS value of the incoming line voltage and digitally "hold" it in a register 124 for a line cycle. The implementation extracts the RMS information directly from the IAC input current signal, which is needed by the ACU anyway, thereby eliminating the need for the external two pole filter 120.
The first stage of the RMS detector 84 mirrors the IAC current to coupling capacitor 52 for one half-cycle of the input line. Capacitor 52 (C rms ) charges to a voltage proportional to the average peak RMS value of the line according to the following equation: ##EQU2##
Next, the current mirror is disconnected from capacitor 52 and the A-D converter 122 converts this voltage to a 6 bit digital word. The A-D converter 122 has a 4.0V full scale range, which yields a step resolution of 64 mV. The 6 bit word is then loaded into the register 124 and capacitor 52 is reset to zero volts in preparation for the next sample. The contents of the register 124 are output to a multiplying DAC 126 in order to produce the denominator term in the ACU transfer function of analog multiply and divide circuit 82. FIG. 7 also illustrates typical operational waveforms for the present invention RMS voltage sensing technique.
There are two important benefits of this technique of RMS voltage extraction. The RMS detector 84 samples and updates the RMS value at the line frequency, which is six times the bandwidth of the typical two stage filter approach. Since the hold function is digital, it is inherently ripple free. Reduction of ripple in the feed forward path improves the THD, but it also opens up the possibility of improving the overall bandwidth of the outer voltage loop. The low bandwidth of the outer voltage loop is a fundamental limitation of all conventional PFC converters, compounded by the need to minimize the contribution of the 120 Hz ripple from the output V OUT . The improvement in bandwidth with the present invention RMS voltage sensing technique is possible because the contribution from the RMS distortion term is virtually eliminated, allowing the distortion producing component of the outer voltage loop to be increased. With higher outer voltage loop bandwidth, and allocation of higher ripple to the output V OUT , smaller output filter capacitors can be specified, saving cost and space.
As shown in the waveforms of FIG. 4, the modified isolated boost converter circuit 40 requires drive signals for the two main (IGBT) switches Q3 and Q4 with certain timing relationships. The delay between turn-off of an IGBT and turnoff of the MOSFET can be programmed for the controller 42. In a PFC application, the input line varies from zero to the AC peak level, resulting in a wide range of required duty ratio.
A fixed delay time will induce line current distortion at the peaks of the AC line under high line and/or light load conditions. This is caused by the minimum controllable duty ratio imposed on the modulator by the fixed delay. If the minimum controllable duty ratio is fixed, the inner current loop can exhibit a limit cycle oscillation at the line peaks, inducing line current distortion.
Referring to FIG. 8, there is shown a schematic representation of the trailing edge delay circuit 102. The trailing edge delay circuit 102 operates as an adaptive MOSFET delay generator which is directly modulated by load power demand. That is, this circuit 102 directly varies the delay time based on the output voltage level of the voltage loop error amplifier 86 which in an average current mode PFC converter with line feed forward is indicative of load power. The delay time is programmed with resistor 70 and capacitor 72. The sequence of events starts when the internal CLK signal resets latch U2, causing PWMDEL to go high and the Q output to go low. Capacitor 72 is discharged via M1 and is held low until the internal PWM signal goes low (indicating turn-off of either of the IGBT drives). At this point M1 turns off and capacitor 72 charges towards the 7.5V reference through resistor 70. A comparator U1 compares this voltage to the output voltage (Vaout) of the voltage loop error amplifier 86. When the voltage on capacitor 72 is greater than Vaout, the latch U2 is set causing PWMDEL to go low. PWMDEL is logically ANDed with CLKNOT to produce the signal which commands the MOSFET driver output.
This technique reduces the overlap delay at light loads or high lines, but maintains a longer delay when the line voltage is low or the load is heavy. This, by definition, reduces the minimum controllable duty ratio to an acceptable level, and is programmable by the user. Reducing the delay time under light current conditions is acceptable since IGBT current is directly proportional to load current. By providing programming flexibility with resistor 70 and capacitor 72, the delay times cam be optimized for current and future classes of IGBT switches. The delay can also be set to zero by removing capacitor 72 from the converter circuit 40.
The controller 42 provides several additional features which ease the converter design. A soft-start function eases input di/dt, which in turn eases stress on output rectifiers. A zero current comparator 106 ensures that the converter circuit 40 delivers zero current when commanded by the voltage loop error amplifier 86. Previous controllers relied on a built-in or an externally induced offset voltage on the current error amplifier 88 to guarantee this condition. A peak current limiting feature prevents inductor current saturation during start-up conditions. Other features of the controller 42 include under voltage lock out (UVLO) circuitry 108 with several volts of hysteresis, and a system shutdown comparator 110 combined with the SS input.
For the isolated boost converter circuit 40, the key design considerations are related to the transformer design, switch selection, boost inductor design, and start-up and shutdown situations. While the steady-state transfer function of the isolated boost converter circuit 40 is similar to the transfer function of a conventional non-isolated boost converter (with turns ratio factor), the presence of extra switches makes the transient conditions considerably different. In particular, output diode conduction is possible only when one of the switches Q3 or Q4 is on.
During start-up and overvoltage/overcurrent situations, if both switches Q3 and Q4 are turned off, the inductor current has no means to discharge to the output V OUT . A transformer winding 78 and a diode 80 are thus provided to allow the inductor L to discharge under fault conditions. The same circuit also provides a path to the output V OUT during start-up. The turns ratio for this auxiliary transformer is made to be equal to or larger than the turns ratio of the main transformer T1 in order to ensure that diode 80 stays off during normal operation. The input inductor L is designed to handle the peak input current which occurs at full load, low line peak conditions.
The turns ratio of the main transformer T1 is determined by the need for the primary side reflected output voltage to be larger than the peak of the high line input. As in other universal input PFC boost converters, this level meeds to be in the 385-400V range. For a 48V output, this means a turns ratio of 8:1. The coupling between the related primary and secondary windings should be very tight to prevent ringing.
The peak voltage and current stresses of the IGBT switches Q3 and Q4 are depicted in FIG. 4. Without consideration of ringing, the peak stresses are twice the reflected output voltage and necessitate 900V or higher rating for the IGBT switches Q3 and Q4. In the available range of IGBT's for this application, a trade-off exists between faster switching speeds and lower forward drop. While the presence of the MOSFET switch QA allows lossless turn-off, it is still desirable to use fast or ultrafast IGBT's for switching frequencies in the 100 kHz range to prevent the delay from becoming a very large portion of the available duty cycle. It should be noted that in this application, the switching frequency of the IGBT switches Q3 and Q4 is half the switching frequency of the MOSFET switch QA (which is also the inductor ripple frequency). The MOSFET switch QA used in this application is rated at half the peak voltage of the IGBT switches Q3 and Q4 and also does not carry current for most of the cycle. However, when it carries current (during the programmed delay period), its peak current is equal to the peak inductor current. The sizing of the MOSFET switch QA should be such that it can handle the desired peak current while still being able to switch off very fast. The waveforms in FIG. 4 depict steady state operation in the absence of any leakage inductance in the transformer T1. However, the high turns ratio and the complex winding structure of the transformer T1 results in significant leakage effects between windings. The isolation requirements of the output also contribute to the leakage. The higher voltage stresses and contribute to power loss and EMI. While the coupling between primaries is important, the coupling from the primary to secondary is even more critical. This can be understood by analyzing the circuit behavior when the MOSFET switch QA turns off. At that point, only one IGBT switch Q3 or Q4 is on and a corresponding output diode 44 or 46 is about to turn on. The equivalent circuit at this point is shown in FIG. 9. For the purpose of this analysis, the input inductor current can be assumed to be constant at I LF .
Unlike conventional boost converters, when the MOSFET switch QA is turned off, current takes longer to transfer to an output diode due to the presence of leakage inductance. In addition, current initially transfers to both the windings if the primary to secondary leakage inductance is significant. As a result of current in the non-conducting branch (Q3 in FIG. 9), there is resonance between the leakage inductance and parasitic capacitance of the IGBT switch Q3 which increases the voltage stresses. Assuming that the input inductor current ILF is equally divided between the two branches initially, the resonant circuit equations for the first half cycle are given by ##EQU3## wherein L (equivalent inductance) and ω are given by ##EQU4##
From the above equations, it can be seen that higher L contributes to higher ringing at v c . By increasing the value of C 0 , this ringing can be snubbed, but that leads to higher losses at the turn-on of the IGBT switch Q3 or Q4. Also, a lower natural impedance of the circuit (achieved with low L or high C 0 ), has a negative impact on the value of i 1 . Hence, careful trade-offs must be made to prevent excessive dissipation during this transition.
Because of the isolation provided by the converter circuit 40, the output rectifiers 44 and 46 see lower voltage and higher current stresses. However, lower voltage stresses are a highly favorable condition for the minimization of reverse recovery effects for these rectifiers. A wide variety of rectifiers are available for desired current levels at the typical voltage rating of 200V for the intended 48V application.
The requirements for the output capacitor C F of the isolated boost converter circuit 40 are somewhat more demanding. It is a demonstrated fact that the energy storage function of the capacitor C F is more easily accomplished at higher voltage levels. The capacitance required for the same hold-up time increases inversely with the square of the output voltage for the same level of percentage ripple and output power requirements. In addition, for PFC circuits, the output capacitor C F is required to be large enough to handle the 120 Hz ripple which cannot be attenuated by the power stage. Another consideration for 48V systems is the voltage rating on the output capacitor C F . Because of the considerable 120 Hz ripple, a 50V rating is not practical and a higher voltage rating is needed. It should be remembered that the output capacitor C F in this case replaces a boost capacitor and an output filter capacitor in a conventional two step front end converter. This offers significant cost and space savings compared to the conventional approach.
An experimental universal (85 to 264VAC) input, 40V-250 W output isolated boost converter with power factor correction was designed using the circuit design considerations outlined above. The key component choices were as follows:
IGBT Switches Q3 and Q4: IRGPH40F, 1200V, 29A
MOSFET Switch QA: IRF840, 500V, 0.85 ohm
Output Diodes: IR10CTF20
LF: 40T/4T (Metglas MicroLite MP3510PDGC core)
C F : 4700 μF, 50V Aluminum Electrolytic Capacitors
T: Magnetics R material, ETD49 core (40 turns each primary, 4 turns each secondary, interleaved P1-S1-P1-P2-S2-P2)
The power stage required accurate timing control and proper snubbing to yield expected results. In particular, the turn-on of the IGBT switches Q3 and Q4 with respect to the turn-on of the MOSFET switch QA had to be accurately slowed down to prevent large current spikes caused by high dv/dt's. The operational waveforms of the isolated boost converter are shown in FIG. 10.
FIG. 10 depicts representative voltage waveforms for the power stage including the gate waveforms of the MOSFET switch QA and the IGBT switch Q3 and their drain and collector voltages, respectively. As seen from the waveforms, inductive ringing (due to leakage inductance) contributes to additional voltage stress on the devices.
Given the complexity of the isolated boost converter circuit 40, it is clear that the controller 42 greatly simplifies its practical implementation. The controller 42 primarily provides accurate and easy control of the isolated boost converter circuit 40. The controller 42 also provides additional performance enhancements in terms of improved RMS voltage sensing and adaptable MOSFET turn-off delay. With these enhancements, the controller 42 enables the implementation of a single stage isolated, power factor corrected front-end power supply with lower harmonic distortion at light loads, improved dynamic feed forward response, and potentially higher bandwidth for the voltage feedback loop.
The present invention is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications to the present invention, in addition to those described herein, will be apparent to those of skill in the art from the foregoing description and accompanying drawings. Thus, such modifications are intended to fall within the scope of the appended claims. | 4y
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FIELD OF THE INVENTION
The present invention relates generally to rotary unions. More particularly, the present invention relates to rotary unions which incorporate a retraction port which provides the user with the ability to separate the sealing surfaces of the rotary union, when flow of lubricant is not required.
BACKGROUND OF THE INVENTION
Rotary unions that incorporate a rotating fluid seal between the axial mateable sealing surfaces of a pair of relatively rotatable parts thereof are well known in the art. Typical of these rotary unions is a rotary union of the kind for effecting the transfer of fluid from a stationary fluid source to a fluid conduit in the form of a rotating spindle, shaft, clutch hub or other such device into which fluid is to be fed.
A typical fluid rotary union includes a rotor seal member and a stator seal member which are assembled in co-axial relationship in a common housing for relative rotation and passing fluid. The stator and rotor are axially biased towards one another such that the axial sealing surfaces thereof are in engagement and define a rotating seal interface in the housing that is generally perpendicular to the axis of rotation. The rotor seal member is journalled on a bearing for rotation relative to the housing and normally includes a threaded shaft on the line which extends from the housing to be affixed to the rotating spindle for rotation therewith.
These prior art rotary unions must be capable of containing very high pressures while rotating at very high speeds. This is made possible by an almost perfect mating of the sealing surfaces which are disposed generally perpendicular to the axis of rotation. These micro-lapped sealing surfaces must rotate smoothly and easily with a minimum amount of friction to assure long life and still not leak. In order to maintain the sealing at high pressures, these prior art rotary unions utilize the pressure seal principle. A nominal load is applied to the two sealing surfaces by a biasing spring in order to seal the union during times when the fluid within the coupling is not pressurized. As the pressure of the fluid within the coupling increases, the load between the two sealing surfaces increases due to the fluid pressure acting against either the rotor or the stator to force these two components together. The total amount of pressure acting on the rotating sealing surfaces can be controlled by controlling the surface areas exposed to the fluid pressure. This, in turn, will control the amount of friction between the sealing surfaces, the amount of torque to rotate the coupling and thus the wear of the sealing surfaces. While the total amount of load is controllable, these prior art unions maintain a load between the sealing surfaces when the union is not subjected to fluid pressure. The presence of this load means the friction between the sealing surfaces continues to cause a higher torque to rotate the union and additional wear between the sealing surfaces.
Rotary unions have been designed to control this pressure seal principle by incorporating a balanced sealing pressure on the loaded rotor or stator. The balanced sealing pressure on the rotor or stator means that the sealing load on the sealing surfaces is maintained only by the biasing spring with loading by the pressurized fluid being generally eliminated. While this balanced sealing approach has increased the durability of the rotary union, the sealing of the rotary union is somewhat compromised due to the identical sealing load being applied at both low pressure and high pressure conditions of the rotary union. In addition, when these balanced sealing pressure rotary unions are operated without fluid pressure, the load between the sealing surfaces is still present. The presence of this load means the friction between the sealing surfaces continues to cause a higher torque to rotate the union and additional wear between the sealing surfaces.
Accordingly, what is needed is a rotary union which is capable of providing sufficient sealing loads on the sealing surfaces during periods when the rotary union is subjected to fluid pressures to insure a positive seal between the sealing surfaces and is also capable of eliminating the load between the sealing surfaces during periods when the rotary union is not subjected to fluid pressures.
SUMMARY OF THE INVENTION
The present invention provides the art with a rotary union which conducts pressurized fluid between a stationary and a rotating component. The rotary union incorporates a stationary and a rotating sealing surface which are generally perpendicular to the axis of rotation. A separate fluid port is provided which provides a pressurized fluid to the coupling in order to eliminate the sealing load between the sealing surfaces. The pressurized fluid supplied to the separate fluid port can be the same pressurized fluid being transported by the rotary union or it can be from a separate pressurized fluid source.
Other advantages and objects of the present invention will become apparent to those skilled in the art from the subsequent detailed description, appended claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
FIG. 1 is an exploded perspective view of the rotary union according to the present invention;
FIG. 2 is a side elevational view, partially in cross section, of the assembled rotary union in accordance with the present invention;
FIG. 3 is a side elevational view, in cross section, of the rotor shown in FIGS. 1 and 2;
FIG. 4 is a side elevational view, in cross section, of the stator shown in FIGS. 1 and 2;
FIG. 5 is a side elevational view, in cross section, of the stator housing shown in FIGS. 1 and 2;
FIG. 6 is a side elevational view, partially in cross section, of an assembled rotary union in accordance with another embodiment of the present invention;
FIG. 7 is an end view of the rotary union shown in FIG. 6; and
FIG. 8 is a side elevational view, partially in cross section, of an adjustment plug being utilized to align the axes of the rotary union shown in FIGS. 6 and 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in which like reference numerals designate like or corresponding parts throughout the several views, there is shown in FIGS. 1 through 5, a rotary union for transferring pressurized fluid according to the present invention which is designated generally by the reference numeral 10. Rotary union 10 is comprised of a support housing 12, a stator housing 14, a stator 16 and a rotor 18. Rotary union 10 is shown for exemplary purposes being secured to an apparatus 20. Apparatus 20 includes a stationary member 22 and a rotating shaft 24 having an axis of rotation 26. Rotary union 10 is designed to be an original equipment component which is secured to apparatus 20.
Support housing 12 includes a generally cylindrical body 28 having an annular flange 30 extending radially outward from one end to facilitate the mounting of union 10 to stationary member 22 of apparatus 20. Housing 12 is secured to member 22 using a plurality of bolts 32 and a plurality of dowel pins 34 both of which extends through flange 30 and into member 22. Housing 12 defines an axis 36 which is the functional axis for union 10. Bolts 32 and dowel pins 34 are incorporated into apparatus 20 to mount housing 12 such that axis 36 is aligned with axis 26 of rotating shaft 24. Cylindrical body 28 defines a bore 38 which extends through body 28 to provide a chamber 40 for housing the sealing surfaces of rotary union 10. A drain port 42 extends through cylindrical body 28 into chamber 40 to drain any fluid which may flow between the sealing surfaces of union 10 back to a sump or tank (not shown) which supplies the pump (not shown) for providing pressurized fluid to rotary union 10. A labyrinth 43 insures that the fluid which flows from between the sealing surfaces will be directed towards drain port 42. Cylindrical body 28 is adapted at the end of body 28 opposite to flange 30 for mounting stator housing 14.
Stator housing 14 includes a generally cylindrical body 44 having an annular flange 46 extending radially outward from the exterior surface of body 44 to facilitate the mounting of housing 14 to housing 12. Housing 14 is secured to housing 12 using a plurality of bolts 48 which extend through flange 46 and into housing 12. Cylindrical body 44 defines a bore 50 which extends through housing 14 to provide for the locating of stator 16. The end of housing 14 opposite to support housing 12 defines a threaded bore 52 to which the stationary fluid supply source is attached. Bore 50 of housing 14 includes an inwardly extending annular flange 54 for mounting a seal 56 which seals the interface between housing 14 and stator 16.
Stator 16 includes a generally cylindrical body 58 having an annular flange 60 extending radially outward from the exterior surface of body 58. Stator 16 includes a through bore 62 for transporting the pressurized fluid through union 10. Stator 16 is disposed within bore 50 of stator housing 14 such that stator 16 is capable of axial movement along axis 36. The outside diameter of flange 60 is designed to be slidingly received within bore 50 and flange 60 defines a plurality of sills 64 which extend through flange 60 for the passing of pressurized fluid. A plurality dowel pins 66 extend through the wall of body 44 of stator housing 14 and into a respective slot 64 to prohibit the rotation of stator 16 with respect to housing 14 while still allowing the axial movement of stator 16 along axis 36. The end of body 58 extending from flange 60 away from housing 12 defines a first external diameter 68 which mates with annular flange 54 and seal 56 of stator housing 14 to define an inlet pressure chamber 70 and a retraction pressure chamber 72. A retraction port 74 extends through flange 46 of stator housing 14 into chamber 72 to provide access to chamber 72 by an external source of pressurized fluid (not shown). A coil spring 76 is disposed within chamber 72 between flanges 54 and 60 in order to urge stator 16 to the left as shown in FIG. 2 or into sealing engagement with rotor 18. The end of body 58 extending from flange 60 towards housing 12 defines a second external diameter 78 which is smaller than diameter 68 to provide for the selective pressurized unloading or retraction of the sealing faces as will be discussed later herein. Annular ring 80 extends between external diameter 78 and bore 50. Annular ring 80 is provided with an internal seal 82 which seals between ring 80 and stator 16 and an external seal 84 which seals between ring 80 and stator housing 14. Retraction chamber 72 is thus isolated from bore 62, inlet pressure chamber 70 and the external environment by seals 56, 82 and 84. Annular ring 80 is retained within bore 50 by a snap ring 86 which extends into cylindrical body 44. Stator 16 defines a sealing surface 88 which mates with a sealing surface 90 located on rotor 18.
Rotor 18 includes a generally cylindrical body 92 defining a through bore 94 for transporting the pressurized fluid through union 10. Rotor 18 is adapted at one end to rotatably engage shaft 24. As illustrated in FIG. 3, rotor 18 includes an external thread 96 which threadingly engages an internal thread 98 disposed within a fluid passage 100 of shaft 24. A seal 102 disposed between rotor 18 and shaft 24 maintains a fluid seal for bore 94 and passage 100. The end of rotor 18 opposite to splines 96 defines sealing surface 90 which sealingly mates with sealing surface 88 on stator 16 to complete the route for pressurized fluid to flow through union 10.
Sealing surfaces 88 and 90 are normally micro-lapped such that rotor 18 rotates smoothly and easily with respect to stator 16 while insuring a sealing interface between stator 16 and rotor 18. With the incorporation of labyrinth 43 and drain port 42 which transport any fluid passing between sealing surfaces 88 and 90 back to the tank or sump, sealing surfaces 88 and 90 can be supplied with micro-lapped grooves 104 which transport a minute portion of the pressurized fluid moving through union 10 to the interface between sealing surfaces 88 and 90. The fluid which is transported between sealing surfaces 88 and 90 by micro-lapped grooves 104 will lubricate the interface between sealing surfaces 88 and 90 thus reducing friction and wear between the sealimg surfaces as well as reducing the torque required to rotate union 10. The fluid which is transported by micro-lapped grooves 104 will eventually leak from between sealing surfaces 88 and 90 and be returned to the tank or sump by labyrinth 43 and drain port 42.
The operation of rotary union 10 begins with union 10 being mounted to apparatus 20 as shown in FIG. 2. A source of fluid (not shown) is provided to threaded bore 52 of stator housing 14. When the fluid being supplied to bore 52 is not under pressure, coil spring 76 urges stator 16 against rotor 18 thus engaging sealing surfaces 88 and 90. The load applied between sealing surfaces 88 and 90 will only be dependant upon the design of coil spring 76. Retraction port 74 is provided in order to allow pressurized fluid to be supplied to reaction pressure chamber 72 totally independant of inlet pressure chamber 70. Pressurized fluid supplied to chamber 72 reacts against both surfaces of flange 60 due to the plurality of slots 64 extending through flange 60. The pressurized fluid within chamber 72 will act against stator 16 and urge stator 16 to the right as shown in FIG. 2 against the load of coil spring 76 thus eliminating the load applied between sealing surfaces 88 and 90 by separating sealing surfaces 88 and 90. This urging of stator 16 to the right is due to the fact that diameter 78 of stator 16 is smaller than diameter 68 of stator 16 thus providing a larger surface area on the left side of flange 60 than on the right side of flange 60 as shown in FIG. 4. The load applied between sealing surfaces 88 and 90 can be totally eliminated by knowing the strength of coil spring 76, the difference in areas between the sides of flange 60 and then applying a specified pressure to retraction port 74.
When the fluid being supplied to threaded bore 52 is under pressure, coil spring 76 urges stator 16 against rotor 18 and the pressurized fluid within inlet pressure chamber 70 reacts against the end of stator 16 to increase the load by which stator 16 is urged against rotor 18 engaging sealing surfaces 88 and 90. The load applied between sealing surfaces 88 and 90 can be controlled by knowing the strength of coil spring 76, the pressure of the fluid within inlet pressure chamber 70 and the surface area exposed to inlet pressure chamber 70. When pressurized fluid is being supplied to bore 52, pressurized fluid is not being supplied to port 74.
Retraction port 74 is totally independant from threaded bore 52. When connecting the pressurized fluid to threaded bore 52, a valve 106 can be included which selectively supplies the pressurized fluid to either threaded bore 52 or retraction port 74. This allows an operator to switch valve 106 such that pressurized fluid is being supplied to threaded bore 52 when apparatus 20 requires the flow of pressurized fluid. Sealing surfaces 88 and 90 are urged together due to the load exerted by coil spring 76 and the load exerted by the fluid pressure acting on the area of stator 16 exposed to the fluid pressure. When apparatus 20 does not require the flow of pressurized fluid, valve 106 can be switched to supply pressurized fluid to retraction port 74, thus separating sealing surfaces 88 and 90 in order to eliminate any wear or friction between surfaces 88 and 90.
FIGS. 6 through 8 show a rotary union 110 according to another embodiment of the present invention. Rotary union 110 is similar to rotary union 10 with the exception that support housing 12 of union 10 has been replaced by support housing 112 in union 110. Support housing 112 is similar to support housing 12 except for the elimination of flange 30. Support housing 112 is secured in an axially aligned position with shaft 24' by an L-shaped bracket 120 rather than by flange 30. Rotary union 110 is designed to be incorporated into an apparatus 20' as an after market retro-fit instead of the original equipment manufacture design of rotary union 10.
L-shaped bracket 120 provides of the adjustment of axis 36' of housing 112, in relationship to axis 26' of shaft 24'. Axis 36' is the functional axis for union 110 while axis 26' is the axis of rotation for shaft 24'. Support housing 112 is mounted to a stationary member 122 by utilization of L-shaped bracket 120 and a plurality of bolts 124. Stationary member 122 can be a portion of apparatus 20 or member 122 can be a separate component. A partially tubular support frame 126 is fixedly secured to bracket 120 and bracket 120 is positioned to locate frame 126 generally coaxial with shaft 24 of apparatus 20. A plurality of threaded adjustment screws 128 extend through frame 126 and support housing 112 within frame 126. Thus, by adjusting the individual screws 128, axis 36' of housing 112 can be perfectly aligned with axis 26' of shaft 24' in order to insure the proper interfacing of sealing faces 88 and 90. The remainder on union 110 including the function and operation are identical to those shown and described for rotary union 10.
FIG. 8 illustrates the adjustment procedures of adjusting screws 128 in order to align axis 36' of housing 112 with axis 26' of shaft 24'. L-shaped bracket 120 is first fixedly secured to member 122 using the plurality of bolts 124 with frame 126 generally co-axial with axis 26'. An installation plug 140 is fixedly secured to housing 112 by the plurality of bolts 48. Adjusting plug 140 has an exterior surface 142 which mates with an internal surface 144 on housing 112 to co-axially locate housing 112 relative to plug 140. With adjusting screws 128 being loosened or removed, the assembly of installation plug 140 and housing 112 is threaded into shaft 24' and tightened using an integral hex drive 146. Adjusting screws 128 are then tightened against housing 112 to positively secure housing 112 to frame 126 of bracket 120. Once adjusting screws 128 are tightened, axis 36' which is defined by housing 112, is aligned with axil 26' of shaft 24' due to plug 140 being threadingly received within shaft 24' and the mating of surfaces 142 and 144. Once housing 112 has been secured by screws 128, bolts 48 and plug 140 are removed and the remainder of the internal components of rotary union 110 are assembled into housing 112. Stator housing 14 includes an external surface 148 which is also designed to mate with surface 144 to insure that stator housing 14 will be located coaxial with axis 36'.
While the above detailed description describes the preferred embodiment of the present invention, it should be understood that the present invention is susceptible to modification, variation and alteration without deviating from the scope and fair meaning of the subjoined claims. | 4y
|
REFERENCE TO AN RELATED APPLICATION
This applications claims the benefit of the Provisional Application Ser. No. 60/053,219 filed Jul. 18, 1997 which is relied on and incorporated herein by reference.
INTRODUCTION AND BACKGROUND
The present invention relates to an automotive exhaust gas catalyst which has a single-layered, catalytically active coating of high surface area support oxides on an inert carrier structure, wherein the coating contains palladium as the only catalytically active noble metal.
Internal combustion engines emit carbon monoxide CO, unburnt hydrocarbons HC and nitrogen oxides NO x as the main pollutants in the exhaust gas, a high percentage of these being converted into the harmless components water, carbon dioxide and nitrogen by modern exhaust gas treatment catalysts. Conversion takes place under substantially stoichiometric conditions, that is the oxygen in the exhaust gas is controlled using a so-called lambda sensor in such a way that the oxidation of carbon monoxide and hydrocarbons and the reduction of nitrogen oxides to nitrogen can take place almost quantitatively. The catalysts developed for this purpose are called three-way catalytic converters.
Stoichiometric conditions prevail when the normalized air/fuel-ratio λ is 1. The normalized air/fuel-ratio λ is the air/fuel ratio standardized to stoichiometric conditions. The air/fuel ratio states how many kilograms of air are required for complete combustion of one kilogram of fuel. In the case of conventional gasoline engine fuels, the stoichiometric air/fuel ratio has a value of 14.6. The engine exhaust gas has more or less large, periodic variations in normalized air/fuel-ratio depending on the load and the engine speed. To produce better conversion of oxidizable hazardous components under these conditions, oxygen-storing components such as, for example, cerium oxide are used which bind oxygen when it is present in excess and release it again for oxidative conversion when there is a deficiency of oxygen in the exhaust gas.
Future exhaust gas limits for internal combustion engines require an increasingly stringent reduction in the emissions of hazardous substances in standardized driving cycles. Given the current status of exhaust gas treatment, the hazardous substance emissions which still remain are produced during the cold-start phase. A substantially improved hazardous substance conversion over an entire driving cycle is therefore only possible by reducing cold-start emissions. This can be achieved, for example, by a catalyst with the lowest possible light-off temperature for hazardous substance conversions and/or by locating the catalyst only just downstream of the exhaust gas outlet from the engine in order to reduce the heating-up time required to reach the operating temperature of the catalyst.
If the catalyst is installed near to the engine, it is subjected to exhaust gas temperatures of up to 1100° C. during continuous operation of the engine, and at full speed. Thus catalysts which are temperature-resistant and have long-term stability are required for this type of use.
The present invention deals with catalyst coatings on inert, monolithic support structures, normally honeycomb structures with parallel flow channels for the exhaust gas. The number of flow channels per cross-sectional area is called the cell density. Inert carriers with cell densities between 10 and 250 cm −2 are used, depending on the requirements of the application. These may be extruded, ceramic carriers made from cordierite, mullite or similar, temperature resistant materials. Alternatively, honeycomb structures made from steel sheeting may be used.
The catalytic coating generally contains several noble metals from the platinum group of the Periodic System of elements as catalytically active components, these being deposited in highly dispersed form on the specific surface area of high surface area support materials. The coating also contains further components such as oxygen-storing materials, promoters and stabilizers. The coating is applied to the internal walls of the flow channels by known coating processes, using an aqueous coating dispersion which contains the various components of the catalyst.
The inert monolithic carriers are also called support carriers in the context of this invention in order to be able to differentiate them more easily from the high surface area support materials for the catalytically active components. High surface area materials are those materials whose specific surface area, or BET surface area (measured in accordance with DIN 66132), is at least 10 m 2 /g. So-called active aluminum oxides satisfy this condition. These are finely divided aluminum oxides which have the crystal structures of the so-called transition phases of aluminum oxide. These include chi, delta, gamma, kappa, theta and eta-aluminum oxide.
The catalyst components may be added to the coating dispersion in a variety of forms:
a) as “finely divided solids”
This is understood to mean powdered materials with particle sizes between 1 and about 50 μm. In the English language literature, the expressions “bulk material” or “particulate material” are used for these.
b) as “colloidal solids”
These have particle sizes of less than 1 μm. The particulate structure of finely divided and colloidal solids is retained even in the final catalyst coating.
c) in the form of soluble “precursor compounds”
Precursor compounds are converted into actual catalyst components only by subsequent calcination and optionally reduction and are then present in a highly dispersed form.
The catalytically active metals from the platinum group or stabilizers such as lanthanum oxide and barium oxide are preferably incorporated into the coating as soluble precursor compounds in the coating dispersion or introduced only later by impregnating the coating. After a subsequent calcination procedure, these materials are present in a highly dispersed form (crystallite sizes in general of less than 5-10 nm) on the specific surface areas of the high surface area, finely divided components of the catalyst. They are also called “highly dispersed materials” in the context of this invention.
The aim of the present invention is to develop a catalyst suitable for use in the area mentioned above which operates exclusively with palladium as the catalytically active noble metal. Palladium is characterized, as compared with platinum, by a lower price, which is important with regard to the economic viability of the catalyst. In addition, it is known that palladium is a very effective catalyst for the oxidation of unburnt hydrocarbons, in particular paraffins and aromatic compounds. It has a superior effect, with reference to the same mass, to that of platinum.
U.S. Pat. No. 4,624,940 describes a three-way catalytic converter in the form of a coating on a monolithic support carrier which contains only palladium as a catalytically active component and which retains its catalytic activity even after aging at temperatures higher than 1000° C. The coating contains at least three different finely divided materials: thermally stable aluminum oxide as support material for a metal from the platinum group, further metal oxides as promoters which do not contain metals from the platinum group and inert, thermally stable fillers. The support material is stabilized with lanthanum, barium and silicon. The lanthanum oxide used for stabilizing purposes may contain up to 10 wt. % of praseodymium oxide. Cerium oxide, zirconium oxide or mixtures thereof are used as promoters. Finely divided cordierite, mullite, magnesium/aluminum titanate and mixtures thereof are used as fillers. Palladium is preferably used as a metal from the platinum group. According to U.S. Pat. No. 4,624,940, care has to be taken to ensure that palladium is not deposited on the cerium oxide-containing promoters because this would impair the effectiveness of both the palladium and the promoter.
U.S. Pat. No. 5,057,483 describes a catalyst composition which consists of two discrete layers on a monolithic carrier structure. The first layer contains a stabilized aluminum oxide as support material for platinum and finely divided cerium oxide. The first layer may also contain finely divided iron oxide and nickel oxide to suppress hydrogen sulphide emissions and also highly dispersed barium oxide and zirconium oxide as thermal stabilizers, these being distributed throughout the entire layer. The second layer contains a coprecipitated cerium/zirconium mixed oxide, onto which rhodium is deposited, and an activated aluminum oxide as support material for platinum. The coprecipitated cerium/zirconium mixed oxide preferably contains 2 to 30 wt. % of cerium oxide.
U.S. Pat. No. 4,294,726 describes a single-layered catalyst composition on an inert carrier structure which has platinum, rhodium and base metals as catalytically active components, these being deposited on an active aluminum oxide. The active aluminum oxide contains cerium oxide, zirconium oxide and iron oxide. The catalyst is obtained by impregnating active aluminum oxide with an aqueous solution of cerium, zirconium and iron salts. After calcining the aluminum oxide treated in this way, it is then impregnated again with an aqueous solution of platinum and rhodium salts.
U.S. Pat. No. 4,965,243 also describes a single-layered, thermally stable, three-way catalytic converter on a monolithic carrier structure which is obtained by coating the carrier structure with a coating dispersion which contains a metal from the platinum group, active aluminum oxide, cerium oxide, a barium compound and a zirconium compound.
WO 95/00235 describes a two-layered catalyst on an inert carrier structure which contains only palladium as a catalytically active component. The first layer contains a first support material and at least one first palladium component and a first oxygen-storing component which is in intimate contact with the palladium component. The second layer contains a second support material and at least one second palladium component. γ-aluminum oxide is used as a first support material and palladium is deposited on this by impregnating with an aqueous palladium nitrate solution. The aluminum oxide obtained in this way is processed with a colloidal dispersion of cerium oxide (particle size about 10 nm), cerium nitrate crystals, lanthanum nitrate crystals, barium acetate crystals, a zirconium acetate solution, a cerium/zirconium mixed oxide powder and a nickel oxide powder to give a coating dispersion for the first layer. For the second layer, a coating dispersion is made up which contains aluminum oxide coated with palladium in the same way as for the first layer as well as lanthanum nitrate crystals, neodymium nitrate crystals, zirconium nitrate crystals and strontium nitrate crystals. After each coating procedure, the carrier structure is calcined at 450° C. in order to convert the precursor compounds of the various coating components into the corresponding oxides.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a catalyst which contains only palladium as the catalytically active noble metal, which can be prepared very cost-effectively and which has, in addition to good degrees of conversion for hydrocarbons, carbon monoxide and nitrogen oxides, exceptional heat and aging resistance.
This and other objects are achieved by an automotive exhaust gas catalyst which contains, on a carrier structure, a single-layered, catalytic coating containing the following components:
a) finely divided, stabilized, active aluminum oxide,
b) at least one finely divided oxygen-storing component,
c) optionally, finely divided nickel oxide,
d) and additional highly dispersed cerium oxide, zirconium oxide and barium oxide and
e) as the only catalytically active noble metal, palladium which is in close contact with all the components in the coating.
γ-aluminum oxide with a specific surface area of more than 100 m 2 /g and stabilized with lanthanum is preferably used for the catalyst. 2 to 4 wt. % of lanthanum oxide, which may for example be incorporated in the aluminum oxide in a known manner by impregnation, is sufficient for stabilizing purposes.
DETAILED DESCRIPTION OF INVENTION
The present invention will now be described in further detail. A cerium/zirconium mixed oxide which can be obtained, for example, by coprecipitation in the way described in EP 0605274 A1 is preferably used as an oxygen-storing component. The material preferably contains 15 to 35 wt. % of zirconium oxide, with reference to its total weight. If the amount of zirconium oxide is less than 15 wt. %, the aging resistance of the material is no longer sufficient. Due to its high cerium oxide content, this material has an outstanding oxygen-storage capacity.
If very high temperatures of up to 1100° C. are expected during use of the catalyst, it is recommended that the mixed oxide mentioned above be replaced, entirely or partly, by a zirconium-rich cerium/zirconium mixed oxide containing 70 to 90 wt. % of zirconium oxide. Due to its high zirconium oxide content, this material is particularly heat resistant, but it has a lower oxygen-storage capacity in the freshly-prepared state.
As an alternative to this, a material may also be used which comprises cerium oxide in highly dispersed form on finely divided zirconium oxide. The highly dispersed cerium oxide may be fixed on the zirconium oxide by impregnation followed by calcination. This material has sufficient oxygen-storage capacity even with a cerium oxide concentration of only 10 to 30 wt. %. Highly dispersed mixtures of cerium oxide and praseodymium oxide on zirconium oxide are also particularly advantageous, wherein 1 to 20 wt. % of praseodymium oxide is present, with reference to cerium oxide.
Another finely divided oxygen-storage component, which is characterized by particularly good aging stability, is obtained by impregnating the cerium-rich cerium/zirconium mixed oxide mentioned above with 1 to 10 wt. %, with reference to the total weight of the final component, of praseodymium oxide.
The ratio by weight in the catalyst between active aluminum oxide, the oxygen-storing component and additional highly dispersed cerium oxide, zirconium oxide, barium oxide and finely divided nickel oxide is preferably adjusted to:
100:20-100:15-40:20-40:10-30:0-10.
Optimum light-off temperatures and activities for the catalyst are produced when the amount of catalyst coating on the carrier structure is between 50 and 600 g/l of carrier structure volume and the palladium concentration is between 1 and 15, preferably 2 to 5 g/l of carrier structure volume.
The actual amount of coating used on the carrier structure depends on the specifications for hazardous substance conversion and long-term stability as well as on the cell density of the honeycomb structure. Average layer thicknesses of about 30 to 50 μm are preferably produced on the channel walls. The amount of coating required for this is 50 to 600 g/l of carrier structure volume, depending on the cell density, wherein the upper value is used for carrier structures with cell densities of 250 cm −2 . The larger the amount of coating on a given carrier structure, the greater is the risk that the exhaust gas pressure will rise to an excessive extent due to narrowing of the flow channels, thus reducing the power of the engine. This effect restricts the amount of coating which can realistically be applied to a maximum value.
To prepare the catalyst, an aqueous coating dispersion is made up by dispersing the active aluminum oxide, the oxygen-storing component and optionally nickel oxide in powdered form in water, with the addition of soluble cerium oxide, zirconium oxide and barium oxide precursors. The inner walls of the flow channels in a honeycomb carrier structure made of ceramic or metal is coated with this coating dispersion by, for example, immersion. In the case of carrier structures made from strips of metal sheeting, the films may also be applied to the strips before shaping into the carrier structure. After drying and calcining the coating, palladium is deposited on all the components in the coating in highly dispersed form by immersing the carrier structure in an aqueous impregnating solution of soluble precursors of palladium.
As an alternative to this procedure, there is also the possibility of first making up a coating powder which contains all the components for the catalyst. Here, an aqueous dispersion of powdered aluminum oxide, the oxygen-storing component and optionally nickel oxide as well as soluble cerium oxide, zirconium oxide and barium oxide precursors is made up. The dispersion is dewatered, dried and calcined. The coating powder obtained in this way is then redispersed, a palladium precursor is added and it is then applied to the inner walls of the carrier structure using known methods. The coating obtained in this way is then dried and calcined. Calcination may optionally be performed in a hydrogen-containing stream of gas at 300 to 500° C. (for example, forming gas consisting of 5 vol-% hydrogen, the remainder being nitrogen) to reduce the palladium.
Both alternative methods of preparation for the catalyst ensure the close contact between palladium and all the other components in the catalyst which is required by the manner in which the palladium is applied.
Suitable soluble precursors of cerium oxide, zirconium oxide and barium oxide are nitrates, ammonium nitrates, chlorides, oxalates, acetates, citrates, formates, propionates, thiocyanates and oxychlorides of cerium, zirconium and barium. Nitrates and acetates are preferably used. A variety of palladium salts are suitable as precursors of palladium. Palladium nitrate is preferably also used here.
The drying stages used during preparation of the catalyst are not critical. They may be performed in air in the temperature range between 100 and 180° C. for a period of 0.25 to 2 hours. Calcination is preferably performed at temperatures between 300 and 800° C. for a period of 0.5 to 3 hours.
To homogenize the coating dispersion, this is usually milled in a ball mill until an average particle size d 50 of 1 to 5, preferably 3 to 5 μm is reached for the finely divided material to be used (d 50 is understood to represent the particle diameter which is greater than or equal to the diameter of 50 wt.% of the material). To improve turbulence of the exhaust gas in the flow channels, a coarse-grained but high surface area material may be added to the coating dispersion, as described in U.S. Pat. No. 5,496,788. This roughens the surface of the final coating and causes turbulence in the exhaust gas and thus an improvement in material exchange between the exhaust gas and the catalyst coating.
Depending on the consistency of the coating dispersion, the required amount of coating may be extracted onto the carrier structure by immersing the carrier structure, for example, once or several times. The solids content and viscosity of the coating dispersion are preferably adjusted in such a way that the amount of coating required can be applied in a single coating procedure. This is the case, for example, when the solids content of the coating dispersion is 30 to 70 wt.% and the density is 1.4 to 1.8 kg/dm 3 .
Raw materials with the following properties were used to make up the catalysts in the following examples and comparison examples to explain the invention in more detail:
La/Al 2 O 3 : γ-aluminum oxide, stabilized with 2 to 4 wt. % of lanthanum, calculated as lanthanum oxide;
BET surface area: 140 m 2 /g;
initial particle size: d 50 ≈15 μm;
γ-Al 2 O 3 : pure gamma-aluminum oxide;
BET surface area: 140 m 2 /g
initial particle size: d 50 ≈15 μm;
CeO 2 /ZrO 2 (70/30): coprecipitated cerium/zirconium mixed oxide;
concentration of zirconium oxide: 30 wt. %;
BET surface area: 60 m 2 /g;
initial particle size: d 50 ≈30 μm;
CeO 2 /ZrO 2 (20/80): coprecipitated cerium/zirconium mixed oxide;
concentration of zirconium oxide: 80 wt. %;
BET surface area: 80 m 2 /g;
initial particle size: d 50 ≈2 μm;
CeO 2 / ZrO 2 /Pr 6 O 11 : highly dispersed Pr 6 O 11 on cerium/zirconium mixed oxide with 67 wt. % of cerium oxide, 28 wt. % of zirconium oxide and 5 wt. % of praseodymium oxide;
BET surface area: 60 m 2 /g;
initial particle size: d 50 ≈17 μm;
Ce(C 2 H 3 O 2 ) 3 : cerium acetate;
zrO(C 2 H 3 O 2 ) 2 : zirconyl acetate;
Ba(C 2 H 3 O 2 ) 2 : barium acetate;
NiO: nickel oxide;
BET surface area: 20 m 2 /g;
initial particle size: d 50 ≈14 μm;
carrier structure: honeycomb structure made from cordierite with 62 channels per square centimeter of cross-sectional area;
dimensions: 3.8 cm diameter; 15.2 cm length
EXAMPLE 1
A coating dispersion was made up to coat the carrier structure, containing 300 g of cerium/zirconium mixed oxide, 300 g of cerium oxide as cerium acetate, 300 g of zirconium oxide as zirconium acetate, 200 g of barium oxide as barium acetate and 43 g of nickel oxide per 1000 g of stabilized aluminum oxide. The final coating dispersion had a solids content of 34 wt. %.
The carrier structure was coated by immersing once in this coating dispersion, dried in air at 120° C. for 0.5 h and calcined in air for a period of 4 h at 500° C. Then the coating was impregnated by immersing the carrier structure in an aqueous solution of palladium nitrate and then dried and calcined again. After drying and calcining, the carrier structure had a coating concentration of about 218 g/l, which was made up as follows:
Concentration
Substance
[g/l]
La/Al 2 O 3
100
CeO 2 /ZrO 2 70/30
30
CeO 2 ex acetate
30
ZrO 2 ex acetate
30
BaO ex acetate
20
NiO
4.3
Pd ex nitrate
3.9
Total
218.2
COMPARISON EXAMPLE 1
A comparison catalyst was made up with the same chemical composition as that in example 1. Differently from example 1, however, the palladium was prefixed onto the aluminum oxide before making up the coating dispersion. Here, 1000 g of aluminum oxide were treated with an aqueous solution of palladium nitrate which contained 39 g of palladium, using the pore volume impregnation method. In this case, the total amount of palladium was fixed on the aluminum oxide.
COMPARISON EXAMPLE 2
Another comparison catalyst was made up with the same chemical composition as the one in example 1. Differently from example 1 and comparison example 1, half of the palladium was prefixed on the cerium/zirconium mixed oxide and half on the aluminum oxide.
APPLICATION EXAMPLE 1
The conversion rates of the catalysts according to example 1, comparison example 1 and comparison example 2 for the hazardous substances CO, HC and NO x were tested after aging using a 1.8 1 gasoline engine. Aging was performed at a bed temperature (temperature of the catalyst) of 1000° C. for a period of 40 hours. The conversion rates were measured on an engine test-stand at a bed temperature of 400° C. and with different normalized air/fuel-ratios λ. To simulate real conditions, the normalized air/fuel-ratio was modulated with a frequency of 1 Hz and amplitudes of ±0.5 A/F (air/fuel ratio) and ±1.0 A/F. The space velocity during these measurements was approximately 50000 h −1 .
The results of the measurements are given in Tables 1 and 2. The experimental values recorded in the Tables are averages of at least two measurements.
TABLE 1
Engine test of catalysts from example 1 (E1), comparison example 1 (CE1) and comparison
example 2 (CE2) after engine aging at 1000° C. for a period of 40 hours;
Exhaust gas temperature 400° C.; exhaust gas modulation: 1.0 Hz ± 0.5 A/F (air/fuel ratio)
λ = 0.993
λ = 0.996
λ = 0.999
λ = 1.002
λ = 1.006
Ex.
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
E1
58.8
89.6
72.9
62.5
90.2
66.6
63.4
90.5
63.2
65.4
90.6
57.7
67.9
90.5
55.9
CE1
44.7
87.9
62.4
47.7
88.5
57.6
50.2
88.4
56.4
51.8
88.8
53.8
54.0
88.7
52.3
CE2
27.5
77.9
44.9
29.8
78.8
41.7
31.5
78.6
41.4
32.2
79.8
39.9
32.8
80.3
39.7
TABLE 2
Engine test of catalysts from example 1 (E1), comparison example 1 (CE1) and comparison
example 2 (CE2) after engine aging at 1000° C. for a period of 40 hours;
Exhaust gas temperature 400° C.; exhaust gas modulation: 1.0 Hz ± 1.0 A/F (air/fuel ratio)
λ = 0.993
λ = 0.996
λ = 0.999
λ = 1.002
λ = 1.006
Ex.
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
E1
63.1
88.4
77.3
68.4
88.5
77.3
85.3
91.3
73.9
91.7
91.4
62.8
93.7
91.4
57.7
CE1
61.9
88.5
74.5
67.0
88.6
71.7
75.7
89.6
67.0
81.6
89.7
60.0
86.3
90.1
55.4
CE2
36.7
66.3
34.8
36.2
67.1
36.1
52.3
81.8
46.1
57.7
83.7
44.9
63.9
85.7
43.4
EXAMPLE 2
Another catalyst was prepared in accordance with the invention. Differently from example 1, however, the palladium was not introduced into the coating by impregnation but palladium nitrate was added to the coating dispersion. The chemical composition of the catalyst was identical to that in example 1.
COMPARISON EXAMPLE 3
A carrier structure was coated with a two-layered catalyst in accordance with example 1 in WO 95/00235. The coating dispersions were made up exactly in accordance with the data in the WO document which is relied on and corporate by reference for this purpose. The individual preparation steps can therefore be obtained from that document. The final coating had the following composition:
1st layer
2nd layer
Substance
[g/l]
Substance
[g/l]
γ-Al 2 O 3 +
43
γ-Al 2 O 3 +
43
Pd
1.94
Pd
1.94
CeO 2
colloidal
18.4
ZrO 2
ex nitrate
6.1
CeO 2
ex
30.7
La 2 O 3
ex nitrate
6.1
nitrate
CeO 2 /ZrO 2
20/80
30.7
Nd 2 O 3
ex nitrate
6.1
ZrO 2
ex
8.6
SrO
ex nitrate
6.1
acetate
La 2 O 3
ex
6.1
nitrate
BaO
ex
3.7
acetate
NiO
4.3
Total
147.44
Total
69.34
APPLICATION EXAMPLE 2
The conversion rates of catalysts according to example 2 and comparison example 3 were measured after aging as described in application example 1. Differently from application example 1, the measurements were performed with an exhaust gas temperature of 450° C. The experimental results are given in Tables 3 and 4. They show that, with the catalyst according to the invention, the object of the invention, a single-layered catalyst with a simple layer structure, which provides the same or better performance data than conventional catalysts, is achieved in full.
EXAMPLE 3
Preparation of the catalyst in example 2 was repeated.
EXAMPLE 4
Another catalyst according to the invention was prepared with a slightly modified ratio of components in the coating dispersion with respect to each other in the same way as in example 2. Instead of the cerium/zirconium mixed oxide, the cerium/zirconium modified by impregnating with praseodymium oxide was used. The composition of the final coating is given below:
Concentration
Substance
[g/l]
La/Al 2 O 3
100
CeO 2 /ZrO 2 /Pr 6 O 11
45
67/28/5
CeO 2 ex acetate
20
ZrO 2 ex acetate
25
BaO ex acetate
20
NiO
4.3
Pd ex nitrate
3.9
Total
218.2
APPLICATION EXAMPLE 3
The same tests were performed with the two catalysts in examples 3 and 4 as with the other catalysts. The experimental results are given in Tables 5 and 6. Differently from the preceding examples, the catalysts were subjected to a more intense aging procedure in order to demonstrate the positive effect on aging stability of cerium/zirconium mixed oxide modified with praseodymium oxide. The more intense aging procedure was performed using a 2.0 1 gasoline engine at an exhaust gas temperature of 1050° C. for a period of 40 hours. The space velocity during measurement of the rates of conversion was again 50,000 h −1 .
TABLE 3
Engine test of catalysts from example 2 (E2) and comparison example 3 (CE3) after engine
aging at 1000° C. for a period of 40 hours;
Exhaust gas temperature 450° C.; exhaust gas modulation: 1.0 Hz ± 0.5 A/F (air/fuel ratio)
λ = 0.993
λ = 0.996
λ = 0.999
λ = 1.002
λ = 1.006
Ex.
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
E2
52.2
90.4
78.3
69.6
92.4
82.6
87.1
94.3
86.2
97.6
94.7
76.2
98.7
93.9
59.3
CE3
55.9
90.5
80.8
66.5
91.3
79.5
78.1
91.7
76.8
89.8
92.4
69.9
95.6
92.1
57.5
TABLE 4
Engine test of catalysts from example 2 (E2) and comparison example 3 (CE3) after engine
aging at 1000° C. for a period of 40 hours;
Exhaust gas temperature 450° C.; exhaust gas modulation: 1.0 Hz ± 1.0 A/F (air/fuel ratio)
λ = 0.993
λ = 0.996
λ = 0.999
λ = 1.002
λ = 1.006
Ex.
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
E2
72.9
94.5
94.4
73.6
94.1
81.6
77.0
94.2
74.7
80.5
94.2
69.9
83.0
94.0
66.0
CE3
52.1
90.1
66.2
54.0
90.2
62.0
56.1
90.7
60.8
60.2
90.9
58.6
63.6
90.9
57.4
TABLE 5
Engine test of catalysts from example 3 (E3) and example 4 (E4) after intensified engine
aging at 1050° C. for a period of 40 hours;
Exhaust gas temperature 450° C.; exhaust gas modulation: 1.0 Hz ± 0.5 A/F (air/fuel ratio)
λ = 0.993
λ = 0.996
λ = 0.999
λ = 1.002
λ = 1.006
Ex.
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
E3
59.8
89.4
70.6
77.3
91.3
75.4
91.2
92.1
62.5
95.0
91.7
51.1
95.8
92.0
45.9
E4
64.2
90.6
78.5
83.8
93.6
80.9
97.7
94.2
63.2
98.1
93.2
55.1
98.3
93.3
48.2
TABLE 6
Engine test of catalysts from example 3 (E3) and example 4 (E4) after intensified engine
aging at 1050° C. for a period of 40 hours;
Exhaust gas temperature 450° C.; exhaust gas modulation: 1.0 Hz ± 1.0 A/F (air/fuel ratio)
λ = 0.993
λ = 0.996
λ = 0.999
λ = 1.002
λ = 1.006
Ex.
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
E3
53.7
90.6
56.4
55.5
90.7
54.6
57.0
90.6
53.1
63.5
90.9
49.1
66.8
91.3
46.5
E4
71.5
93.7
73.1
76.9
94.0
70.2
79.2
93.9
67.9
82.8
93.9
63 2
85.5
94.1
57.2
EXAMPLE 5
Another catalyst was prepared in the same way as described in example 4. However, 20 g of the CeO 2 /ZrO 2 /Pr 6 O 11 were replaced by 70 g of the zirconium-rich cerium/zirconium mixed oxide with a concentration of zirconium of 80 wt. %. This meant that the concentration of CeO 2 in the catalyst was approximately the same as in example 4. The source of the CeO 2 was now distributed between CeO 2 /ZrO 2 /Pr 6 O 11 , CeO 2 /ZrO 2 (20/80) and highly dispersed cerium oxide. The composition of the final coating is given below.
Concentration
Substance
[g/l]
La/Al 2 O 3
100
CeO 2 /ZrO 2 /Pr 6 O 11
25
67/28/5
CeO 2 /ZrO 2 20/80
70
CeO 2 ex acetate
20
ZrO 2 ex acetate
25
BaO ex acetate
20
NiO
4.3
Pd ex nitrate
3.9
Total
268.2
APPLICATION EXAMPLE 4
One catalyst from each of examples 4 and example 5 were subjected to an intensified aging procedure at 1050° C. for a period of 40 hours, as described in application example 3. Measuring the rates of conversion for the catalysts was performed at double the space velocity, i.e. at 100000 h −1 .
The results of the measurements are given in Tables 7 and 8.
As can be seen from the example of the invention, the catalysts of this invention are platinum-free.
Further modifications and variations will be apparent to those skilled in the art from the foregoing and are intended to be encompassed by the claims appended hereto.
German priority application 197 14 536.1 is relied on and incorporated herein by reference.
TABLE 7
Engine test of catalysts from example 4 (E4) and example 5 (E5) after intensified engine
aging at 1050° C. for a period of 40 hours;
Exhaust gas temperature 450° C.; exhaust gas modulation: 1.0 Hz ± 0.5 A/F (air/fuel ratio)
λ = 0.993
λ = 0.996
λ = 0.999
λ = 1.002
λ = 1.006
Ex.
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
E4
59.9
81.4
55.4
66.7
81.4
52.3
69.7
81.9
49.4
74.5
81.7
46.6
80.3
81.6
42.9
E5
71.0
86.6
69.8
80.9
87.1
66.2
86.0.
87.5
60.0
88.9
86.9
52.7
93.2
86.7
43.6
TABLE 8
Engine test of catalysts from example 4 (E4) and example 5 (E5) after intensified engine
aging at 1050° C. for a period of 40 hours;
Exhaust gas temperature 450° C.; exhaust gas modulation: 1.0 Hz ± 1.0 A/F (air/fuel ratio)
λ = 0.993
λ = 0.996
λ = 0.999
λ = 1.002
λ = 1.006
Ex.
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
CO %
HC %
NO x %
E4
40.1
77.0
43.4
42.2
77.2
41.0
44.4
77.4
40.5
45.2
76.6
38.0
45.6
77.3
37.9
E5
57.2
84.9
55.0
62.2
85.0
51.2
64.4
84.8
47.8
64.8
84.4
45.4
65.2
84.5
44.8 | 4y
|
FIELD OF THE INVENTION
[0001] The present invention relates to an anti-tubercular extract of Salicornia species. More particularly, the invention relates to enhancement of anti-tubercular activity of the 1:1 chloroform-methanol fraction of root extract of Salicornia brachiata growing naturally along the Gujarat coast of India.
BACKGROUND OF THE INVENTION
[0002] Antitubercular chemotherapeutic drugs presently used all over the world comprise primarily of synthetic drugs, e.g., Isoniazid (i.e. Isonicotinic acid hydrazide) used singly or in combination with sodium PAS (Sodium para amino salicylate), Isonex, Erbazide (Calcium methane sulfonate of Isoniazid), Cyclocerine, Morphazinamide hydrochloride, Rifampicin, Ethambutol/Myambutol, Sparfloxicin etc. which were developed subsequent to the synthesis of the antibiotic Streptomycin.
[0003] While there are cures for tuberculosis by using the above-mentioned drugs along with the BCG vaccination, several drawbacks are noticed, especially in terms of side effects of such drugs, the requirement of prolonged intake/duration of therapy. Another problem observed is that even after treatment, some mycobacterium continues to reside in the subject. It is therefore imperative to create alternatives to the above class of drugs so that either the dosage or the intake duration is reduced or the problem of resistance to the drugs is obviated.
[0004] Reference is made to Raritan, N.J. in a science article entitled “Novel Antibiotic shows promise in shortening treatment duration of Tuberculosis” published in BioSpace by AstraZeneca press (2005), describing a compound which belongs to a new family of anti TB agents called diarylquinolines (DARQ) as a better and promising drug individually and in combination than triple cocktail regimen currently recommended by World Health Organization A cocktail regimen containing DARQ cleared infection in mice in half the time than the currently used regimen. It further also stated that no new anti-TB drugs have been brought into the clinic in the past 40 years and although doctors have effective first-line TB drugs that work, there have been difficulties getting these medicines to the patients who need them as well as effectively treating patients with drug resistant diseases. However, this drug is tested on mice and considerable work needs to be done to fully determine this compound's clinical potential.
[0005] Similar such reference is also made to an issue dedicated to TB in Journal of Indian Medical Association, vol 101. No. 03 (March 2003), Edited by Subhas, Ch. Chakrabortti under TB Control—The Government & The Private Sector Alliance in which great significance is attached to alternative therapy of existing TB drug therapy & research in alternative MDR therapy under Govt. of India policy of RNTCP. It also highlights that nearly 50000 deaths are taking place in India with 2 million new cases registered every year.
[0006] Reference is also made to Jan Koci et. al., in a paper entitled “Heterocyclic Benzazole Derivatives with Antimycobacterial In Vitro Activity” in Bioorganic & Medicinal Chemistry Letters 12 (2002) 3275:278, describes the series of 2-benzylsulfanyl derivatives of benzoxazole and benzothiazole synthesized, and evaluated for their in vitro antimycobacterial activity against Mycobacterium tuberculosis and non-tuberculous mycobacteria, and the activity expressed as the minimum inhibitory concentration (MIC) in mmol/L. The substances bearing two nitro groups (4e, 4f, 5e, 5f) or a thioamide group (4i, 4j, 5i, 5j) exhibiting appreciable activity particularly against non-tuberculous strains. However, the most active compounds were subjected to the toxicity assay and were evaluated as moderately cytotoxic.
[0007] Reference may also be made to Sandra M. Newton et. al., in a paper entitled “The evaluation of forty-three plant species for in vitro antimycobacterial activities, isolation of active constituents from Psoralea corylifolia and Sanguinaria canadensis ” in the Journal of Ethnopharmacology 79, 57-67 (2002), describes the extracts from forty-three plant species were selected on account of reported traditional uses for the treatment of TB and/or leprosy. These were assayed for antimycobacterial activities A simple in vitro screening assay was employed using two model species of mycobacteria, M., aurum and M. smegmatis . Crude methanolic extracts from three of the plants, C. mukul, P. corylifolia and S. canadensis , were found to have significant antimycobacterial activity against M. aurum only (MIC=62.5 μg/ml). Bioassay guided fractionation led to the isolation of two known benzophenanthridine alkaloids, sanguinarine (1) and chelerythrine (2), from the roots S. canadensis and the known phenolic meroterpene, bakuchiol (3) from the seeds of P. corylifolia . The fractionation of the resin of C. mukul lead to a decrease in antimycobacterial activity and hence further work was not pursued. Compound (2) was the most active against M. aurum and M. smegmatis (IC50=7 30 μg/ml [19.02 μM] and 29 0 μg/ml [75.56 μM], respectively). M. aurum was the most susceptible organism to all three compounds. No significant difference in antimycobacterial activity was observed when the two alkaloids were tested for activity in media of differing pH values. The activities of the pure compounds against M. aurum were comparable with those against M. bo_is BCG with compound (2) being the most active (M. bo_is BCG, IC50=14.3 μg/mL [37.3 μM]). These results support the use of these plants in traditional medicine. The drawback of the present invention is the in-vivo study is not conducted for further confirmation of activity.
[0008] Reference is also made to Usha K. et al., who in a paper entitled “Antitubercular potential of selected plant materials” in Journal of Medicinal and Aromatic plant Sciences, 22/4A-23/1A, 182-184 (Eng.)(2001), describe the anti-tubercular potential of the plants viz., neem, tulsi, garlic, ginger and adhatoda, which were tested by in-vitro culture using 100 mL of aqueous puree (50% w/v) of plant material added to sputum and then inoculated in to L. J medium. All the plant extracts arrested the growth of Mycobacterium tuberculosis , which was ascribed to enzymic and nonenzymic antioxidants such as Catalase, peroxidase, total carotene, ascorbic acid, tocopherol, and polyphenols thus preventing tissue damage by ROS (reactive oxygen species). Besides the large quantity of potion that needs to be applied, it is unclear as to the extent of inhibition and the MIC of the potion.
[0009] Reference is made to N. Lall et al in a paper entitled “In vitro inhibition of drug-resistant and drug-sensitive strains of Mycobacterium tuberculosis by ethno-botanically selected South African plants” in Journal of Ethno pharmacology, 66, 347-354 (1999), which describes the preliminary screening of 20 South African medicinal plant extracts against a drug-sensitive strain, H37Rv, of Mycobacterium tuberculosis by agar plate method (Middlebrook and Cohn, 1958). Herein the author ascribes 14 out of 20 acetone extracts showing inhibitory activity at concentration of 500 μg/mL whereas acetone as well water extracts of plant species namely Cryptocarya latifolia, Euclea natalensis, Helichrysum melanacme, Nidorella anomala and Thymus vulgaris indicated MIC of 100 μg/mL against H37Rv strain by radiometric method.
[0010] Reference is also made to Cantrell, Charles L. et al. in a review article entitled “Antimycobacterial plant terpenoids” in Journal of Planta Medica, 67(8), 685-694. (Eng.) (2001), which covers recent report on plant-derived terpenoids that have demonstrated moderate to high activity in In-vitro bioassays against M. tuberculosis . In this review, mono-, sesqui-, di- and triterpenes and sterols, their structural analogue and semi synthetic derivatives have been discussed with particular emphasis on the structural features essential for Antimycobacterial activity.
[0011] Reference is made to Ma, Junrui in a patent entitled “Compositions containing herbal medicine for pulmonary tuberculosis” No. CN 1265315 A 6 Sep. 2000, 4 pp. (Chinese) (2001), which contains the different forms of composition (aerosol, inhalant, tablet, capsule, powder, oral concentrate and liquid) for treating pulmonary tuberculosis composed of Taraktogenos, Coptis, Stemona, Cordyceps, Scutellaria, Lonicera japonica, Forsythia vahl, Herba violae, Anemarrhena, Salvia miltiorrhiza, Fructus mume, Ginkgo biloba, Anacamptis pyoamidalis Richard, Polygonatum, Glycyrrhiza, Polygonum multiflorum thunb, Brunella vulgaris, Cirsium japonicum , leaf of Thuja ortentalis, Sguisorba officinalis, Heracleum, common Andrographis, Houttuynia, herba artemistae and Magnolia officinalis . However the drawback here is the use of multiple herbs for the purpose of elucidating the positive gains of plant against mycobacterium tuberculosis and without referring to MIC level either of individual herb or collectively of the combination.
[0012] Reference is made to a paper titled “Preliminary antimicrobial screening four South African Asteraceae species” by F. Salie, P F K Eagles and H M J Leng in Journal of Ethanopharmacology 52(1996), 27-33 pp., wherein the author has investigated the flora of the Western Cape—a part of Cape Floral kingdom in South Africa. The author ascribes efficacy of four Asteraceae species ( Arctopis auriculanta, Ertocephalus africanus L. Felicia erigeroides DC. and Helichrysum crispum (L.) D. Don.) exhibiting selective antimicrobial activity to various degrees for Mycobacterium smegmatis . Identifying the 8500 μg/mL. of MIC in leaves of Arctopis auriculanta . The drawback of the invention is the very high MIC value.
[0013] Reference is also made to the Internet website benefits@coqui.net on Salicornia plant wherein the use of the Salicornia plant as a source of edible oil and use of dried crushed stems as fuel briquettes or particleboard are reported. However, there is no mention of any bioactivity of the plant.
[0014] Reference is also made to U.S. patent application Ser. No. 10/106,334 dt. 26 th Mar. 2002 by P. K. Ghosh et. al. wherein a vegetable salt preparation from residual dry matter after removal of seeds using the halophyte has been described to maximize the value derived from the plant. However this application does not provide any utilization of the plant for drug/medicinal purpose.
[0015] Reference is made to Wealth of India, vol. IX RH-SO, Raw Material Page No. 169 which documents various bioresources of India and application thereof has listed Salicornia Linn. and its taxonomy beside use of the species as fodder. The plant is also listed in Flora of India by Hooker (1889), However no mention is made in both documents on any kind of bioactivity associated with Salicornia . It is a small genus of annual or perennial leafless fleshy herbs or shrubs, native to salt marshes of Asia, Africa, Europe and North America. Only one species occurs in India. D.E.P. VI (2), 387:1, 399:II, 60, Fl. Br. Ind., V.12 Kirt. and Basu, Pl. 800. It is known under different name in various regions of India as: Gujarati.—Muchul, Telugu:—Kagalu, Tamil & Malayalam: Umari Keerai.
[0016] It is a perennial much branched, herbaceous plant with jointed stamps 30-45 cm. High found in salt marsh along with the sea coast from Bengal to Gujarat. Branches rather slander joints 6-12 mm. long; flowers sunk in cavities of the joints, three on each side, fruits membranous.
[0017] The plant is a source of alkaline, earth or saji used for extracting sodium carbonate The ash of the plant called saji or barilla was formerly used in soap and glass making. Air dried plant contains 6.98% protein (N×6.25) and 8.97% ash. It contains of high percentage of sodium chloride ions which constitutes C 86% of total water soluble salt. Water extractable mineral are Cl=10.02 m, Na=5.6, S=0.70, P=1.13, C=0.72, Ca=0.01, Mg=0.02%. (Parekh and Rao. curr. Sci. 1965, 34; 247). The plants are strongly salty nature, lower and young shoots are eaten after pickling. The shoots are sometimes used at pot-herb. The plants are used as camel fodder also (Mc Canr, J. Bombay Nat. Hist. Soc, 1951-52, 50, 870) The ashes are used in mange and itch, and are also considered to be emmengogue and abortifacient (Kirt. and Basu, III 2082).
[0018] Reference is made to U.S. patent application Ser. No. 10/829,400 dated 22 nd Apr. 2004 and PCT patent application No. PCT/IN03/00292 dated 29 th Aug. 2003 by Rathod et al. where activity of Salicornia brachiata growing naturally in the Gujarat coast of India against M. Tuberculosis is disclosed. The main drawback of the application is that the HPLC of the fraction is too complex and provides little clue of the nature of the constituents in the active fraction. Moreover, the maximum inhibition in in-vitro studies was only 75% when the dosage was 6.25 μg/mL.
OBJECTS OF THE INVENTION
[0019] The main object of the invention is to provide the bioactive fractions from Salicornia species.
[0020] Another object of the present invention is to identify the source of anti TB activity in the F2 fraction of the root extract of Salicornia brachiata as previously disclosed by the applicants in their pending U.S. patent application Ser. No. 10/829,400 dated 22 nd Apr. 2004 and PCT patent application No. PCT/IN03/00292 dated 29 th Aug. 2003.
[0021] Further object is to improve the chromatographic separation condition to resolve the various peaks in the active fraction as reported in the prior art for separation through semi-preparative HPLC.
[0022] Another object is to correlate the different sub-fractions obtained from the active fraction with their activities.
[0023] Another object is to demonstrate the efficacy of the most active sub-fraction against tuberculosis both in vitro and in vivo against infected mice.
[0024] Another object is to show that the MIC of the most active sub-fraction is ≦3 125 μg/mL.
[0025] Another object is to show enhanced survival duration of infected mice that have been administered the active sub-fraction orally at a dosage of 50 mg/kg body weight.
[0026] Another object is to show that the most active sub-fraction has no observable toxicity through cytotoxicity studies using VERO cell line.
[0027] Another object is to show that healthy mice which have been administered the active fraction remain healthy and gain weight thereby demonstrating the non-toxic nature of the active sub-fraction.
[0028] Another object is to characterize the constituents of the active sub-fraction.
[0029] Another object is to show that sucrose is the principle component of the sub-fraction and further that there are minor constituents that co-elute with the sucrose.
[0030] Another object is to demonstrate that sucrose alone has no anti-TB activity and that activity lies in the minor constituents that act singly or in combination with other minor constituents and/or the major constituent.
[0031] Another object is to utilize the most active sub-fraction as a possible cure for tuberculosis either as is or through further purification to enhance activity still further.
[0032] Another object is to separate and individually study the minor constituents for their anti-TB activity.
SUMMARY OF THE INVENTION
[0033] Accordingly, the present invention provides bioactive fractions from extracts of Salicornia species.
[0034] The invention also provides a means of enhancing the anti-tubercular activity of the chloroform-methanol (1:1) fraction obtained from the roots of matured Salicornia brachiata as disclosed in the pending U.S. patent application Ser. No. 10/829,400 dated 22 nd Apr. 2004 and PCT patent application No. PCT/IN03/00292 dated 29 th Aug. 2003.
[0035] In one embodiment of the invention, the Salicornia species comprises of Salicornia brachiata , preferably a mature plant, and wherein the preferred plant parts extracted are selected from the group consisting of whole plant without root, roots, spikes, husk and seeds.
[0036] In another embodiment of the invention, the bioactive fractions comprise F1, F2, F3, F4 and F5.
[0037] In another embodiment of the invention, the bioactive fraction F2 further comprising sub-fractions SF1, SF2, SF3, SF4, SF5, SF6 and SF7.
[0038] In another embodiment of the invention, the SF3-K is the sub-fraction of SF3.
[0039] In another embodiment of the invention, the SF3-K is stable for 4 hours even at a temperature ranging upto 50° C.
[0040] In another embodiment of the invention, the major constituent of SF3K comprising Sucrose to the extent of 75-80% based on HPLC with RI detection.
[0041] In another embodiment of the invention, the bioactive fraction possess antitubercular activity and is useful as an antitubercular agent.
[0042] In one embodiment of the invention, the MIC value of the anti-tubercular fraction (henceforth referred to as SF3-K) of this invention is ≦3.125 μg/mL when tested against M. tuberculosis H37Rv on 7H10 Middlebrook's medium containing OADC.
[0043] In another embodiment SF3-K shows complete inhibition against M. Tuberculosis H37Rv at dosage of 50 μg/mL and 100 μg/mL when evaluated in vitro by the BACTEC method and further shows dose dependence of the growth index.
[0044] In another embodiment SF3-K exhibits no cytotoxicity in tests conducted with the VERO cell line even for dosage up to 100 μg/mL, i.e., beyond ten times the MIC value of SF3-K as estimated by the method of claim 1 .
[0045] In another embodiment SF3-K is also active in vivo and increases the mean survival time (MST) of infected mice by 5 days when a dose of SF3-K amounting to 50 mg/kg of body weight is administered orally for 12 days after infection.
[0046] In another embodiment SF3-K shows no toxicity towards healthy mice administered SF3-K orally at the dosage of 50 mg/kg of body weight.
[0047] In another embodiment SF3-K is shown to comprise of mainly Sucrose [75-80%] on the basis of HPLC-RI detector], the balance being minor constituents having molecular weights of 113, 115, 117. Another constituent has m/z of 143 [142+H + ].
[0048] In another embodiment of the invention, anti-tubercular activity of SF3-K is shown to reside in the minor constituents of the fraction that amount to only 20-25% of the weight of the fraction.
[0049] Accordingly the present invention provides a process for preparation of bioactive fractions from extracts of Salicornia species comprising the following steps:
(i) providing F2 fraction from Salicornia brachiata according to the procedure claimed in U.S. patent application Ser. No. 10/829,400 dated 22 nd Apr. 2004 and PCT patent application No. PCT/IN03/00292 dated 29 th Aug. 2003, the contents of which are incorporated herein by reference, (ii) subjecting the F2 Bioactive fraction to sub-fractionation on Semi-preparative HPLC using RP-18 column (Phenomenex) and 03:97::CH 3 CN:H 2 O mobile phase at 7 mL/min, (iii) collecting seven sub-fractions SF1, SF2, SF3, SF4, SF5, SF6 and SF7 between 0 to 22 minutes as per the Semi-prep HPLC profile provided in the application; (iv) subjecting the sub-fractions obtained in step (iii) to anti-tubercular screening; (v) identifying the sub-fraction SF3 as best compromise in terms of activity of sub-fraction and quantity of material obtained; (vi) concentrating the sub-fraction obtained in step (v) and re-chromatographing on the same semi-preparative column (keeping all conditions same except alteration of flow rate to 6 to 7 mL/min) to enhance the purity of the peak having retention time of 11.89 min at 6 mL/min flow rate on Semi-preparative column and retention time of 2.95 min at 1 mL/min flow rate on analytical column; (vii) concentrating the fraction obtained in step (vi) and subjecting to freeze drying to obtain SF3-K.
[0057] In another embodiment of the invention, wherein the fraction obtained in step (vi) subjected to freeze drying to obtain solid SF3-K in the range of 0.6 to 0.9% yield from dry root.
[0058] In another embodiment of the invention, the reverse phase chromatographic separation of the chloroform-methanol fraction is improved over that reported in the pending patent application by altering the mobile phase to acetonitrile: water: 03:97 that enabled sub-fractionation of the fraction into seven distinct parts (sub-fractions) and identification of one sub-fraction (SF3) as most desired from the joint consideration of anti-tubercular activity and quantity of material obtained.
[0059] In another embodiment SF3 was re-chromatographed and further purified to obtain SF3-K as an apparently single peak on the analytical reverse phase column.
[0060] In still another embodiment of the present invention, SF3-K was concentrated on a rotary evaporator in a temperature range of 45 to 55° C.
[0061] In still another embodiment of the present invention, the concentrated extract may be freeze dried in the temperature range of −50 to −60° C. for a period of 8 to 16 hours.
[0062] In still another embodiment of the present invention, SF3-K was exposed for 4 hrs. to the hot afternoon sun and found to be stable.
[0063] In another embodiment of the present invention, the SF3-K was chromatographed on a Waters Amino column and eluted with 80:20::CH 3 CN:H 2 O whereupon the various constituents of SF3-K could be resolved and their molecular weights based on Mass Spectroscopy were determined to be 113, 342 (Sucrose), 115 and 117. A minor constituent having m/z of 143 was also observed at long retention time.
[0064] In an embodiment of the invention wherein for characterization of the constituents of SF3-K the constituents of SF3-K were resolved by subjecting it to liquid chromatography on Waters Amino column using 80:20::CH 3 CN:H 2 O and monitoring minor and major constituents both with UV (210 nm) and RI detectors and analyzing for the constituents using LC-MS.
[0065] The bioactive fractions obtained from an extract of Salicornia species useful as an antitubercular agent.
[0066] In an embodiment of the invention, wherein the Salicornia species comprises of Salicornia brachiata.
[0067] In an embodiment of the invention, wherein the Salicornia brachiata is a fully matured plant.
[0068] In another embodiment of the invention, wherein the bioactive extract comprises extracts from parts of Salicornia plant selected from the group consisting of whole plant without root, roots, spikes, husk and seeds.
[0069] In still another embodiment of the invention, wherein the bioactive fractions comprise F1, F2, F3, F4 and F5.
[0070] In a further embodiment of the invention, wherein the fraction F2 is further comprising sub-fractions into SF1, SF2, SF3, SF4, SF5, SF6 and SF7.
[0071] In an embodiment of the invention, wherein the sub-fraction SF3 is further fractionated into SF3K.
[0072] In still another embodiment of the invention, wherein the major constituent of SF3K comprising Sucrose to the extent of 75-80% based on HPLC with RJ detection.
[0073] In an embodiment of the invention, wherein the said fraction possess antitubercular activity.
[0074] In an embodiment of the invention, wherein the fraction SF3K exhibits an MIC value ≦3 125 μg/mL against M. tuberculosis H37Rv when evaluated using 7H10 Middlebrook's medium containing OADC (B-D, USA).
[0075] In an embodiment of the invention, wherein the fraction SF3K exhibits complete inhibition against M. Tuberculosis H37Rv at dosage of 50 μg/mL and 100 μg/mL when evaluated in-vitro by the BACTEC method and further shows dose dependence of the growth index.
[0076] In an embodiment of the invention the bioactive fraction is also active in-vivo and increases the mean survival time (MST) of infected mice by 5 days when a dose of SF3-K amounting to 50 mg/kg of body weight is administered orally for 12 days after infection.
[0077] In an embodiment of the invention, that fraction exhibits no cytotoxicity in tests conducted with the VERO cell line even for dosage up to 100 μg/mL, i.e., beyond ten times the NHC value of SF3-K.
[0078] In an embodiment of the invention. Fraction shows no toxicity towards healthy mice administered SF3-K orally at the dosage of 0 to 50 mg/kg of body weight.
[0079] In an embodiment of the invention wherein the major constituent sucrose is unlikely to have any activity as pure sucrose even for dosage of 100 μg/mL.
[0080] In an embodiment of the invention, wherein the most prominent minor constituent exhibits m/z values of 118 [117+H] + and 140 [117+Na + ] corresponding to a molecular weight of the constituent of 117.
[0081] In an embodiment of the invention, wherein the minor constituent having molecular weight of 117 shows daughter peaks corresponding to m/z values of 58 and 59 whereas in the form of sodium salt daughter fragments are found with m/z values of 96, 81, 53 and 23.
[0082] In an embodiment of the invention, wherein the constituent having M.W. 117 form self-clusters under the conditions of mass spectroscopy and also clusters with the major constituent (Sucrose).
[0083] In an embodiment of the invention, wherein other minor constituents are observed with molecular weights of 113, 115 and 142.
[0084] In an embodiment of the invention, wherein the sub fractions SF1, SF5, SF6 and SF7 were also found having anti-tubercular activity at 100 to 12.5 μg/mL & SF2 and SF4 were found having anti-tubercular activity at 100 to 25 μg./mL.
[0085] The present invention also provides a method for the treatment of tuberculosis comprising administering to a subject suffering therefrom, a pharmaceutically effective amount of an antitubercular fraction obtained from Salicornia species optionally along with any other antitubercular drug of synthetic or natural origin and a pharmaceutically acceptable additive or carrier.
[0086] In an embodiment of the invention, wherein the method comprises administering either bioactive fraction or the crude extract of Salicornia species to the subject.
[0087] In an embodiment of the invention, wherein the Salicornia species comprises of Salicornia brachiata.
[0088] In one of the embodiment of the invention, wherein the Salicornia brachiata is a fully matured plant.
[0089] In an embodiment of the invention, wherein the fractions comprise F1, F2, F3, F4 and F5.
[0090] In an embodiment of the invention, wherein the fraction F2 is sub-fractionated into SF1, SF2, SF3, SF4, SF5, SF6 and SF7.
[0091] In an embodiment of the invention, wherein the sub-fraction SF3 is further fractionated into SF3K.
[0092] In an embodiment of the invention, wherein the major constituent of SF3K comprising Sucrose to the extent of 75-80% based on HPLC with RI detection.
[0093] In an embodiment of the invention, wherein the said fraction possess antitubercular activity.
[0094] In an embodiment of the invention, wherein the fraction SF3 K exhibits an MIC value ≦3.125 μg/mL against M. tuberculosis H37Rv when evaluated using 7H10 Middlebrook's medium containing OADC (B-D, USA).
[0095] In an embodiment of the invention, wherein the fraction SF3K exhibits complete inhibition against M. Tuberculosis H37Rv at dosage of 50 μg/mL and 100 μg/mL when evaluated in-vitro by the BACTEC method and further shows dose dependence of the growth index.
[0096] In an embodiment of the invention, wherein the fraction is also active in-vivo and increases the mean survival time (MST) of infected mice by 5 days when a dose of SF3-K amounting to 50 mg/kg of body weight is administered orally for 12 days after infection wherein the fraction exhibits no cytotoxicity in tests conducted with the VERO cell line even for dosage up to 0-100 μg/mL, i.e., beyond ten times the MIC value of SF3-K.
[0097] In an embodiment of the invention, wherein the fraction does not show toxicity towards healthy mice administered SF3-K orally at dosage of 0-50 mg/kg of body weight.
[0098] In an embodiment of the invention, wherein the major constituent sucrose is unlikely to have any activity as pure sucrose even for dosage of 100 μg/mL.
[0099] In an embodiment of the invention, wherein the most prominent minor constituent exhibits m/z values of 118 [117+H] + and 140 [117+Na + ] corresponding to a molecular weight of the constituent of 117.
[0100] In an embodiment of the invention, wherein the minor constituent having molecular weight of 117 shows daughter peaks corresponding to m/z values of 58 and 59 whereas in the form of sodium salt daughter fragments are found with m/z values of 96, 81, 53 and 23.
[0101] In an embodiment of the invention, wherein the constituent having M.W. 117 form self-clusters under the conditions of mass spectroscopy and also clusters with the major constituent (Sucrose).
[0102] In an embodiment of the invention, wherein other minor constituents are observed with molecular weights of 113, 115 and 142.
[0103] In an embodiment of the invention, wherein the fraction is administered in a form selected from tablets, lozenges, capsules, powder, solution, intravenously and orally.
[0104] The present invention also provides a pharmaceutical composition comprising bioactive fraction[s] isolated from extracts of Salicornia species optionally along with any other anti-tubercular drug of synthetic or natural origin and a pharmaceutically acceptable additive or carrier.
[0105] In an embodiment of the invention, wherein the Salicornia species comprises of Salicornia brachiata.
[0106] In an embodiment of the invention, wherein the Salicornia brachiata is a fully matured plant.
[0107] In an embodiment of the invention, wherein the extract comprises extracts from Salicornia plant part selected from the group consisting of whole plant without root, roots, spikes, husk and seeds.
[0108] In an embodiment of the invention, wherein the fractions comprise F1, F2, F3, F4 and F5.
[0109] In an embodiment of the invention, wherein the fraction F2 further comprising sub-fractions into SF1, SF2, SF3, SF4, SF5, SF6 and SF7
[0110] In an embodiment of the invention, wherein the sub-fraction SF3 is further fractionated into SF3K.
[0111] In an embodiment of the invention, wherein the major constituent of SF3K comprising Sucrose to the extent of 75-80% based on HPLC with RI detection.
[0112] In an embodiment of the invention, wherein the said fraction possess antitubercular activity.
[0113] In an embodiment of the invention, wherein the fraction SF3K exhibits an MIC value ≦3.125 μg/mL against M. tuberculosis H37Rv when evaluated using 7H10 Middlebrook's medium containing OADC (B-D, USA).
[0114] In an embodiment of the invention, wherein the fraction SF3K exhibits complete inhibition against M. Tuberculosis H37Rv at dosage of 50 μg/mL and 100 μg/mL when evaluated in-vitro by the BACTEC method and further shows dose dependence of the growth index.
[0115] In an embodiment of the invention, that is also active in-vivo and increases the mean survival time (MST) of infected mice by 5 days when a dose of SF3-K amounting to 50 mg/kg of body weight is administered orally for 12 days after infection.
[0116] In an embodiment of the invention, that exhibits no cytotoxicity in tests conducted with the VERO cell line even for dosage up to 100 μg/mL, i.e., beyond ten times the MIC value of SF3-K.
[0117] In an embodiment of the invention, that shows no toxicity towards healthy mice administered SF3-K orally at the dosage of 0 to 50 mg/kg of body weight.
[0118] In an embodiment of the invention, wherein the major constituent sucrose is unlikely to have any activity as pure sucrose even for dosage of 50 to 100 μg/mL.
[0119] In an embodiment of the invention, wherein the most prominent minor constituent exhibits m/z values of 118 [117+H] + and 140 [117+Na + ] corresponding to a molecular weight of the constituent of 117.
[0120] In an embodiment of the invention, wherein the minor constituent having molecular weight of 117 shows daughter peaks corresponding to m/z values of 58 and 59 whereas in the form of sodium salt daughter fragments are found with m/z values of 96, 81, 53 and 23.
[0121] In an embodiment of the invention, wherein the constituent having M.W. 117 form self-clusters under the conditions of mass spectroscopy and also clusters with the major constituent (Sucrose).
[0122] In an embodiment of the invention, wherein other minor constituents are observed with molecular weights of 113, 115 and 142.
[0123] In an embodiment of the invention, wherein the sub fractions SF1, SF5, SF6 and SF7 were also found having anti-tubercular activity at 100-12.5 μg/mL & SF2 and SF4 were found having anti-tubercular activity at 100-25 μg./mL.
[0124] In an embodiment of the invention, wherein the composition is in a form selected from the group consisting of a tablet, lozenge, solution, capsules, powder and solution.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0125] FIG. 1 is an analytical HPLC profile of the fraction F2 at 254 nm. Using RP-18 column (Phenomenex) and 1:1::CH 3 CN:MeOH as isocratic eluting solvent system at a flow rate of 1 mL/min.
[0126] FIG. 2 is a analytical HPLC profile of fraction F2 at 220 nm, using RP-18 column (Phenomenex) and 03:97::CH 3 CN:H 2 O as isocratic eluting solvent system at a flow rate of 1 mL/min. that is the starting point of the present invention.
[0127] FIG. 3 is a Semi preparative HPLC profile of fraction F2 at 220 nm using RP-18 column (Phenomenex) and 03:97::CH 3 CN:H 2 O as isocratic eluting solvent system at a flow rate of 6 mL./min.
[0128] FIG. 4 is a analytical HPLC profile of SF3-K at 220 nm. using RP-18 column (Phenomenex) and 03:97::CH 3 CN:H 2 O as isocratic eluting solvent system at a flow rate of 1 mL/min.
[0129] FIG. 5 Protection by SF3-K given orally at the dose of 50-mg/Kg. body weight for 12 days in mice against infection of M. tuberculosis H37Rv.
[0130] FIG. 6 is a cytotoxic study of SF3-K on VERO cell line method using MTT assay.
[0131] FIG. 7 is a TOCSY spectrum (2D) of SF3-K indicating the detachment of minor constituents from major constituent sucrose present in the SF3-K.
[0132] FIG. 8 is a Inhibition growth data of M. tuberculosis H37Rv by SF3-K with comparison of Sucrose by BACTEC in-vitro screening method for five days.
[0133] FIG. 9 is a Repeat experiment data for Inhibition of growth of M. tuberculosis H37Rv by SF3-K at two different dose level of 50 and 100 μg./mL conc. in BACTEC.
[0134] FIG. 10 is a HPLC-UV profile of SF3-K under LC-MS condition. HPLC was carried out using Waters Amino column with CH 3 CN:H 2 O::80:20 as mobile phase.
[0135] FIG. 11 - a, b, c and d are Mass Spectrum of the individual peaks of SF3-K identified in the HPLC-TV run under LC-MS condition as FIG.- 10 . FIG. 11 - b is a Mass Spectrum of Sucrose peak, which is not detected under UV at 7.0 min. during LC-MS run of SF3-K.
[0136] FIG. 12 is a Mass Spectrum—ES + Scan of SF3-K.
[0137] FIG. 13 - a & b are MS-MS indicating daughters of m/z=118 and m/z=140 respectively.
[0138] FIG. 14 - a & b are FT-IR spectra of SF3-K and Standard Sucrose on KBr pellet respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0139] The present invention relates to the analysis and study of Salicornia species in order to obtain bioactive fractions or crude extracts thereof which may possess antitubercular activity. In Salicornia genus Salicornia brachiata is species native to India and occurs abundantly in coastal mud flats of Western Coast of India and is also reported in the eastern/southern coast. The other species of Salicornia are Salicornia bigelovi, Salicornia depressa and Salicornia maritima (Occurring in North eastern U.S.), Salicornia herbecea, Salicornia fruiticosa , and Salicornia europaea (Occurring in European countries), are likely to have same activity. So far no compound from Salicornia brachiata or from other Salicornia species have been reported world over to have anti-tubercular activity. Salicornia brachiata plant belonging to Chenopodiaceae family was identified and collected at fully matured stage. The Salicornia species is growing in salt marshes of Asia/Africa, Europe and North America.
[0140] The present invention therefore provides novel bioactive fractions from crude extracts of Salicornia species. The present invention also relates to a process for the preparation of a plant extract of Salicornia species with antitubercular activity which comprises collection of plant at full maturity, washing the plant with using tap water followed by deionised water, removal of all extraneous matter, separation and processing of the plant material to get the desired part, drying, chopping & pulverizing to a certain mesh size, soaking in the solvent & extracting all the soluble matter, concentrating the extract by conventional technique, freeze drying the concentrated extract to get solid residue, fractionating the extract into five fractions using butanol, chloroform, methanol and water, either singly or in combination, testing the crude extract and fractions in-vitro & in-vivo for anti-tubercular activities, specifically against Mycobacterium tuberculosis H37Rv, and recording HPLC profiles for the fractions to serve as finger print.
[0141] The plant material is preferably washed and dried at a temperature range of 20 to 35° C. until the moisture content is in the range of 0.5 to 1.5 percent The plant material prior to soaking is preferably pulverized and the sieved material in the range of 16-20 mesh size sieve may be selected for further treatment. The extracts and fractions were both tested in-vitro and in-vivo for antitubercular activities.
[0142] The plant taxon is an annual, small erect, branched herb, 30-40 cms. in height. It has succulent and articulated stem, opposite branches and short stem internodes. The leaves are reduced to scales, forming a short sheath with rudimentary lamina and sharply pointed tips.
[0143] Flowers are trinate, embedded in cavities along with the upper part of the branches. Seed spikes consist of cymes containing three flowers. The middle flower in cymes is noticeably higher than two lateral ones, resulting in at triangular conformation. Stamen one or two, style distinct, stigma subulate, embryo hook both ends pointing downwards. Seeds are erect, compressed, membranous and exalbuminous.
[0144] The method of the invention comprises:
1. collecting Salicornia brachiata plant material at fully matured stage. 2. washing and drying the plant material at ambient temperature in the range of 25 to 37° C. while maintaining the moisture in the range of 0.5-1.5%. 3. reducing the size of the plant material by pulverizing and selecting the material in the size range of 16-20 mesh sieve. 4. soaking the plant material in deionized water and heated up to 80-90° C. temperature, and repeating the soaking step 5 times with fresh deionized water at an interval of 24 hours. 5. concentrating the extract by conventional/herbal concentrator techniques. 6. freeze drying the concentrated extract in the temperature range of −50 to −60° C. for a period in the range of 8 to 16 hours so as to recover 18-20% yield of crude. 7. fractionating the extract into five fractions F1(5-15% yield) in Butanol, F2 (13-30% yield) in 50% Methanol-Chloroform, F3(34-51% yield) in Methanol, F4(9-15% yield) in 50% Methanol-Water and F5 (3-9% yield) in Water. 8 testing all the five fractions in-vitro and in-vivo for antitubercular activities. 9. sub-fractionating of one of the above active fractions F2 into seven sub-fractions on Semi-preparative HPLC system and testing all the seven sub-fractions for in-vitro anti tubercular activity. 10. purifying the major constituent of the active sub-fraction SF3 on Semi-preparative HPLC system and testing the purified sub-fraction SF3-K for in-vitro & subsequently in-vivo anti tubercular activity. 11. characterizing the purified sub-fraction SF3-K using various spectral analysis for identification of the compound.
[0156] According to the present invention, the plant was identified taxonomically and necessary material was collected from the field at fully matured stage. This material was thoroughly washed with deionized water to remove mud, dust particles and foreign matter. The cleaned plant material was dried at room temperature under shade for a period of 3 to 4 weeks. The plant material was pulverized and sieved to obtain 16 to 20-mesh size powder, soaked in deionised water and heated on water bath at 80-90° C. for 5-6 hours. The extraction cycle was repeated for five times using fresh deionised water and filtered under vacuum in Buckner funnel. All the filtrates were then mixed and concentrated using known technique to obtain crude extract. This concentrated extract was freeze dried to obtain moisture-free crude extract in the powder form. This extract was initially tested in-vitro and after several repeated positive tests the extract was further tested for in-vivo antitubercular activity The extract was fractionated in five fractions with solvent mixtures of different polarity and each fraction was tested in-vitro and in-vivo anti tubercular activity. One of the active fractions F2 was sub-fractionated in seven sub-fractions and tested in-vitro and in-vivo anti tubercular activity The active sub-fraction SF3 was purified and obtained SF3-K. The purified sub-fraction SF3-K was tested in-vitro and in-vivo anti tubercular activity and finally subjected for characterization using various spectroscopic methods.
EXAMPLE-1
[0157] Wildly growing Salicornia brachiata was collected on or before the stage of maturity (November to March) from Gulf of Cambay, India, more precisely from a location at 21° 46′ N Latitude & 72° 11′ E Longitude to 20 42′ N latitude and 71° 01′ E longitude (21° 75′ N Latitude & 72° 17′ E Longitude to 21° 09′ N latitude and 72° 00′ longitude) as disclosed in U.S. patent application Ser. No. 10/829,400 dated 22 nd Apr. 2004 and PCT patent application No. PCT/IN03/00292 dated 29 th Aug. 2003. The different parts of the plant were then further processed for crude extract preparation with the solvents: methanol-water (95:5), methanol-water (1:1) at ambient temperature and pure water at 80-90° C. These crude extracts were subjected to bioassay for anti-tubercular activity. The results of bioactivity for many parts found are as under:
% Mice surviving on Sr Plant part Solvent System Different days 1 Root Methanol-Water (1:1) 17% up to 28 days 2 Root Water (100%) 17% up to 35 days 3 Whole Plant Water (100%) 17% up to 24 days without root 4 Seed husk Methanol-Water (95:5) 17% up to 23 days
[0158] From the above results it was inferred that the water extract of the root is found containing higher activity than the extract prepared from other plant parts and therefore selected for fractionation work to obtain F1 to F5 fractions as disclosed in the above patent. All the five fractions were evaluated for in-vitro anti tubercular activity and all the fractions found active at 50 μg./mL. Of the above fractions the F2 was selected for further fractionation to obtain the isolated active moiety as further disclosed in the Example 1 of the above patent application. Its activity and HPLC profile were established to be the same ( FIG. 1 ). To improve separation of constituents in the fraction F2, the chromatographic conditions were modified as follows: the mobile phase was 03:97::CH 3 CN:H 2 O (isocratic), the column used was 5μ RP-18 analytical column (Phenomenex, U.S.A.), the flow rate was 1 mL/min, the run period was 20 min and the UV detection wavelength was 220 nm. As can be seen from the HPLC profile of FIG. 2 , the constituents of the fraction are better resolved.
EXAMPLE-2
[0159] 1 g. of the F-2 fraction of Example 2 was processed on 10μ RP-18 semi-prep column (Phenomenex, U.S.A.), the flow rate was 6 mL/min, the run period was 28 min and the UV detection wavelength was 220 nm. The HPLC trace is shown in FIG. 3 . Subsequently, 50 injections were carried out with a total of 1 g of the F2 fraction and seven sub-fractions (SF-1 to SF-7) were collected as shown in FIG. 3 . The sub-fractions were concentrated on rotary evaporator and subsequently freeze dried at −58° C. The weights of the individual sub-fractions were: 238 mg, 312 mg, 160 mg, 5 mg, 9 mg, 1 mg and 8 mg for SF1 to SF7 respectively.
EXAMPLE 3
[0160] The sub-fractions SF-1 to SF-7 of Example 2 were tested against M. tuberculosis H37Rv in-vitro. The SF3 sub-fraction was consistently found to be active in inhibiting growth and colony forming ability of M. tuberculosis H37Rv on 7H10 Middlebrook's medium containing OADC, indicating that the peak shown with an arrow in FIG. 3 is likely the peak corresponding to the most active constituent. (As per the activity flow chart).
EXAMPLE 4
[0161] 38 mg of the SF-3 sub-fraction of Example 2 was re-chromatographed on the Semi-prep HPLC column maintaining identical conditions as those described in Example 2. Four sub-sub-fractions of this sub-fraction were collected. The third sub-fraction, after stripping off the solvent, weighed 25.3 mg. It yielded the HPLC of FIG. 4 in the Analytical RP-18 column.
EXAMPLE 5
[0162] A capped glass vial containing the purified compound of Example-4 was kept for 4 hours around noontime in the hot summer sun to check the thermal stability under Indian weather conditions. The HPLC profile was checked after exposure to the sun and the profile was identical to that of FIG. 4 . This demonstrates that the SF3-K has adequate heat stability to withstand storage and transport for the purpose of bioactivity measurements.
EXAMPLE 6
[0163] The SF3-K of Example 4 exhibited an MIC value ≦3.125 μg/mL against M. tuberculosis H37Rv when evaluated as per the method of Example 3 for which details are provided separately under Bioassay Procedures.
EXAMPLE 7
[0164] The in-vitro activity of SF3-K was further determined by another method called BACTEC, for which details are provided separately under Bioassay Procedures. Inhibition of growth of M. tuberculosis H37Rv was measured at 50 and 100 μg/mL concentrations. Complete inhibition of growth was observed.
EXAMPLE 8
[0165] In a small limited study, the antitubercular activity of SF3-K was evaluated in an experimental model of tuberculosis. The activity of SF3-K was tested at 50 mg per kg body weight in mice infected with M. tuberculosis H37Rv. Mice were receiving the purified SF3-K once orally for 12 days. The description and treatment of the two groups is as follows:
Group I Infected, untreated mice Group II Infected but treated with purified SF3 at 50 mg/kg body weight for 12 days after infection.
[0168] The mice in Group I began to loose weight after 10 days following infection. They looked weak with ruffled hairs and mortality began after 14 days of infection. All the mice died of tuberculosis within 16 days. The spleen was enlarged with visible lesion in the lung. All the mice in Group II, which were treated with SF3-K, survived longer and mean survival time was enhanced by 5 days ( FIG. 5 ).
EXAMPLE-9
[0169] SF3-K was tested for cytotoxicity (IC50) in VERO cell at different concentrations: 0, 12.5, 25, 50 and 100 μg/mL, The range covers the dose equal to 10 times the MIC of SF-3 for M. tuberculosis H37Rv. After 72 hours exposure, viability was assessed on the basis of cellular conversion of MTT into a formazan product (using the Promega CellTitre 96 non-radioactive Cell Proliferation Assay), which was measured by absorbance at 492 nm. There was no inhibition up to 100 μg/mL, suggesting that the compound was non-cytotoxic. The result is shown in FIG. 6 . Two cytotoxic compounds designated X and Y were taken for comparison.
EXAMPLE 10
[0170] Toxicity studies were also conducted on healthy mice treated with SF3-K. Seven mice were given once daily (by oral route) a dose of SF3-K amounting to 50 mg/kg of body weight for 12 continuous days and observed for survival and weight till 35 days. None of the mice died and they gained weight.
EXAMPLE-11
[0171] The TOCSY (Total Correlation Spectroscopy) proton NMR spectrum of SF3-K was recorded on a 500 MHz Varian NMR machine ( FIG. 7 ). Except for the circled peaks, all other peaks are attributable to sucrose and separate NMR experiments with pure sucrose (Sigma) have confirmed this. Based upon HPLC with RI detection, the approximate percentage of Sucrose in SF3-K is 75-80%, indicating thereby that the minor constituents comprise no more than 20-25%. Further based on comparative 1 H NMR of SF3-K and standard Sucrose (Sigma) having equal quantity of weight indicates approximately 5% difference in the proton signal area. Similarly, in minor constituents the ratio between the compounds with molecular weight 117 and 142 is approximately 4:1 based upon HPLC with UV detection This example illustrates that SF3-K is primarily sucrose with presence of one or more minor constituents responsible for the circled peaks.
EXAMPLE-12
[0172] Experiments were conducted with control, pure sucrose from Sigma (100 μg/mL) and SF3-K (50 μg/mL) in-vitro against H37Rv using the BACTEC method. As can be seen from FIG. 8 no inhibition was observed with sucrose and the behaviour was similar to that found with control, whereas SF3-K showed significant inhibition. If Sucrose plays no role other than being a diluent, the MIC value of the active constituent(s) in SF3-K would be expected to be much lower than the value indicated in Example 6 since the active constituents comprise no more than 20-25% in SF3-K as indicated in Example 11.
EXAMPLE-13
[0173] The experiment of Example 12 was repeated at two different dose levels of SF3-K, namely 50 μg/mL and 100 μg/mL. As can be seen from FIG. 9 , the observations of Example 12 were found to be reproducible ( FIG. 9 ). Moreover, dose dependence of inhibition was seen.
EXAMPLE-14
[0174] The HPLC conditions of Example 1 using 03:97::CH 3 CN:H 2 O was repeated with pure Sucrose and no peak was found in the chromatogram under 220 nm detection whereas RI detection revealed a peak with similar retention time as that of SF3-K under 220 nm UV detection or under RI detection. No other peaks due to any minor constituent were observed either by UV detection or by RI detection of the SF3-K. This example suggests that minor constituents in SF3-K, whose presence is evident from the TOCSY NMR of Example 11 and the activity data of Examples 12 and 13, co-elute with sucrose under the chromatographic conditions adopted.
EXAMPLE-15
[0175] The HPLC conditions were modified to resolve the constituents of SF3-K having the chromatogram of FIG. 4 under the prior conditions of HPLC. For this the following changes were made The RP-18 column was replaced with a Waters Amino column and the mobile phase was changed to 80:20::CH 3 CN:H 2 O. The chromatogram obtained (210 nm detection) under LC-MS run conditions is shown in FIG. 10 . As can be seen from the figure, peaks were obtained at 3.09 min, 4.26 min, 15.92 min, and 20.74 min. Separate experiments with pure Sucrose (Sigma) under the same conditions using RI detection revealed a peak at 7.70 min, i.e., Sucrose elutes at 7.70 min but goes undetected in UV. Accordingly, mass spectral characterization was attempted of the constituents eluting at 4.26 min, 7.70 min, 15.92 min, and 20.74 min (FIGS. 11 A-D). The mass spectrum (scan ES + ) of SF3-K as such is shown in FIG. 12 . The constituent eluting at 4.26 min shows m/z=114 corresponding to [113+H] + , i.e., it has the molecular weight of 113. Under MS conditions, the compound also forms the dimeric aggregate [(113) 2 +H] + having peak at m/z=227. The constituent eluting at 7.70 min ( FIG. 11B ) has m/z=360 corresponding to [Sucrose (342)+NH 4 + (18)], i.e., it is due to Sucrose as expected. The constituent eluting at 15 92 min ( FIG. 11 C ) shows the MS peak at m/z=118 corresponding to [117+H] + , i.e., it has the molecular weight of 117. Under MS conditions, the compound also forms dimeric [(117) 2 +H] + and trimeric [(117) 3 +H] + clusters having m/z=235 and 352, respectively. MS-MS showing the daughter peaks of the m/z=118 [117+H] + and 140 (1.17+Na + ) in the spectrum of FIG. 12 are shown in FIGS. 13 a & b . Based on the fragmentation pattern of FIGS. 13 a & b , NMR positions of “non-Sucrose” circled peaks in FIG. 7 , and IR evidence of amide and carbonyl bands for SF3-K ( FIG. 14 a ) not seen with sucrose ( FIG. 14 b ) the structure (1) below could be one of the possible structures corresponding to m/z=118 (this constituent appears to be dominant among the “minor constituents” of SF3-K). The constituent eluting at 20.74 min ( FIG. 11D ) shows the m/z at 143 [142+H + ] but has not been characterized further. Besides these peaks, a peak at m/z=116 [115+H] + has been observed as also a peak at m/z=138 [115+Na + ] both under direct spray of SF3-K as also as co-constituent of m/z=118 during LC-MS. The complex pattern of the mass spectrum of FIG. 12 can be explained in terms of clusters of Sucrose either with itself or with the minor constituent having molecular weight of 117.
[0000] Methods
[0000] Preparation of SF3-K from Dry Mature Root of Salicornia Brachiata
[0176] Salicornia brachiata was collected at fully matured stage and the roots were used preparation of aqueous extract as disclosed in the pending U.S. patent application Ser. No. 10/829,400 dated 22 nd Apr. 2004 and PCT patent application No. PCT/IN03100292 dated 29 th Aug. 2003 by Rathod et al. The root was washed with tap water followed by deionized water to remove mud, dust particles and other foreign matter, dried, cut to small pieces, pulverized and soaked in the deionized water. The soaked root was heated on water bath at 80-90° C. The water-soluble extract was decanted and filtered. The above process was carried out for three to five days so as to recover au the water-soluble material. The filtrate was concentrated on a rotary evaporator and subsequently dried on Freeze Drier to obtain a solid. The solid was fractionated to obtain five fractions through successive extraction with Butanol, 1:1 Chloroform:Methanol, Methanol, 1:1 Methanol:Water and Water. The Chloroform:Methanol fraction (referred to as F2) was taken for sub-fractionation on Semi-preparative HPLC using RP-18 column (Phenomenex) and 03:97::CH 3 CN:H 2 O mobile phase at 7 mL/min. Seven sub-fractions were collected between 0 to 22 minutes and the sub-fraction collected between 9.9 minutes and 10.65 minutes was labeled as SF3 The SF3 was concentrated on rotary evaporator at 50° C. and then subjected to chromatography once again on the same column and under the same conditions except for change of flow rate to 6 mL/min and total run period of 19 minutes. The fraction corresponding to the main peak was collected between 11.8 to 12.6 minutes, i.e., the collection began during the rising phase of the peak above baseline and was discontinued during the declining phase of the peak but before reaching baseline. This sub-fraction was once again concentrated on rotary evaporator and freeze dried to obtain a powder. Starting with 100 g of dry root 0.805 g of SF3-K was obtained.
[0000] In-Vitro Screening of SF3-K against M. Tuberculosis H37Rv Using 7H10 Middlebrook's Medium Containing OADC (B-D, USA).
[0177] The antitubercular activity of SF3-K was determined by inhibition of growth and colony forming ability of M, tuberculosis H37Rv on 7H10 Middlebrook's medium containing OADC (B-D, USA). The medium was autoclaved and supplemented with OADC and 2 mL was dispensed in sterile tubes. A suspension of 1 mg/mL. concentration of SF3-K fraction was prepared in sterile water, which was added into test tubes containing supplemented medium at different concentrations keeping the volume constant, i.e. 0.1 mL. After proper mixing, the tubes were kept in slanting position and allowed to cool and solidity. These tubes were incubated at 37° C. for 24 hours to observe any contamination. If not, the tubes were streaked with a culture suspension of M. tuberculosis H37Rv (1−5×10 4 bacilli/tube). The inoculated tubes were incubated at 37° C. along with two controls, one in which no inhibitory compound was present but streaked with the same inoculum of M. tuberculosis H37Rv and second, in which a standard antitubercular compound was added at the reported minimum inhibitory concentration which will inhibit the growth of tubercle bacilli. Growth of bacilli was observed till 4 weeks of incubation. SF3-K containing tubes were compared with control tubes described above.
[0000] BACTEC Method of In-Vitro Screening:
[0178] Aqueous stock solution of SF3-K (1 mg/mL) was filter sterilized. 50 μL of SF3-K was added to 4 mL radiometric 7H12 broth (BACTEC 12B) to achieve final concentration of 50 and 100 μg/mL of SF3-K. 50 μL sterile water was added in the control vial in which SF3-K was not added. Finally, 10 4 to 10 5 colony forming units of M. tuberculosis H37Rv was inoculated in all the vials, that is, the 4 mL. BACTEC radiometric 7H12 broth containing 50 and 100 μg/mL of SF3-K and the control vial without SF3-K. All the vials were kept in duplicate and incubated at 37° C. Growth index (GI) was recorded daily. Experiments were done in analogous fashion with Sucrose (Sigma; 100 μg/mL) instead of SF3-K to ascertain its activity, if any.
[0000] Method of In-Vivo Screening.
[0179] M. tuberculosis H37Rv, grown on L-J slants, was harvested and a homogenous Suspension was prepared in Tween-saline at approximately 1×10 8 bacilli/mL. Female swiss mice, bred in the animal house of Central Drug Research Institute, Lucknow, India and weighing 18-20 g were taken. The mice were divided in 2 groups with 7 mice in each group. Infection of mice with M. tuberculosis H37Rv (1×10 7 bacilli/mouse) was given by injecting 0.1 mL of the bacterial suspension as prepared and described above via lateral tail vein. Treatment of mice with SF3-K (50 mg/kg body weight, dissolved in sterile water) was started after 48 hours post infection and administered via oral route for 12 days.
[0000] The main inventive steps are:
[0000]
(i) changing the chromatographic condition that enabled purification of F2.
(ii) Correlating the sub-fractions of F2 with activity and selecting SF3 for further study.
(iii) Further purifying SF3 to obtain SF3-K that yielded a single peak in the HPLC that suggested apparent high purity.
(iv) Identifying sucrose as major constituent of SF3-K and further demonstrating that it is inactive.
(v) Showing thereafter that sucrose elutes at the same place as where UV-responsive peaks are detected, where these peaks are likely due to minor constituents.
(vi) Proving by 2D-NMR that additional NMR peaks other than for Sucrose are due to minor constituents and not due to functional modification of Sucrose.
(vii) Evolving methodology for separating the various constituents of SF3-K and attempting preliminary characterization.
(viii) Indirectly demonstrating that the <3.125 μg/mL MIC of SF3-K translates into a very low MIC of active minor constituents which therefore need to be isolated and studied separately.
(ix) Showing that the SF3-K is completely non-toxic.
(x) Demonstrating efficacy of action both in-vitro and in-vivo
The Main Advantages of the Present Invention are:
Reduction in the MIC value of anti-tubercular extract from Salicornia brachiata through concentration of activity in a specific sub-fraction named SF3-K, leading to MIC values ≦3.125 μm/mL.
2. Proven efficacy of anti-tubercular action in-vivo through limited studies on mice infected with H37Rv as demonstrated through enhanced survival period.
3 Proven non-toxic nature of the sub-fraction through cytotoxicity studies conducted with dosage well above ten times the MIC value.
4. Mirroring of the same non-toxic behaviour in healthy mice administered with the active
5 Adequate thermal and photochemical stability of SF3-K as demonstrated through exposure of the solid to mid-noon Indian sun that led to no change in HPLC profile with UV detection.
6. Reproducibility of activity through repeat collections of the plant and repeat extraction and fractionation.
7 Demonstration that activity of SF3-K resides in minor constituents and thereby holding out the promise of achieving further 3 to 5 fold reduction in the MIC value by isolating the active constituent free from the major inactive constituent, namely Sucrose.
8 Demonstration of the feasibility of separating the minor constituents of SF3-K from the major inert constituent by chromatographic means which would make possible a detailed study of the anti-TB activity of the different minor constituents of SF3-K with a view to identify the key active ingredient and synergy of action, if any, with other constituents of SF3-K or even with other known drugs currently in vogue or to be introduced soon.
9. Demonstration that the minor constituent(s) of SF3-K, one or more of which are active against Mtuberculosis , are simple molecule(s) based on mass spectral data and possibly not investigated previously for anti-tubercular activity.
10 Possibility that the SF3-K may be used as a novel, non-toxic and efficacious herbal drug against M. Tuberculosis once detailed tests from all angles are completed.
11. Possibility that SF3-K may yield a new chemical entity against M. Tuberculosis that may be amenable to synthesis as well.
12. So far the known compounds of tuberculosis are found having complex structure and heterocyclic. Where as the compound isolated in present investigation appears to be very simple, and having low molecular weight (117). | 4y
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BACKGROUND
[0001] The invention relates to a drive device for the adjustment of an actuating element of a throttle, valve, connecting device (coiled connector) or a dosage feed device or similar item of equipment, in particular in the mining of mineral oil or natural gas, with at least one spindle drive movably connected to the actuating element and a gear unit arranged between the spindle drive and at least one motor.
[0002] Such a drive device is known from DE 200 18 561. The prior device is used for the adjustment of a shut-off element as actuating element in a blow-out valve arrangement (blow-out preventer, BOP), whereby a connecting channel in the BOP can be closed by the shut-off element. The shut-off element is movably connected to the spindle drive. Through this spindle drive a rotational movement produced by the motor is converted into a linear movement for the adjustment of the actuating element. In addition, a worm gear is arranged as a further gear unit between the motor and the spindle drive.
[0003] This drive device and especially due to the application of the worm gear is characterised by a self-locking mechanism and also otherwise can be well employed for the adjustment of various actuating elements. Such a drive device exhibits substantial advantages over other devices without worm gear. However, generally the efficiency is restricted to less than 50% and also the self-locking mechanism is only produced at a high transmission ratio. In addition, relatively high axial forces sometimes occur with worm gears.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0004] The object of the invention is to improve a drive device of the type mentioned at the beginning such that with a simple and compact construction an increase in the efficiency for reduction of the dissipated losses is possible, at the same time especially avoiding high axial forces and needing only a low number of components.
[0005] This object is solved by the features of claim 1 .
[0006] Through the application of an especially self-locking spur gear as part of the gear unit a very compact construction is produced and also the efficiency is increased to over 50% through the use of such a spur gear. In addition, at least only reduced axial forces occur due to the appropriate arrangement of the spur gear.
[0007] The spur gear here in this respect is assigned to the motor and is appropriately movably connected to it, whereby the gear unit furthermore exhibits a reduction gear which is assigned to the spindle drive and is movably connected to it. One such reduction gear is especially a so-called harmonic drive. Due to this further reduction gear the rotational speed of the motor can be reduced so far in a simple manner that even extremely slight adjustments to the corresponding actuating element are possible and accurately controllable. Due to the arrangement of spindle drive, reduction gear, spur gear and motor, a short, compact construction is also produced, requiring little space.
[0008] To obtain a spindle drive which features high loadability with a long service life and simultaneously very good mechanical properties, such a spindle drive can be a roller or ball screw drive with spindle nut and threaded spindle. In particular a suitable roller screw drive can be regarded as advantageous when applied in the mining of mineral oil or natural gas at inaccessible places, because it operates essentially free of maintenance.
[0009] Depending on the actuating element, its adjustment by different parts of the spindle drive is of advantage. For example, the spindle nut can be supported rotationally, but axially immovable in the device housing. In this way the threaded spindle is moved accordingly in an axial or linear direction when the spindle nut rotates and can consequently with an appropriate connection to the actuating element also move the actuating element linearly. It is also possible to support the spindle nut rotationally rigidly, but axially movable in the device housing. In this respect the threaded spindle can rotate, but is arranged axially immovable. Through the appropriate coupling of the spindle nut and the actuating element, the movement of the spindle nut is then transferred to the actuating element.
[0010] A simple assignment of spindle drive and reduction gear can be seen when the spindle nut or threaded spindle is rotationally rigidly joined to the reduction gear. Accordingly, the rotation of the reduction gear on its output side is transferred to the spindle nut or threaded spindle. This can also occur by an essentially direct connection to the spindle nut or to the threaded spindle from the side of the reduction gear.
[0011] If the reduction gear is a so-called harmonic drive, it generally exhibits three components. The first component is a flexible, cup-shaped toothed sleeve. The second component is a fixed ring element and the third a wave generator. The toothed sleeve is in partial engagement with its outer teeth engaging suitable inner teeth on the ring element. The wave generator is arranged inside the toothed sleeve and through its rotation the flexible toothed sleeve is extended so far at two opposite points that its outer teeth engage the inner teeth of the ring element. Generally, the toothed sleeve exhibits two teeth less than the ring element so that with one rotation the relative movement between the toothed sleeve and the ring element amounts to two teeth. Such a harmonic drive is capable of extreme loads and requires little maintenance.
[0012] The transfer of the rotational movement of the harmonic drive to the spindle drive can for example occur in that the toothed sleeve is rotationally rigidly joined to the spindle nut or the threaded spindle.
[0013] There is the possibility of directly connecting the toothed sleeve and an appropriate part of the spindle drive. However, to design the drive device in a more variable manner and where applicable to construct it in a modular way, a rotationally supported but axially immovable connecting sleeve can be arranged between the toothed sleeve and the spindle drive. This connecting sleeve can be used at one end for the connection to the spindle nut or to the threaded spindle and at the other end for connection to the toothed sleeve.
[0014] In order to obtain a secure connection between the threaded spindle and the toothed sleeve or connecting sleeve, the threaded spindle can be rotationally rigidly inserted with one drive end in a retention hole of the connecting sleeve. Various possibilities are conceivable to fix the drive end in the retention hole. One possibility, which also permits the transfer of large forces, is the formation of splines between the threaded spindle and the inner side of the retention hole.
[0015] With a simple embodiment the spur gear can be helically toothed.
[0016] In order to retain the advantages of the spur gear, such as high efficiency, low reduction, simple construction, parallel axes, etc. and to also simply realise the self-locking or self-braking, the spur gear is formed as a double helical gear. Such a double helical gear exhibits double helical teeth and an approximate screw-shaped appearance. The self-braking effect can be varied depending on the helix angle of the double helical gear and its various helical gears. This applies analogously to the self-braking, whereby self-braking is in principle regarded as being on the drive side and self-locking on the driven side and with appropriate direction of rotation. Particularly, for devices in the mining of mineral oil and natural gas such self-braking and self-locking gears are of advantage, because separate holding/braking devices can be omitted.
[0017] Such helically toothed spur gears or also double helical gears feature small dimensions, a long service life, high reliability in operation and stable transmission. Furthermore, due to the parallel arrangement of the individual helical gears, a compact construction is produced. The gears can be easily adapted to different application conditions and also feature low noise levels.
[0018] An appropriate spur gear exhibits at least two helical gear wheels. According to the invention, the reduction gear and in particular its wave generator can be movably connected to a first spiral toothed gear wheel and the motor to a second spiral toothed gear wheel of the spur gear. It is again pointed out that efficiency for such spur gears and in particular for double helical gears is greater than 65% and can even amount to 80% or more. In addition, with such gears a linear contact of the tooth faces arises instead of a point contact as with a worm gear.
[0019] In order to transfer the drive power of the motor on the shortest and easiest path into the spur gear, the second spiral toothed gear wheel can be arranged on a drive shaft of the motor.
[0020] In order to construct the drive device redundantly or to design it also for higher powers, two or more motors can be assigned to the drive shaft. Here, there is the possibility that generally the actuating element can be adjusted by the operation of only one motor, so that the other motor or motors are only employed when that one motor fails. Similarly, there is the possibility of attaining an appropriate drive power through the application of a large number of relatively small motors.
[0021] There is also the possibility that two or more drive shafts each with at least one motor are supported essentially parallel to the threaded spindle in the device housing. This also provides redundancy or an increase in the power of the drive device. Of course, here two or more motors on each of the drive shafts are also possible. If motors on different drive shafts are employed simultaneously, then they are synchronised, whereby the synchronisation can occur electronically as well as mechanically, for example, directly between the drive shafts. Preferably two drive shafts can be arranged diametrically opposed in the device housing. However, arrangements are also possible in which the drive shafts are arranged offset from one another by certain angles in the circumferential direction of the device housing. Examples of such angles are 45°, 90°, 270° and also other intermediate values between 0° and 360°. This applies analogously to the arrangement of more than two drive shafts.
[0022] In order to connect each of the drive shafts directly to the spur gear, a second spiral toothed gear wheel, which engages the first spiral toothed gear wheel of the spur gear, can be arranged on each drive shaft.
[0023] In order to design a drive device independently of complicated feeds for compressed air or any other pressure medium, the motor can be an electric motor. Consequently, there is the possibility of electrifying the complete drive device as well as its control and monitoring system. One example of such an electric motor is a servomotor or an asynchronous motor.
[0024] With regard to the spur gear there is, of course, also the possibility that the various second spiral toothed gear wheels engage in each case different first spiral toothed gear wheels, whereby these first spiral toothed gear wheels, for example, can all be appropriately connected to the spindle drive. It has already been pointed out that the teeth of the spur gear can be so-called helical teeth, exhibiting a certain helix angle. Due to the helical orientation of the teeth, there is the possibility of reducing the normal number of teeth significantly. According to the invention, a helix angle for example of the first and/or the second spiral toothed gear wheel can be in the range from 50° to about 90° and particularly in the range from 65° to 85°. With an appropriately high helix angle the number of teeth can be reduced to one.
[0025] In contrast, in particular, to a worm gear in which self-locking is only provided for transmission ratios down to a certain smallest transmission ratio, with a spur gear transmission ratios lower than 25 and lower than 1 can be realised without having to dispense with a self-locking or self-braking mechanism. For the simple construction of the spur gear the first and second spiral toothed gear wheels exhibit 1 to 10 , preferably 1 to 7 and especially preferred 1 to 4 teeth, whereby reduction ratios in the range 1 to 5 up to 1 to 100 on the drive device according to the invention are generally sought.
[0026] In order to proceed further with the modular construction of the drive device according to the invention and at the same time to be able to simply fit and remove certain parts, the connecting sleeve can be releasably connected at its end facing away from the spindle drive to the toothed sleeve.
[0027] When the spindle nut is the axially movable part of the spindle drive, there is the possibility of coupling the actuating element directly to the threaded nut, so that the actuating element can also be moved linearly. Another possibility is to provide another gear, which converts the linear movement of the spindle nut into a rotational movement, between the actuating element and the spindle nut. This can occur, for example, in a simple manner in that at least one engaging element protrudes from the threaded spindle or the spindle nut essentially radially outwards and engages in slots of a fixed sleeve and a rotating sleeve, whereby a first slot extends essentially in the axial direction and a second slot extends at an acute angle to the first slot. If, for example, the first slot is in the fixed sleeve, the rotating sleeve rotates when the corresponding part of the spindle drive is moved in the axial direction by the appropriate engagement of the engaging element in both slots. In this way the conversion of the linear movement into the rotational movement is determined by the slope of the corresponding second slot in the rotating sleeve. Here it is possible, for example, that the corresponding alignment of the slots changes so that in a first slot section only a slight rotation of the rotating sleeve occurs relative to the fixed sleeve. Consequently, an extremely fine rotation of the actuating element is possible, as is for example of advantage for throttles and the corresponding throttle elements. Once the throttle has then opened partially, the angle between the two slots can increase quickly so that the throttle is then completely opened very quickly. Further possibilities of the orientation of the two slots relative to one another are obvious.
[0028] As already stated, it can be favourable in this respect if the actuating element can be rotated together with the rotating sleeve.
[0029] There are various possibilities of monitoring the movement of the actuating element and of applying the monitored movement for the control of the drive device and therefore of the actuating element. With one embodiment a position sensor can be assigned to the axially movable part of the spindle drive. Of course, assignment of a position sensor and a rotating part of the spindle drive are also possible. In addition, an appropriate position sensor can also be assigned to another part of the drive device, from the movement of which the displacement of the actuating element can be determined.
[0030] In order to be able to accommodate a suitable position sensor in the device housing without this position sensor being disturbed by the other parts of the drive device, the position sensor can exhibit an essentially flat code carrier which is offset radially outwards with respect to the threaded spindle and arranged parallel to it. The code carrier also moves in the axial direction corresponding to the movement of the threaded spindle or spindle nut, so that this axial movement is directly acquired and the corresponding conclusions about the displacement of the actuating element can be drawn from it.
[0031] With a simple embodiment a dog can be arranged between the axially moving part of the spindle drive, in particular the engaging element and the code carrier. As previously explained, the engaging element is used for engaging the pair of slots so that with appropriate movement of the code carrier, conclusions can be drawn about the rotation of the rotating sleeve and therefore also about the displacement of the actuating element.
[0032] At this point it should be noted that such a code carrier of the position sensor can exhibit an appropriate position-specific pattern which passes by an appropriate scanning device of the position sensor when the code carrier moves. Through this passage of the pattern, accurate conclusions can be drawn about the displacement of the code carrier and therefore about the movement of the corresponding part of the spindle drive or of the actuating element.
[0033] For the further preferred design of the drive device and for increasing its variability a distance sleeve can be arranged in a motor hole of the device housing on a side, facing away from the second spiral toothed gear wheel, of the at least one motor. This distance sleeve can be removed where applicable to accommodate a second, third or more motors in the corresponding motor hole. Furthermore, the distance sleeve can also be used as further support for the drive shaft.
[0034] In order to adapt as applicable and, with regard to the motorisation, to vary the drive device in a simple way to various circumstances and possibly also to various actuating elements, the device housing can be of modular construction. In this way there is the possibility that, for example, the gear unit, spindle drive and motors are accommodated in one part of the device housing, whereas in another part the actuating element is arranged. It may also be conceived as favourable that only the connecting sleeve, gear unit and motors are arranged in one housing part, whereas the spindle drive is arranged in another part of the housing and the actuating element is arranged in a further housing part. Of course, each of the housing parts exhibits an appropriate opening for the connection of the particularly moving devices arranged in each of the housing parts.
[0035] In addition, the device housing can be provided with various, diagonally running surfaces on its outer side which enable easy insertion by remote control of the complete drive device in, for example, a so-called tree on the sea bed.
[0036] Furthermore, due to the modular construction of the device housing, easy disassembly is provided, for example, to replace or maintain parts.
[0037] With the sideward parallel offset code carrier, in order to guide it in a simple manner within the device housing, the code carrier can be guided in a guide sleeve in the axial direction.
[0038] It is conceivable that with an embodiment of the drive device according to the invention the threaded spindle and the spindle nut are rotationally supported together in the device housing, but are axially immovable. In this way, for example, the rotation of the threaded spindle is converted directly into a rotation of the actuating element. The threaded nut is used in this connection as a support for the threaded spindle without it being axially displaced. Essentially here, only a corresponding rotation of the threaded nut occurs synchronously to the threaded spindle.
[0039] There is the possibility of displacing a valve element for more or less closing or opening the valve directly with a corresponding end of the threaded spindle. In this case however the modular character of the drive device is restricted, because the corresponding end of the threaded spindle is matched to the special valve element or similar component. It would be more convenient if the threaded spindle was releasably connected at its end facing away from the spindle nut to a sliding rod of the actuating element. In this way the sliding rod can be formed in the same way, also for different devices, only at its end facing the threaded spindle. Consequently, sliding rods assigned to different actuating elements can be connected to a threaded spindle with the same construction in each case.
[0040] If there is adequate space available and in particular when the threaded spindle is axially movable, the code carrier of the position sensor can at least be inserted with one end section into an inner hole of the threaded spindle and be releasably connected there for common movement of the code carrier and threaded spindle in the axial direction. In this respect the code carrier is accordingly also brought out through the following connecting sleeve, reduction gear and the spur gear so that an appropriate scanning of the code carrier only takes place outside of the gear unit. Consequently, the corresponding position sensor is easier to contact electrically and, where applicable, easier to replace.
[0041] There is also the possibility that the spindle nut and connecting sleeve are connected together releasably. In this way the rotation of the connecting sleeve is directly transferred to the spindle nut, whereby the spindle nut is here immovable in the axial direction due to the corresponding support of the connecting sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Advantageous embodiments of the invention are explained in more detail in the following based on the figures enclosed in the drawings.
[0043] The following are shown:
[0044] FIG. 1 shows a longitudinal section through a first embodiment of a drive device;
[0045] FIG. 2 shows a section along the line II-II in FIG. 1 ;
[0046] FIG. 3 shows an enlarged view of a detail “X” in FIG. 1 ;
[0047] FIG. 4 shows a longitudinal section through a second embodiment of a drive device according to the invention;
[0048] FIG. 5 shows a section along the line V-V in FIG. 4 ;
[0049] FIG. 6 shows a longitudinal section through a third embodiment of the drive device according to the invention, and
[0050] FIG. 7 shows a longitudinal section through another embodiment of the drive device according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] With all embodiments according to the invention, the same reference symbols refer in each case to the same parts and are sometimes only discussed in connection with one of the figures. In part, reference symbols used in one or some of the figures are omitted in the other figures for reasons of clarity.
[0052] In all embodiments the arrangement of the various parts of the drive device 1 is common. These parts comprise in particular an appropriate actuating element 2 for the corresponding device, such as valve, throttle, dosage feed device or similar equipment, which are particularly employed in the mining of mineral oil and natural gas. Apart from the actuating element 2 which is formed differently according to the device, each drive device 1 exhibits a spindle drive 3 , a gear unit 6 movably connected to it and consisting of a reduction gear 7 and spur gear 9 as well as the motor or motors 4 , 5 driving the spur gear.
[0053] With the embodiment according to FIG. 1 , the actuating element 2 exhibits a sliding rod 40 which is connected at one of its ends to a holed sleeve 43 . At the free end of the holed sleeve 43 a number of holes 49 are formed in the sleeve, through which depending on the position of the holed sleeve 43 in the axial direction 38 more or less fluid flows from the inlet end 45 to the outlet end 46 according to the fluid flow 50 . In the illustrated position of the holed sleeve 43 all the holes 49 are closed so that no flow occurs through the outlet end 46 .
[0054] To prevent the holed sleeve 43 from rotating, it is rotationally rigidly connected to a circulation body 44 by means of a keyed shaft 47 . The circulation body is arranged in the device housing 42 . The various parts of the drive device 1 , such as the spindle drive 3 , gear unit 6 and motors 4 , 5 , are arranged inside the circulation body 44 .
[0055] The spindle drive 3 is formed as a recirculating roller spindle drive with an appropriate threaded spindle 11 and spindle nut 10 . The threaded spindle 11 is connected with its end 39 pointing away from the spindle nut 10 to the sliding rod 40 .
[0056] The spindle nut 10 is releasably attached to a connecting sleeve 15 by means of a number of threaded bolts, whereby the spindle nut 10 can rotate by means of a suitable rotational support of the connecting sleeve 15 , but is immovable in the axial direction.
[0057] The connecting sleeve 15 exhibits a retention hole 17 , refer also to FIG. 4 , in which the spindle nut 10 is partially inserted. In this retention hole 17 the threaded spindle 11 is also inserted depending on the axial displacement, whereby its drive end 16 located in the retention hole 17 is provided with an internal hole in which a code carrier 33 of a position sensor 32 is inserted. The code carrier 33 can be moved in the axial direction 38 together with the threaded spindle 11 .
[0058] A reduction gear 7 is connected as part of the gear unit 6 for the rotation of the connecting sleeve 15 to an end of the connecting sleeve 15 pointing away from the spindle nut 10 . The reduction gear 7 is formed as a so-called harmonic drive 8 . This exhibits a flexible toothed sleeve 12 which is at its closed end rotationally rigidly connected to the connecting sleeve 15 . The toothed sleeve 12 exhibits at its open end outer teeth which partially engage inner teeth of a fixed ring element 13 as another part of the harmonic drive 8 . Inside the toothed sleeve 12 a wave generator 14 is also arranged as part of the harmonic drive 8 in the region of the ring element 13 .
[0059] The harmonic drive 8 operates in a known manner in that the flexible toothed sleeve 12 is extended at two opposite points by the wave generator 14 such that its outer teeth engage the inner teeth of the ring element 13 . Generally, the toothed sleeve exhibits two teeth less than the ring element so that for one rotation the relative movement between the toothed sleeve and the ring element amounts to two teeth. The corresponding wave generator 14 is according to the invention rotationally rigidly connected to a first spiral toothed gear wheel 20 of a spur gear 9 as another part of the gear unit 6 . The first spiral toothed gear wheel 20 engages at least a second spiral toothed gear wheel 21 , whereby in a further embodiment the corresponding helical teeth 24 , refer also to FIG. 3 , of the spiral toothed gear wheels 20 , 21 can be formed such that a double helical gear 23 is produced. Such a helically toothed spur gear 9 is self-braking and self-locking. The helical teeth of the various spiral toothed gear wheels are formed by appropriate teeth which are arranged at an appropriate helix angle 25 , again refer to FIG. 3 .
[0060] For the first and/or second spiral toothed gear wheel the helix angle is 50° to approximately 90° and preferably 65° to 85°. Due to the spur gear a transmission ratio in the range between i=25 and i<1 is produced. Accordingly, the spiral toothed gear wheels exhibit 1 to 10 , preferably 1 to 7 and especially preferred 1 to 4 teeth.
[0061] With the embodiments according to the figures, a second spiral toothed gear wheel 21 in each case externally engages the first spiral toothed gear wheel 20 . Of course two, three or more second spiral toothed gear wheels 21 can be arranged along the circumference of the first spiral toothed gear wheel 20 and can engage the first spiral toothed gear wheel 20 .
[0062] With the embodiment according to FIG. 1 the second spiral toothed gear wheel 21 is arranged on a drive shaft 22 which is offset radially outwards and extends parallel to the threaded spindle 11 . Transfer of the drive force from two electric motors 4 , 5 occurs on the drive shaft 22 .
[0063] There is the possibility that according to the arrangement of further second spiral toothed gear wheels also further drive shafts 22 can be accordingly arranged with motors 4 , 5 . These are then analogously distributed along the circumference of the first spiral toothed gear wheel 20 , whereby the corresponding drive shafts 22 are in each case arranged parallel to one another.
[0064] With the embodiment according to the invention of the drive device 1 the drive shaft 22 extends with its end facing away from the second spiral toothed gear wheel 21 to a distance sleeve 35 , whereby an appropriate end of the drive shaft 22 is rotationally supported in the distance sleeve 35 . There is the possibility of omitting this distance sleeve 35 , in that for example the drive shaft 22 is extended and is provided with further motors 4 , 5 in the region of the distance sleeve 35 .
[0065] The code carrier 33 of the position sensor 32 is passed through the first spiral toothed gear wheel 20 and the reduction gear 7 . The code carrier is inserted, with its end facing the threaded spindle 11 , in the same and fixed there. The code carrier 33 exhibits a position-specific pattern on its outer side, the said pattern being able to be scanned by a suitable scanning or sensor device of the position sensor 32 . This scanning produces an exact position determination of the code carrier 33 with displacement in the axial direction 38 , the said position displacement being convertible into a corresponding position displacement of the threaded spindle 11 , the sliding rod 40 and therefore the holed sleeve 43 . Consequently, the relevant position of the holed sleeve 43 and accordingly the arrangement of the holes 49 can be determined by the position sensor 32 , whereby the corresponding throttling of the actuating element 2 is determined with regard to the fluid flow 50 .
[0066] For the electrical supply of both the motors 4 , 5 and the position sensor 32 an electrical connection device 52 in the form of an electrical connector 48 is brought externally to the device housing 42 and attached there. The appropriate electrical supply cables are routed into the interior of the drive device 1 where they are connected to the appropriate units.
[0067] It is again pointed out that the corresponding parts of the drive device 1 —refer to the actuating element 2 , spindle drive 3 , motors 4 , 5 and gear unit 6 —are essentially similarly constructed and combined for all embodiments of the drive device. With the following embodiments only the differences to the embodiment according to FIG. 1 are explained.
[0068] In FIG. 2 a section along the line II-II from FIG. 1 is illustrated, whereby FIG. 1 corresponds to an appropriate section along the line I-I in FIG. 2 .
[0069] The circulation body 44 is circular shaped in cross-section, whereby the corresponding electrical connection devices or electrical connectors 48 are arranged at three equally spaced points in the circumferential direction. Centrally in the circulation body 44 the first spiral toothed gear wheel 20 is arranged which engages the second spiral toothed gear wheel 21 . Centrally in the first spiral toothed gear wheel 20 a sleeve-shaped end 68 of the position sensor 32 is inserted, refer also to FIG. 1 , whereby the code carrier 33 is located inside this sleeve-shaped end 68 .
[0070] Opposite the second spiral toothed gear wheel 21 an empty cavity 51 is arranged which can be used for the accommodation of a further second spiral toothed gear wheel 21 with appropriate drive shaft 22 and motors 4 , 5 and, where applicable, distance sleeve 35 . Further such empty cavities can be arranged at other points in the circumferential direction of the first spiral toothed gear wheel 20 .
[0071] In FIG. 3 an enlarged illustration of the detail “X” from FIG. 1 is shown, whereby this illustration corresponds to a side view from the radial direction of the second spiral toothed gear wheel 21 . This exhibits double arranged helical teeth 24 so that a double helical gear 23 is formed. An appropriate helix angle 25 for the helical teeth is between 50° and about 90° and preferably between 65° and 85°.
[0072] Analogously to the second spiral toothed gear wheel 21 , the first spiral toothed gear wheel 20 is formed with such a double helical tooth arrangement. There is also the possibility of only using one helical tooth arrangement.
[0073] FIG. 4 illustrates a section in the axial direction through a second embodiment of a drive device 1 .
[0074] The arrangement of the gear unit 6 and the motors 4 , 5 corresponds to that of FIG. 1 , refer to the explanations there.
[0075] A difference to the embodiment according to FIG. 1 is that the threaded spindle 11 is rotationally rigidly connected as part of the spindle drive 3 to the connecting sleeve 15 by means of splines 19 , but is fixed in the axial direction 38 . Accordingly, the drive end 16 of the threaded spindle 11 is inserted into the retention hole 17 of the connecting sleeve 15 and held rotationally rigidly on its inner side 18 by means of the splines 19 .
[0076] Along the threaded spindle 11 , the spindle nut 10 can be moved in the axial direction, whereby it is however arranged rotationally rigidly. The rotational rigidity is produced especially in that engaging elements 27 protrude radially outwards from the spindle nut 10 , the engaging elements engaging in diametrically opposite slots 28 of a fixed sleeve 30 . The slots 28 extend in the axial direction 38 and ensure the rotational rigidity of the spindle nut 10 due to the guidance of the engaging elements 27 . The appropriate engaging element 27 does not only engage the slot 28 of the fixed sleeve 30 , but also appropriate slots 29 of a rotating sleeve 31 . The slots 29 of the rotating sleeve 31 run diagonally to the slots 28 of the fixed sleeve 30 . In this respect the diagonal orientation in the longitudinal direction of the slots can vary so that for example first only a slight angle is present between the slots 28 , 29 so that only a slight relative rotation between the rotating sleeve 31 and the fixed sleeve 30 is produced even with a longer displacement of the spindle nut 10 in the axial direction 38 . Following that, the angle can enlarge so that then also with just a slight movement of the spindle nut 10 , a comparatively substantially large relative rotation between the rotating sleeve 31 and the fixed sleeve 30 occurs. Of course, different conversions of the appropriate axial movements of the spindle nut 10 into a rotational movement of the rotating sleeve 31 relative to the fixed sleeve 30 are possible by means of appropriate orientation of the slots 28 , 29 relative to one another.
[0077] The rotation of the rotating sleeve 31 is transferred by means of its attachment with appropriate threaded bolts to an intermediate ring 26 . This ring is connected rotationally rigidly by means of inserted pins to a rotary coupling sleeve 58 which in turn is rotationally rigidly connected to a first perforated screen 55 by means of appropriate inserted pins. By rotating the first perforated screen 55 relative to a second, stationary perforated screen 54 , an aperture opening of varying size is produced by the overlapping of appropriate openings in both perforated screens 54 , 55 . If the corresponding openings do not overlap, then no flow occurs through the perforated screen arrangement in the direction of flow 50 .
[0078] For determining the position of the spindle nut 10 and therefore also for the monitoring of the rotation of the first perforated screen 55 , the engaging element 27 exhibits at least on one side of the spindle nut 10 a dog 34 which protrudes further radially outwards. This dog 34 is connected to an essentially flat and rod-shaped code carrier 33 . Corresponding to FIG. 1 , this forms part of a position sensor 32 . Differing from the embodiment according to FIG. 1 , the position sensor 32 and code carrier 33 are offset radially outwards and arranged parallel to the threaded spindle 11 . Through the associated movement of the code carrier 33 with spindle nut 10 , an accurate position determination of the spindle nut 10 is provided by appropriate scanning of a position-specific pattern arranged on the code carrier. The position of the spindle nut 10 can be converted into an accurate rotated position of the first perforated screen 55 relative to the second perforated screen 54 .
[0079] Analogously as with the embodiment according to FIG. 1 , the spindle drive 3 according to FIG. 4 is a recirculating roller spindle drive and the spur gear 9 can be formed as a double helical gear 23 . Similarly analogously to the first embodiment, there is the possibility of arranging several drive shafts 22 with corresponding drive motors 4 , 5 and assigned second spiral toothed gear wheels 21 in the circumferential direction of the first spiral toothed gear wheel 20 .
[0080] FIG. 5 corresponds to a section along the line V-V from FIG. 4 , whereby FIG. 4 corresponds to a section along the line IV-IV according to FIG. 5 .
[0081] Essentially FIG. 5 corresponds to FIG. 2 , whereby however the second spiral toothed gear wheel 21 is not arranged to the side of the first spiral toothed gear wheel 20 , refer to FIG. 2 , but instead below it. The position sensor 32 is arranged diametrically opposed. There is the possibility of arranging further appropriate empty cavities 51 , refer to FIG. 2 , along the circumferential direction of the first spiral toothed gear wheel 20 for the accommodation of further drive shafts 22 and corresponding second spiral toothed gear wheels 21 .
[0082] Inside the first spiral toothed gear wheel 20 there is in accordance with the other arrangement of the position sensor 32 with the code carrier 33 no such code carrier 33 arranged, refer here instead to FIG. 2 .
[0083] FIG. 6 shows another embodiment of a drive device 1 according to the invention, which is essentially constructed analogously to the drive device 1 according to FIG. 1 . The differences essentially relate to the other application of the drive device 1 , i.e. the combination with another actuating element 2 , whereby similarly the corresponding parts of the drive device 1 are not integrated in a circulation body 44 according to FIG. 1 .
[0084] Instead the actuating element according to FIG. 6 exhibits a sliding rod 14 which is rotationally rigidly connected at its end facing away from the threaded spindle 11 to a pot holder 62 . The pot holder 62 is open at one end and a closing pot 61 is inserted in this open end. In the upper half according to FIG. 6 the closing pot is, as a maximum, pushed on to an appropriate holed sleeve 43 with holes 49 as a further part of the actuating element 2 . In the lower half according to FIG. 6 the closing pot 61 is pulled off the holed sleeve 43 as far as possible so that all the holes 49 let fluid pass according to the fluid flow 50 .
[0085] In order to prevent rotation of the pot holder 62 relative to the device housing 42 a keyed shaft 47 is arranged between them analogous to FIG. 1 .
[0086] It should be pointed out that with FIG. 6 also the same position sensor 32 as with FIG. 1 is used. This applies analogously also to the corresponding code carrier 33 and its arrangement within the drive device or its mounting on the threaded spindle 11 .
[0087] With regard to FIG. 6 is should be noted that here in particular the oblique roller bearings 63 of the connecting sleeve 15 have reference symbols which are however also used analogously with the other embodiments.
[0088] Furthermore, it should be noted that the device housing 42 , as also with the other embodiments, is of modular construction and with the steps on the outer surface, in particular with embodiments 4 and 6 , is used for the automatic insertion of the corresponding drive device 1 with the actuating element 2 in a so-called tree in the mining of mineral oil and natural gas. The arrangement is simplified by the various steps and diagonal surfaces on the outside of the device housing 42 so that insertion can also occur using a remotely controlled robot or similar equipment.
[0089] With the last embodiment according to FIG. 7 the arrangement of the corresponding parts of the drive device 1 in turn corresponds to that in FIG. 1 , refer particularly to the arrangement of the connecting sleeve 15 of the gear unit 6 and the motors 4 , 5 . Also with FIG. 7 a circulation body 44 is used about which the fluid flows according to the fluid flow 50 from the inlet end 45 in the direction of the outlet end 46 . In contrast to the embodiment according to FIG. 1 , another type of throttle element is used which is formed from two perforated screens 54 , 55 , refer here also to FIG. 4 . The first perforated screen 55 is supported rotationally and the second perforated screen 54 is supported rotationally rigidly inside the device housing 42 . The rotation of the first perforated screen 55 is transferred directly by rotation of the threaded spindle 11 of the spindle drive 3 . The threaded spindle 11 is employed analogously to the embodiment according to FIG. 4 in an appropriate retention hole 17 of the connecting sleeve 15 and is rotationally rigidly and axially immovably held there by splines 19 .
[0090] In contrast to the previous embodiments, with the embodiment according to FIG. 7 no displacement of a part of the spindle drive 3 occurs in the axial direction, because the spindle nut 10 can also rotate, but is supported immovably in the axial direction within the circulation body 44 . The corresponding support occurs by means of a bearing 66 arranged between two retention rings 64 , 65 .
[0091] The electrical supply of the corresponding units of the drive device 1 according to FIG. 7 occurs analogously to FIG. 1 . One difference between the embodiments according to FIGS. 1 and 7 arises in the application of a different position sensor 32 which according to FIG. 7 is a torsion spring 67 as the relevant rotary position of the connecting sleeve 15 and is therefore the element detecting the threaded spindle 11 . The corresponding torsion of the spring leads to different extended and compressed regions along the coil of the spring, which results in different resistance changes on electrical wires arranged in these regions. These resistance changes are converted into a corresponding torsion of the spring and hence into a corresponding rotated angle of the connecting sleeve 15 , of the threaded spindle 11 and finally of the first perforated screen 55 .
[0092] In the following the functioning principle of the drive device 1 according to the invention is explained based for example on FIG. 1 .
[0093] On actuating the motors 4 , 5 accordingly a rotation of the drive shaft 22 occurs and hence of the second spiral toothed gear wheel 23 of the helical spur gear 9 . The rotation of the second spiral toothed gear wheel 23 is transferred by engagement of the helical teeth to the first spiral toothed gear wheel 20 .
[0094] Through the helically toothed spur gear self-locking or self-braking is provided as well as a high efficiency with low dissipation losses. The corresponding tooth faces of the teeth 24 of the first and of each of the second spiral toothed gear wheels are in linear contact. Due to the parallel arrangement of the corresponding spiral toothed gear wheels essentially no axial forces occur and overall a simple construction arises. Furthermore, such a gear has relatively low noise levels, is compact in construction and exhibits a long service life.
[0095] As already explained, several of the second spiral toothed gear wheels 23 can be arranged in the circumferential direction of the first spiral toothed gear wheel 20 with corresponding drive shafts 22 and motors 4 , 5 .
[0096] The rotation of the first spiral toothed gear wheel 20 is transferred to the harmonic drive where it is further reduced. A drive of the connecting sleeve 15 occurs by means of the flexible toothed sleeve 12 and depending on the embodiment rotation of the spindle nut 10 or of the threaded spindle 11 occurs through the connecting sleeve. Due to the rotation of the corresponding part of the spindle drive 3 formed as a recirculating roller spindle drive a displacement or rotation of the relevant actuating element 2 occurs, whereby in addition a further gear unit comprising the fixed sleeve and the rotating sleeve 30 , 31 can be arranged between the spindle drive 3 and the actuating element 2 .
[0097] The actuating elements of the various embodiments are formed differently and generally exhibit a suitable sliding rod and flow control elements connected to it, such as perforated screens 54 , 55 or holed sleeves 43 . It should however be noted that drive devices according to the invention can also be used for other devices such as throttles, i.e. for example also for valves, dosage feed devices or similar equipment. | 4y
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This Appln is a 371 of PCT/US99/17219 filed Aug. 5, 1999 which claims benefit of Prov. No. 60/097,373 filed Aug. 21, 1998 which claims benefit of Prov. No. 60/095,614 filed Aug. 6, 1998.
BACKGROUND OF THE INVENTION
The US EPA currently restricts the total nitrate plus nitrite concentration (as nitrogen) in drinking water to less than 10 mg/L, and has reported that exposure to perchlorate should not exceed the 4-18 μg/L range in order to provide an adequate health protection margin. High nitrate/nitrite and perchlorate levels in drinking water have been linked to serious health problems and sometimes death. The concern over nitrate/nitrite has been driven by increasing levels of these contaminants being detected in drinking water supplies originating from both inorganic and biological sources. Inorganic sources include intense agricultural practices which contribute both ammonium and potassium nitrate fertilizers, explosives and blasting agents, heat transfer salts, glass and ceramics manufacture, matches, and fireworks. Biologically derived organonitrogen compounds are converted to nitrate in natural waters relatively rapidly. The main source for compounds is human sewage and livestock manure, which are not effectively removed by current treatment systems. Once in the environment, nitrates move rapidly into ground water reservoirs which supply drinking water. Recent studies have indicated the presence of perchlorate in drinking water wells throughout the Western United States. Perchlorate contamination of ground and surface waters originates from the manufacture and destruction of ammonium perchlorate; a strong oxidant used in the aerospace, munitions, and fireworks industries. Practical and efficient methods to treat water contaminated by these pollutants do not currently exist and are needed to insure a safe drinking water supply.
Ammonium perchlorate has been widely used by the aerospace, munitions, and fireworks industries, resulting in widespread soil and water contamination. The end of the Cold War has left the Department of Defense (DOD) with approximately 140 million pounds of ammonium perchlorate to be disposed of between 1993 and 2005. Perchlorate contamination in drinking water wells was first detected in early 1997 in northern California. These findings prompted further investigation, and perchlorate was detected in southern California wells, the Colorado River, Las Vegas wells, and Lake Mead. Although Federal drinking water standards do not currently exist for perchlorate, it has been placed on the current Drinking Water Contaminant Candidate List by the EPA. 1 There is significant concern over the human health effects of perchlorate due to its known interference with the thyroid gland's ability to utilize iodine and produce thyroid hormones. As a result of these findings, the California Department of Health Services (DHS) adopted an action level for perchlorate in drinking water of 18 μg/L. 2 This level was based upon an earlier recommendation by the EPA for a provisional reference dose (RfD) of 14 mg/kg/day. 3,4 In August of 1997, DHS notified drinking water utilities of their intent to treat perchlorate as an unregulated contaminant that must be monitored and reported to the DHS.
Perchlorate contamination has been detected in eastern Sacramento County at Aeroj et General Corporation's facility, a site previously owned by McDonnnell-Douglas, and a site previously owned by Purity Oil Company. Due to the presence of volatile organic chemicals (VOCs), contaminated groundwater at the Aerojet General site was treated and then reinjected into aquifers in the area. Monitoring of the reinjected water indicated that it contained up to 8000 μg/L of perchlorate. In February 1997, perchlorate was detected in drinking water wells in the Rancho Cordova area at levels as high as 280 μg/L. In July of 1997, DHS tested 62 wells in northern California, and detected perchlorate in 13. Of the 13, eight exceeded the 18 μg/L action level. Also, groundwater monitoring wells associated with the United Technologies Corporation in Santa Clara County yielded perchlorate concentrations as high as 180,000 μg/L, although no contamination of the drinking water systems was evident.
In southern California, perchlorate contamination has been detected in wells at Loma Linda and Redlands (5-216 μg/L) associated with past operations of the Lockheed Propulsion Company. Perchlorate was also detected at low levels in wells at Riverside, Chino, Colton, Cucamonga, and Rialto. In Los Angeles County, perchlorate has been detected in concentrations ranging from 4 to 159 μg/L in the areas of Azusa, Baldwin Park, Irwindale, La Canada, Flintridge, La Puente, Newhall, Pasadena, Santa Clarita, and West Covina. The perchlorate contamination was thought to originate from Aerojet (Azusa), the Azusa landfill, the Whittaker-Bernite site (Santa Clarita), and two Superfund sites, the Jet Propulsion Laboratory (Pasadena) and the Baldwin Park Operable Unit.
Outside of California, perchlorate has been found at levels of 5 to 9 μg/L in the Colorado River. These findings prompted testing in Nevada. In August, Nevada sites were found to contain perchlorate levels of up to 13 μg/L in drinking water wells, 1700 μg/L in the Las Vegas Wash, and 165 μg/L in Lake Mead. Monitoring wells in areas of ammonium perchlorate manufacturing were then found to have levels of 630,000 to 3,700,000 μg/L. In Utah perchlorate was found at levels of 200 μg/L at a rocket motor manufacturing facility.
Potassium perchlorate's health effects were originally discovered due to its use in the 1950's to treat Graves' disease, an autoimmune disorder in which patients develop antibodies to the thyroid stimulating hormone (TSH) receptors in the thyroid resulting in hyperthyroidism. Perchlorate was found to displace iodine in the thyroid, causing a decrease in production of triiodothyronine (T3) and tetraiodothyronine (T4), two regulating hormones which control TSH production. This effect has been shown to be reversible, with the perchlorate eventually being expelled from the thyroid. A study by Stansbury and Wyngaarden 5 was performed on Graves' disease patients following a single dose of perchlorate. Studies by Godley and Stansbury, Crooks and Wayne, Morgans and Trotter, Hobson, Johnson and Moore, Fawcett and Clarke, Krevans et al., Gjemdal, and Barzilai and Sheinfeld followed perchlorate administration to Graves' disease patients for periods up to several weeks. 6-14 Only one case by Connell 15 reported long term treatment in one patient for 22 years. Doses of perchlorate in these studies ranged from <1 mg/kg/day 5 to >20 mg/kg/day 7 with the typical exposure being 6-14 mg/kg/day. The observable effects of perchlorate include blocking of iodine uptake and discharge by the thyroid, 5 gastrointestinal irritation and skin rash, 6,7 and hematological effects including agranulocytosis and lymphadenopathy. 7,8 Seven cases of fatal aplastic anemia were reported at the same dose level, 6-14 mg/kg/day, at which other side effects occurred. 9-14
Following these early studies, the effects of perchlorate exposure on healthy volunteers were studied by Burgi et al. 16 in five subjects for eight days at 9.7 mg/kg/day dosage levels. Brabant et al. 17 studied five subjects dosed with 12 mg/kg/day of perchlorate for four weeks. Both of these studies observed effects on the thyroid at these levels. Studies in laboratory animals have included administration of perchlorate for four days by Mannisto et al. 18 and for two years by Kessler and Krunkemper. 19 The animal studies only examined thyroid effects at dosage levels too high to evaluate the perchlorate level defined as the no observable adverse effects level (NOAEL).
The initial effort to establish a RfD for perchlorate was undertaken by the Perchlorate Study Group (PSG), a consortium of companies that use and/or manufacture perchlorates. The PSG submitted a provisional perchlorate RfD) to the EPA's National Center for Environmental Assessment Office (NCEAO) in 1995. The critical health effect cited in the PSG report was the interference with the thyroid functioning including the release of iodine from the thyroid, inhibition of iodine uptake by the thyroid, increased thyroid weight and volume, increased TSH levels, and decreased T3 and T4 thyroid regulating hormone levels. The PSG's approach to a perchlorate RfD was to select a dose level that represented the highest level tested at which no adverse effects were observed. The critical study used by the PSG in their assessment was by Brabant. 17 The PSG report recommended a RfD of 12 mg/kg/day.
In response to this report, the NCEAO derived the provisional RfD of 1×10 −4 mg/kg/day later used by the DHS in their recommendations. This RfD was based upon the NOAEL for potassium perchlorate in the functioning of the thyroid combined with uncertainty factors designed to account for sensitive populations, the less than chronic nature of the studies, and database deficiencies. 2,3,5 The critical study used in this assessment was that of Stansbury and Wyngaarden which was the only study to report a NOAEL for humans. 5 The NOAEL dosage was established at 0.14 mg/kg/day based on the release of iodine from the thyroid. To account for unknowns in the risk assessment process, the U.S. EPA used uncertainty factors (UF) to evaluate the NOAEL. An UF of 1000 was applied to perchlorate based upon 10 for a less than chronic study, 10 for database insufficiencies, and 10 for the protection of sensitive individuals. This resulted in a RfD of 0.00014 mg/kg/day, and a 4 μg/L drinking water limit (70 kg average weight and two liters of drinking water per day). The U.S. EPA later reviewed the findings and available data, and changed the database uncertainty factor to 3, resulting in a higher RfD of 0.0005 mg/kg/day. Using the two UF analyses, the U.S. EPA concluded, “until adequate chronic data becomes available that addresses the effects of perchlorate on the hematopoietic system (i.e., bone marrow), we feel that the provisional RfD is in the range of 1 to 5×10 −4 (i.e., 0.0001 to 0.0005) mg/kg/day″ or 4-18 μg/L of perchlorate in drinking water.
After review of earlier attempts to establish a RfD, the International Toxicity Estimates for Risk (ITER) Peer Review Panel concluded in March of 1997 that the database for perchlorate exposure was inadequate for the development of a RfD and that additional studies were required to establish a RfD. Due to this recommendation, the PSG and the U.S. Air Force obtained funding to support new studies to assess the toxicities of perchlorate. 20 In September of 1997, the first study was initiated. New laboratory animal studies are in progress or about to begin at this time to determine the effects of perchlorate ingestion on neurobehavioral development, receptor kinetics, developmental fetal skeletal abnormalities, ADME (absorption, distribution, metabolism, and elimination), mutagenicity/genotoxicity, reproductive, and immunotoxicity. These studies will be used to fill in holes in the perchlorate database that have made it difficult for the EPA to set a RfD. The findings of these studies will be used to establish a new RfD.
Nitrate and nitrite levels in drinking water have also received intense regulatory scrutiny in the past due to their potential to cause serious health problems especially in infants and the elderly. High nitrate/nitrite levels in drinking water have been linked to serious illness and sometimes death. In infants, the conversion of nitrate to nitrite by the body can interfere with the ability of blood to carry oxygen. Under exposure to excessive nitrate levels, an acute condition can occur leading to shortness of breath and blueness of the skin (i.e., “blue baby syndrome” or methemoglobinemia). In its acute form, this may lead to rapid health deterioration over a period of days. Chronic exposure to high levels of nitrate/nitrite can lead to diuresis, and increased starchy deposits and hemorrhaging of the spleen. Current EPA regulatory limits include a Maximum Contaminant Limit (MCL) of 10 mg/L (as nitrogen) and a 10-day Health Advisory Limit (HAL) of 10 mg/L. 21 For example, a safe short term exposure for a 10 kg child consuming 1 liter of water per day over a ten day period would be 10 mg/L of total nitrate plus nitrite.
Part of the concern over nitrate/nitrite has arisen from the increasing levels of these contaminants detected in drinking water supplies. Since most nitrogenous chemicals in natural waters are converted to nitrate, all sources of combined nitrogen especially organic nitrogen and ammonia should be considered as nitrate sources. Due to its high solubility and weak retention by soils, nitrates are very mobile and move into groundwater reservoirs (i.e., aquifers) at a rate comparable to that of surface water. Biological degradation of nitrate by anaerobic denitrification reactions to form elemental nitrogen and ammonia is slow so that nitrate persists in the environment. In particular, organic nitrates originating from human sewage and livestock manure are potential sources for this type of ground water contamination. In the latter case, feedlots represent a large point source of this type of organic nitrogen pollution. Intense agricultural practices also contribute through the use of ammonium and potassium nitrate as fertilizers. Other inorganic sources of nitrate contamination include explosives and blasting agents, heat transfer salts, glass and ceramics manufacture, matches, and fireworks. The quantity of nitrate/nitrite released into the environment between 1987 and 1993 in the top fifteen states totaled 2.68×10 7 kg for water releases and 2.42×10 7 kg for land releases. Of these, nitrogeneous fertilizer contributed ˜44% of the total while industrial sources accounted for ˜30%.
The widespread occurrence of perchlorates and nitrate/nitrites in ground and surface water combined with the concern expressed by California's DHS and the U.S. EPA clearly demonstrate the need for new more efficient technologies to eliminate these inorganic contaminants from drinking water. Numerous technologies have been investigated for the destruction of perchlorate, but none of these provide an economical process for treating drinking water to reduce these contaminants to levels below regulatory limits. Ion exchange, reverse osmosis, and electrodialysis are current methods used to remove nitrate/nitrite from drinking water, however, in all cases nitrate/nitrite are concentrated into a brine which then must be disposed of in an appropriate repository. Assurance of safe drinking water supplies in the future will require the development of technology which can eliminate both of these inorganic contaminants from drinking water without producing additional wastes.
The decomposition of perchlorate by biological, physicochemical, electrochemical, and thermal processes has been the subject of numerous patents. 26-35 Included in these are a microbiological treatment using Vibrio dechloraticans Cuznesove B-1168 being fed acetate, ethanol, glucose, and other sugars in the absence of oxygen. The Air Force has investigated the destruction of ammonium perchlorate using Wolinella succinogenes HAP-1, an anaerobic microbe. 20 Thermal destruction of highly concentrated perchloric acid solutions and perchloric acid in the vapor phase is also well known. 26-30 The thermal decomposition of perchloric acid has been measured at moderate temperatures from 295-322° C. 30 Physical processing has been employed in which evaporation and precipitation of KClO 4 were used to remove perchlorate. 31,32 Electrochemical methods have also been used to reduce perchlorates to lower oxidation state chlorine compounds. 33,34 Electrochemical reduction of perchloric acid solutions has been demonstrated using a titanium cathode. 35 Prior to the current research, the catalytic reduction of perchlorates has not been actively pursued.
The elimination of nitrate and nitrite from water has been widely studied. 36-40 The primary and traditional treatment methods have been based on nitrification and denitrification using different groups of bacteria under aerobic and anaerobic conditions. 36-38 Chemical and physical processes such as reverse osmosis, ion exchange, and electrodialysis have all been considered as physico-chemical means to remove nitrate/nitrite from water. 39,40 The use of an aqueous phase catalyst in combination with an organic reductant has not been considered.
Many aqueous phase catalytic oxidation studies have been performed using dissolved molecular oxygen as the oxidant and a variety of organic contaminants as reductants. The primary objective in these studies has been the destruction of aqueous phase organic contaminants. In effect, these studies mirror the proposed perchlorate destruction process with the exception that the contaminant that is being destroyed has changed from the reductant to the oxidant. 41-64
SUMMARY OF THE INVENTION
A process is provided for destroying contaminants in a contaminant containing aqueous stream. In the subject process, the contaminant-containing aqueous feed stream preferably comprises a contaminant-containing aqueous feed stream or aqueous brine feed stream.
The process of the present invention comprises providing the contaminant-containing aqueous feed stream including an initial amount of at least one of a group of contaminants including perchlorates, nitrates, and nitrites. In a preferred process of this invention for the destruction of perchlorate contaminants, an oxidation-reduction process is employed in which it is believed that the oxidation state of chlorine in the perchlorate (+7) contaminant is lowered, forming predominantly chloride (−1). In a preferred process for the destruction of nitrate and nitrite contaminants, it is believed that the oxidation state of nitrogen in the nitrate (+5) and nitrite (+3) contaminants is lowered, forming elemental nitrogen (0).
A reducing agent is provided in the contaminant-containing aqueous feed stream. The reducing agent can be present therein in sufficient amount to facilitate the catalytic oxidation-reduction of the present invention. However, the subject process typically includes adding a non-toxic reducing agent to the contaminant-containing aqueous feed stream. The preferred reducing agents are organic reducing agents, more preferably low molecular weight polar organic species which are highly soluble and have a terminal carbon—oxygen bond. Most preferably, the reducing agent can comprises any one of a carbohydrate, an alcohol or an organic acid, more preferably ethanol or acetic acid.
There are also preferred inorganic reductants including dissolved hydrogen and ammoniacal nitrogen species (i.e., NH 3 and NH 4 + ). Other inorganic species such as hydrogen peroxide, urea, chloramines, or hydrazine hydrochloride which form oxidized by-products that are soluble may also be utilized as reducing agents.
When organic reducing agents are utilized, carbon dioxide and water are the predominant by-products from oxidation of the reductant. If inorganic reducing agents are utilized, then the chief by-products formed depend on the reducing conditions and the specific reducing agent. For example, the oxidation of hydrogen forms hydronium ions, while the oxidation of ammonia forms water, hydronium ions, and nitrogen.
Next, the reducing agent-containing, contaminant-containing aqueous stream is subjected to a heating step. The temperature to which the reducing agent-containing, contaminant-containing aqueous stream is typically raised is to a temperature of not more than about 250 degrees C., preferably to a temperature of not more than about 200 degrees C., more preferably to a temperature of not more than about 150 degrees C., and most preferably to a temperature of not more than about 50 degrees C.
The heated contaminant-containing aqueous stream is then contacted with an oxidation-reduction catalyst for a period of time sufficient for reducing the initial amount of any of the perchlorates, nitrates, and nitrites contaminants. Preferably, the step of contacting the reducing agent-containing, contaminant-containing aqueous stream with the oxidation-reduction catalyst is typically conducted for a period of time of not more than about 500 seconds, preferably not more than about 300 seconds, more preferably not more than about 150 seconds, and most preferably not more than about 50 seconds.
The oxidation-reduction catalyst is preferably a metallic oxidation-reduction heterogeneous catalyst. Oxidation-reduction catalysts can comprise chemically robust, high surface area supports impregnated with a metal, metal oxide, or with mixtures of metal salts which are subsequently reduced to metallic form. The supports are stable in aqueous solutions at the above-described reduction temperatures. The preferred supports are zirconium dioxide extrudates.
The heated contaminant-containing aqueous stream can be subject to pressure, as well as temperature, when it is contacted with an oxidation-reduction catalyst. The preferred pressures employed during the oxidation-reduction sequence is typically up to about 40 atmospheres, preferably up to about 10 atmospheres, more preferably up to about 3 atmospheres, and most preferably up to about 1 atmospheres.
The supports generally have a surface area of at least 20 m 2 /g, preferably at least 25 m 2 /g, more preferably at least 30 m 2 /g, and most preferably at least 35 m 2 /g. Moreover, the particle size of the support material is preferably up to about 2 mm, more preferably up to about 3 mm, and most preferably up to about 4 mm.
These oxidation-reduction catalysts of the present invention exhibit high activity towards the oxidation of dissolved organic species and towards the reduction of molecular oxygen and other suitable oxidants such as perchlorate, nitrate, and nitrite materials. The preferred metallic materials employed in the oxidation-reduction catalyst of this invention are platinum, palladium, and ruthenium.
The subject oxidation-reduction catalysts suitable for the process of this invention are high activity catalysts provided that the support material remains stable at the reaction conditions. Typical oxidation-reduction catalyst of this invention can comprise platinum and/or palladium and/or ruthenium catalytic metals supported on other materials. Such support materials can include titanium dioxide, cerium oxide, aluminum oxide, silicon dioxide, silicon carbide, and activated carbon. The platinum loading on typical supports employed in the process of this invention may be as high as 20% by weight, based on the weight of the support material, although a cost-benefit analysis generally can reduce this value by a factor of ten for commercial application. The ruthenium loading on these supports is preferably up to about 5.0% by weight. The palladium loading on these supports is less than about 2.0% by weight, based on the total weight of the support material.
Oxidation-reduction catalysts suitable for this process can also include other metals, metal oxides, or mixed metal oxides supported on a variety of materials. Typical metals in this group include copper, iron, cobalt, and nickel. Typical metal oxides include copper oxide with manganese oxide, chromium oxide with iron oxide, and chromium oxide with cobalt oxide. Metal and metal oxide loadings are up to about 4.0% by weight, based on the weight, based on the weight of the support material.
A preferred oxidation-reduction catalyst for the destruction of perchlorate, nitrate, and nitrite using organic reductants comprises platinum and ruthenium on zirconium dioxide. The optimal platinum loading based on performance-cost evaluation is between about 0.5 and 2.5% by weight. The optimal ruthenium loading based on performance-cost evaluation is between about 0.1 and 0.5% by weight, based on the weight of the support.
A preferred oxidation-reduction catalyst for the reduction of perchlorate, nitrate, and nitrite using dissolved hydrogen as the reductant comprises platinum, palladium, and ruthenium on zirconium dioxide. When utilizing hydrogen as the reductant, palladium containing catalysts exhibit higher reaction rates than non-palladium containing catalysts due to the high hydrogen solubility in palladium, combined with the consequent availability of hydrogen at the palladium surface. The optimal loading based on performance-cost evaluation for platinum is between 0.5 and 2.5% by weight, for palladium is between 0.5 and 2.0% by weight, and for ruthenium is between 0.1 and 0.5% by weight of the support.
A variety of reactor configurations may be utilized to perform the aqueous phase catalytic oxidation-reduction process of this invention. The preferred catalytic reactor comprises a plug flow reactor containing the catalyst bed. Reducing agents are added at the inlet at ambient temperature and pressure. The aqueous stream is then pressurized, heated, pumped through the reactor, and cooled at the outlet. Reactor temperature control and overall energy efficiency is improved by coupling inlet and outlet flows through a regenerative heat exchanger. Depending on the contaminated stream and reducing agent, perchlorate, nitrate, and nitrite will be reduced in the presence of a stoichiometric excess of the reducing agent at a kinetically determined residence time within the catalyst bed. When hydrogen is the reducing agent of choice, a stoichiometric excess of gaseous hydrogen is injected into the pressurized stream at a concentration sufficient to reduce the contaminant species at the contact time provided. The reactor operating pressure is adjusted to maintain single phase operation and to supply sufficient dissolved gas to maintain a stoichiometric excess reductant. Operating pressures and temperatures are maintained in a range as previously described above.
A preferred oxidation-reduction catalyst for the reduction of perchlorate, nitrate, and nitrite using ammonium cations as the reductant comprises platinum and ruthenium on zirconium dioxide. The optimal loading based on performance-cost evaluation for platinum is between 0.5 and 2.5% by weight, and for ruthenium is between 0.1 and 0.5% by weight of the support.
An aqueous phase catalytic reduction (APCAR) process will catalytically reduce perchlorate, nitrate, and nitrite using a variety of organic and inorganic reductants at low temperatures between 25 and 125° C. in water. An APCAR process will catalytically reduce perchlorate, nitrate, and nitrite using a variety of organic and inorganic reductants at temperatures above 150° C. in brines which contain between 1 and 12% by weight sodium chloride.
When organic reductants are utilized, carbon dioxide and water are the predominant reaction by-products. If inorganic reductants are utilized, then the chief by-products formed depend on the reduction conditions and the specific reductant.
When the heated contaminant-containing aqueous stream is contacted with an oxidation-reduction catalyst for a period of time sufficient, the initial amount of any of said perchlorates, nitrates, and nitrites contaminants is substantially reduced. More specifically, the extent of the above-described substantial reduction is preferably by at least about 90%, more preferably by at least about 92%, and most preferably by at least about 95%.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a system 10 of the present invention for destroying contaminants in a contaminant-containing aqueous stream using an organic reducing agent.
FIG. 2 is a graphical representation of the reduction of 50 mg/L NaClO 4 , using the system described in FIG. 1 and PRZr51 oxidation-reduction catalyst, at 60 degrees C. using 50 mM ethanol as the reducing agent.
FIG. 3 is a graphical representation of the reduction of 50 mg/L NaClO 4 , using the system described in FIG. 1 and PRZr51 oxidation-reduction catalyst, at 70 degrees C. using 50 mM ethanol as the reducing agent.
FIG. 4 is a graphical representation of the reduction of 50 mg/L NaClO 4 , using the system described in FIG. 1 and PRZr51 oxidation-reduction catalyst, at 80 degrees C. using 50 mM ethanol as the reducing agent.
FIG. 5 is a graphical representation of an Arrhenius plot of the reduction of NaClO 4 , using results of FIGS. 2-4.
FIG. 6 is a graphical representation of the reduction of 20 mg/L NaNO 3 , using the system described in FIG. 1 and PRZr51 oxidation-reduction catalyst, at 80 degrees C. using 20 mg/L ethanol as the reducing agent.
FIG. 7 is a graphical representation of the reduction of 30.6 mg/L NaNO 3 , using the system described in FIG. 1 and PRZr51 oxidation-reduction catalyst, at 100 degrees C. using 20 mg/L ethanol as the reducing agent.
FIG. 8 is a graphical representation of the reduction of 50 mg/L NaClO 4 , using the system described in FIG. 1 and PRZr51 plus 2% palladium oxidation-reduction catalyst, at 80 degrees C. using hydrogen as the reducing agent. Hydrogen Reduction of 50 mg/L NaCl 4 at 80° C. over the PRZr51+2%Pd Catalyst.
FIG. 9 is a graphical representation of the reduction of NaClO 4 , using the system described in FIG. 1 and PRZr51 plus 2% palladium oxidation-reduction catalyst, at 90 degrees C. using hydrogen as the reducing agent.
FIG. 10 is a graphical representation of the reduction of NaClO 4 , using the system described in FIG. 1 and PRZr51 plus 2% palladium oxidation-reduction catalyst, at 100 degrees C. using hydrogen as the reducing agent.
FIG. 11 is a graphical representation of an Arrhenius plot of the reduction of NaClO 4 , using the system described in FIGS. 8-10.
FIG. 12 is a graphical representation of the reduction of 50 mg/L NaClO 4 , using the system described in FIG. 14 below, catalyzed by a PRZr51 oxidation-reduction catalyst, at 120 degrees C., using ammonium ions in the form of NH 4 Cl as the reducing agent.
FIG. 13 is a graphical representation of the reduction of NaClO 4 , using the system described in FIG. 14 below, at 130 degrees C., using ammonium ions in the form of NH 4 Cl as the reducing agent.
FIG. 14 is a schematic view of a system 40 of the present invention for destroying contaminants in a contaminant-containing aqueous stream using a non-organic reducing agent.
DESCRIPTION OF PREFERRED EMBODIMENTS
The process of the present invention utilizes a highly active oxidation-reduction catalyst to destroy particularly perchlorates and nitrates/nitrites contaminating aqueous streams. The development of an aqueous phase catalytic reduction (APCAR) process for the destruction of contaminants in water, particularly perchlorates and nitrates/nitrites, offers an innovative solution to potentially serious health problems.
A schematic representation of a preferred APCAR system 10 is shown in FIG. 1 . The system is configured as a plug flow reactor 20 containing an oxidation-reduction catalyst designed to promote perchlorate and/or nitrate/nitrite reduction, forms innocuous inorganic by-products. The choice of reductants and the APCAR process configuration will depend on the perchlorate or nitrate/nitrite concentration. For example, at low perchlorate concentrations the intrinsic organic carbon levels in drinking water will suffice for destruction and only a single reactor pump 24 is needed. When high concentrations of perchlorate are encountered, non-toxic organic reductants such as carbohydrates, alcohols, or organic acids are metered from the reduction reservoir 28 by the metering pump 26 into the inlet stream 30 prior to the reactor pump 24 . Inorganic reductants may also be used including hydrogen gas, ammoniacal nitrogen species (i.e., NH 3 and NH 4 + ), and other soluble inorganic species which form soluble oxidized by-products. Metering pumps are used to introduce water soluble reductants, while a pressurized tank coupled to a mass flow controller is utilized to introduce gaseous reductants. In the next stage, heat is transferred from the reactor's treated water to the influent water by passage through a regenerative heat exchanger 22 .
In order to raise the water temperature to reaction conditions, additional heat is provided in the preheater 25 . The APCAR reactor temperature is controlled through a combination of heat exchanger 22 , preheater 25 , and resistive heating within the reactor 20 . The temperature from the preheater 25 is read by the inlet thermocouple 21 , and the temperature at the outlet of the reactor 20 is read by the outlet thermocouple 23 . After passage through the reactor 20 , the water perchlorate and nitrate/nitrite levels are typically reduced below 5 μg/L and 10 mg/L, respectively. The amount of reductant as quantified by the Total Organic Carbon (TOC) level which decreases as the reducing agent is oxidized. The effluent water temperature is then reduced to ambient conditions following flow through the regenerative heat exchanger. The pressure in the line prior to heat exchanger 22 is determined by pressure gauge 27 . The pressure can be modified, if necessary, by pressure regulator 29 . The water is then available from outlet 32 for transfer to the water treatment plant for normal processing.
A catalytic reduction test system 10 , similar to that shown in FIG. 1, was constructed. A 19.63 cm 3 plug flow reactor was filled with PRZr51 catalyst (i.e., 2% platinum and 0.5% ruthenium on zirconium oxide extrudates between 1 mm and 3 mm in diameter) and challenged with 50 ppm (mg/L) of NaClO 4 . As a reductant, the NaClO 4 solution contained 50 mM of ethanol. The effluent NaClO 4 concentration was monitored using a perchlorate ion selective electrode (i.e. nitrate ion selective electrode) which has previously been shown to respond to ClO 4 − more strongly than to NO 3 − . 22 Using this electrode, ClO 4 − concentrations between 0.2 and 20 ppm were accurately determined.
Reaction kinetics for the reduction of NaClO 4 were studied as a function of flow rate and temperature. At each temperature, the effluent NaClO 4 concentration (C) was determined for different flow rates (Q). The residence time within the reactor (reactor space-time, τ) was determined according to the following (l), τ = V r φ Q ( 1 )
where φ is the fractional void volume of the packed catalyst bed and V r is the reactor volume. Since a twenty fold stoichiometric excess of ethanol was used during these runs, the reaction becomes zero order with respect to the reductant and was determined to be first order with respect to NaClO 4 . The rate constant (k) for a psuedo first order reaction in a plug flow reactor are given by the following (2):
C=C o e −kτ (2)
Equation 2 was derived from the resulting (C, τ) ordered pairs using the Levenberg-Marquardt method. 23 . Correlation coefficients (r 2 ) for the derived rate constants were calculated using a linear regression of experimentally observed concentrations versus those calculated from Equation 2. At least four data points were gathered for each temperature of operation.
Reaction kinetics experiments were conducted at three temperatures. Rate constants, which are shown as functions of temperature were then fitted to the Arrhenius expression as (1/T, ln k) ordered pairs using a least squares approximation to a linear equation, are given by the (3), k = Ae E a RT ( 3 )
where T is the temperature in degrees Kelvin, E a is the Arrhenius activation energy, R is the gas constant, and A is the pre-exponential factor determined from the slope and intercept, respectively.
The reaction kinetic experimental results at 60° C., 70° C., and 80° C. are shown in FIGS. 2-4, respectively. The flow rates were varied between 1.0 and 18.6 mL/min corresponding to reactor space times between 17 and 330 seconds. Good pseudo first order reaction kinetics were obtained for these reaction conditions. A 97 to 99.8% lowering of the influent NaClO 4 concentration was realized over this temperature range. The logarithms of each reaction rate constant were then plotted as a function of the reciprocal of the absolute temperature (° K. −1 ) producing an excellent linear fit as shown in FIG. 5 . Based on the slope of this line, the Arrhenius activation energy was determined to be 49.12 kJ/mole (11.74 kcal/mole) with a pre-exponential factor of 5.74×10 5 sec −1 . Based on these data, the extent of perchlorate reduction can be controlled by a combination of temperature and reactor residence time. Using a properly designed APCAR process, the elimination of perchlorates from ground and surface waters or a variety of waste waters is achievable by adjustment of temperature and catalyst contact time.
For example, a 200 μg/L perchlorate level in water can be lowered to below the provisional RfD) (i.e., 6 μg/L) at 60° C. after contact with the catalyst for 3 minutes. As the concentration of perchlorate increases and/or the solution composition changes, the reaction temperature and catalyst contact time can be adjusted to destroy perchlorate, reducing the concentration to acceptable values. At very low perchlorate levels significant destruction can be achieved at very low temperature.
The reduction of nitrate was evaluated in the same reactor system using ethanol as the reductant. This system was challenged with 20 mg/L solution of NO 3 − (as NaNO 3 ) containing 20 mg/L of ethanol at 80° C. The flow rate was varied between 0.5 and 10 mL/min corresponding to reactor space times between 42 and 942 seconds. Good pseudo first order kinetics were obtained over these reaction conditions. The results are shown in FIG. 6 . The pseudo first order reduction rate was 0.0114 sec −1 . Under these conditions, a 95% reduction of the nitrate concentration can be achieved in ˜260 seconds.
The reduction of 30.6 mg/L of NaNO 3 with 20 mg/L of ethanol as reductant was investigated at 100° C. FIG. 7 shows the destruction of nitrate as a function of reactor space time. The reaction rate determined from this curve was 0.0214 sec −1 . A 95% reduction of the nitrate concentration at 100° C. requires 140 seconds. Using the data at 80° and 100° C., the Arrhenius activation energy for this reaction is 34.5 kJ/mole (8.25 kcal/mole) with a pre-exponential factor of 1,445 sec −1 . Adjustment of either reaction temperature or the catalyst bed size can be used to ensure that the destruction of nitrate in a wide variety of water samples will meet regulatory limits as required.
These reduction data have demonstrated that both perchlorate and nitrate can be destroyed in water by the APCAR process using a non-toxic organic reductant such as ethanol in conjunction with high activity oxidation-reduction catalyst PRZr51 manufactured by Umpqua Research Company of Myrtle Creek. Furthermore, this can be accomplished at relatively low temperature with a variety of other reductants. Clearly, such a unit operation can be integrated into current drinking water or waste water treatment systems in a straightforward manner.
In experiments investigating reductants other than organic species, the APCAR system shown in FIG. 1 utilized hydrogen gas as the reductant. The introduction of dissolved hydrogen into the process stream is accomplished from a pressurized gas source via a membrane saturator or by direct injection. In the experimental apparatus, a membrane saturator is used. The concentration of dissolved hydrogen depends on the hydrogen pressure according to Henry's Law as shown in (4), H k = pH 2 χ ( 4 )
where χ is the mole fraction of hydrogen in water, pH 2 is the hydrogen pressure in atmospheres, and H k is the Henry's Law Constant. Since the χ is independent of temperature, the hydrogen pressure needed to maintain a fixed χ is dependent only on the Henry's Law Constant. At room temperature, the Henry's Law Constant for hydrogen is 77,600. Since Henrys Law Constant increases with temperature reaching a maximum at ˜90° C., the reactor pressure must exceed the equilibration pressure to maintain a single phase.
The stoichiometry for the reaction between hydrogen and perchlorate is given by (5).
ClO 4 − +4H 2 →Cl − +4H 2 O (5)
Based on a 40 mg/L NaClO 4 concentration, a 35 psig (3.38 atm) hydrogen pressure at 22° C., and the complete conversion of perchlorate to chloride, a two fold excess of hydrogen was used during these runs. In the presence of excess hydrogen, the reaction becomes zero order with respect to the reductant and first order with respect to NaClO 4 .
The reaction kinetic experimental results at 80° C., 90° C., and 100° C. are shown in FIGS. 8-10, respectively. The flow rates were varied between 1.3 and 16.6 mL/min, corresponding to reactor space times between 29 and 369 seconds. Good pseudo first order reaction kinetics were obtained for these reaction conditions. The pseudo first order reaction rate constants were 0.0051, 0.0102, and 0.0207 sec −1 at 80°, 90°, and 100° C., respectively. These values are lower than those obtained using ethanol as the reductant (i.e., 0.0116, 0.0185, and 0.0317 sec −1 at 60°, 70°, and 80° C., respectively). The logarithms of each reaction rate constant were then plotted as a function of the reciprocal of the absolute temperature (° K −1 ) producing an excellent linear fit as shown in FIG. 11 . Based on the slope, the Arrhenius activation energy was determined to be 80.5 kJ/mole (19.24 kcal/mole) with a pre-exponential factor of 4.09×10 9 sec −1 .
When the PRZr51 catalyst was tested at 100° C., the reduction of NaClO 4 was considerably slower. The pseudo first order reaction rate constant was 0.0051 sec −1 . This is equivalent to the PRZr51+2% Pd catalyst at 80° C. Clearly, the presence of palladium increases the reduction rates of NaClO 4 using hydrogen as the reductant. The enhanced reaction rates are attributed to the availability of hydrogen at reduction sites due to the enhanced solubility of hydrogen in palladium.
In experiments investigating inorganic reductants other hydrogen, the APCAR system 40 shown in FIG. 14 . System 40 comprises a influent reservoir 41 from which an contaminant-containing aqueous feed stream is transferred by pump 42 into preheater 43 , and in turn into reactor 44 . Themocouples 45 read the inlet temperature into the preheater 43 and the outlet temperature exiting reactor 44 . The inlet and outlet temperatures are regulated by temperature controllers 46 which in turn run the power controllers/resistive heating elements 47 . A secondary regulator 48 controls the flow of product effluent from the reactor 44 which collects in effluent reservoir 49 . System 40 utilizes ammonium chloride, NH 4 Cl, as the reductant. Balancing the oxidation-reduction reaction between sodium perchlorate, NaClO 4 , and NH 4 Cl yields (6),
3NaClO 4 +8NH 4 Cl→4N 2 +3NaCl+8HCl+12H 2 O (6)
After passage through the reactor 4 , pH is lowered and perchlorate is reduced to chloride. The reactor 4 contains 20 cm 3 of the PRZr51 catalyst.
The influent contained 50 mg/L NaClO 4 concentration and 330 mg/L NH 4 Cl concentration. Assuming a complete conversion of perchlorate to chloride, a five fold excess of ammonium was used during these runs. In the presence of excess ammonium, the reaction becomes zero order with respect to the reductant.
The reaction kinetic experimental results at 120° C. and 130° C. are shown in FIGS. 12 and 13, respectively. The flow rates were varied between 0.71 and 4.62 mL/min, corresponding to reactor space times between 104 and 676 seconds. Good zero order reaction kinetics with respect to perchlorate reduction were obtained for these reaction conditions. The pseudo zero order reaction rate constants are 0.1184 and 0.1808 mg L −1 sec −1 at 120° and 130° C., respectively.
The oxidation-reduction catalyst used in these experiments, designated as PRZr51, is composed of 2 weight % platinum and 0.5 weight % ruthenium on a zirconia support. The preparation of this high activity reduction catalyst involves the homogeneous adsorption of aqueous ions containing ruthenium and platinum onto a zirconium oxide (i.e., ZrO 2 ) support. Other catalysts that are effective at oxidizing aqueous organic species using molecular oxygen should exhibit similar reduction behavior, since like PRZr51, they are all effective at reducing molecular oxygen and other oxygen sources using a variety of organic contaminants as a reductant. Other catalysts which should behave in this manner include platinum and ruthenium on supports such as activated carbon, titanium dioxide, silicon dioxide, and other transition metal oxides. Platinum alone and combinations of palladium have also been shown to function as effective oxidation catalysts. In particular, the addition of 2.0 weight % palladium to PRZr51 provided excellent performance when hydrogen was utilized as the reductant.
The development of a heterogeneous catalyst and a process that can efficiently utilize organic contaminants as a reductant to destroy perchlorate or nitrate at moderate temperatures and pressures is unique. Due to the extremely high activity of the PRZr51 catalyst, the reduction reaction occurs rapidly at 80° C. The reduction of inorganic species requires a catalyst, a reductant, and sufficient reaction temperature to drive the reaction forward. The PRZr51 catalyst will eliminate inorganic contaminants from drinking water supplies and also reduce the concentration of organic contaminants in the process.
This innovative technology is uniquely suited to environmental remediation. The utilization of organic contaminants as a reductant by an advanced catalytic reduction technology using this new heterogeneous catalyst provides the basis for a water reclamation system capable of processing highly contaminated water. Perchlorate or nitrate/nitrite contaminants in a variety of waters can be processed at low temperature and pressure. The PRZr51 catalyst has been shown to promote the rapid reaction of both NaClO 4 , NH 4 ClO 4 , and NaNO 3 using a variety of reductants at temperatures between 60° and 80° C. These moderate treatment conditions reduce energy consumption and translate directly into the potential for economies in size, weight, and power.
In the case of perchlorate, the APCAR process can treat water at temperatures below 80° C. where the reaction occurs rapidly. The chief by-products are innocuous inorganic chlorine compounds, carbon dioxide, and water. The small amount of reductant required to destroy the 10 and 100 μg/L of perchlorate typically found in contaminated water is satisfied by the intrinsic organic levels of this water. Processing of more highly contaminated water with perchlorate levels greater than 5000 μg/L will require the addition of a reducing agent such as ethanol, sugar, or acetic acid. The APCAR system can operate as a self-contained process within a drinking water plant or at a wastewater treatment facility. The APCAR system eliminates perchlorate from drinking water or other contaminated water, does not produce a secondary more highly concentrated contaminant stream, and as an added benefit, reduces the concentration of organic contaminants.
In the case of nitrate/nitrite, the APCAR process can also treat water at low temperatures. The chief by-product is nitrogen gas, carbon dioxide, and water. The amount of reductant required to treat contaminated water depends on the contamination level which for nitrate/nitrite will be highly variable depending on the water's source. In general, due to the more typical level of nitrate/nitrite contamination (≧10 mg/L), a reducing agent such as ethanol, sugar, or acetic acid will be needed albeit at low levels since background orangic levels in water will exhibit insufficient reducing capacity. As with perchlorate, the APCAR system will eliminate nitrate/nitrite without producing a secondary waste stream.
The end products for the reduction of perchlorate depends on the reductant, the catalyst, and the reaction conditions. For example, when ethanol is oxidized to carbon dioxide (CO 2 ) in the presence of sodium perchlorate (NaClO 4 ), several reactions are possible. This is shown in (7) through (9), where the formation of the more reduced forms of chlorine (i.e., chlorate, hypochlorite, and chloride) results in the more effective use of ethanol as a reducing agent.
CH 3 CH 2 OH+6NaClO 4 →2CO 2 +6NaClO 3 +3H 2 O (7)
CH 3 CH 2 OH+2NaClO 4 →2CO 2 +2NaOCl+3H 2 O (8)
CH 3 CH 2 OH+1.5NaClO 4 →2CO 2 +1.5NaCl+3H 2 O (9)
The catalyst plays an important role in determining the reduction by-products. In the case of the PRZr51 catalyst, a high chloride residual determined by precipitation with AgNO 3 coupled with very low free chlorine residuals determined by method SM4500Cl 24 indicates that chloride is the chief by-product of NaClO 4 reduction.
In the case of nitrate, (10) and (11) show similar to produce nitrite or nitrogen. The absence of NO 3 − or NO 2 − in the effluent from NaNO 3 reduction (EPA 300.0) indicates that N 2 (g) is the chief by-product formed by the reaction th ethanol. 25
CH 3 CH 2 OH+12NO 3 − →12NO 2 − +2CO 2 +3H 2 O (10)
5CH 3 CH 2 OH+12NO 3 − →6N 2 +10CO 2 +12OH − (11)
The following are the references cited above regarding the scope of the for perchlorate and nitrate problem, the health risks, and previous technologies used for perchlorate and nitrate/nitrite destruction.
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RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 10/222,953, now U.S. Pat No. 7,206,776, filed on Aug. 15, 2002, entitled “Priority Differentiated Subtree Locking,” and naming Zoltan Szilagyi et al. as inventors, which application is incorporated entirely herein by reference.
FIELD OF THE INVENTION
Aspects of the present invention are directed to a locking mechanism for locking resources in a data structure, such as a tree data structure. More particularly, aspects of the present invention are directed to a locking technique that differentiates locks based on their priority, in order to avoid deadlocks.
BACKGROUND OF THE INVENTION
Computers arrange data into organized structures, so that the data can be easily located and accessed. One type of commonly-used data structure is the tree structure. With this structure, related pieces of data form individual nodes in the tree. Each node (except for the root node) will have only a single parent node, but may have a plurality of sibling nodes and a plurality of child nodes. Conventionally, a node A is referred to as a descendant of node B if node A's parent is node B, or if node A's parent is a descendant of node B. Similarly, node A is referred to as an ancestor of node B if node B is a descendant of node A.
FIG. 1 graphically illustrates how a tree structure can be used to organize information.
More particularly, this figure illustrates how a tree structure can be used to organize data relating to electronic ink, so that the ink can be manipulated by a user or recognized by a recognition function of an application. Electronic ink may be made up of strokes, with each stroke corresponding to, for example, movement of a pointing device. Each stroke includes information defining the properties of the stroke, such as the data points making up the stroke, a directional vector of the stroke, a color of the stroke, and a thickness at which the stroke is to be rendered on a display.
While strokes can be individually manipulated, it generally is more efficient to first organize strokes before manipulating them. Thus, a parser may be used to establish relationships between individual strokes, and then organize the strokes into larger units for editing or handwriting recognition. For example, a parser may be used to associate groups of related strokes together into units that form a word. Similarly, the parser may associate groups of one or more words together to form a line, and associate groups of one or more lines together to form a block or paragraph. The parser may then associate groups of one or more blocks or paragraphs together to form a single page or a document.
A parser typically will need to analyze electronic ink several times to produce a tree structure that accurately represents the relationships between the electronic ink strokes. Moreover, each time that the electronic ink is edited, the parser will need to update the tree. The parser may therefore need to operate frequently and for prolonged periods of time. To avoid having the parser constantly interfere with active software applications each time that it needs to refine the tree structure, the parser may instead continuously operate in the background with some environments.
FIG. 1 illustrates a tree structure 101 representing the results that might typically be provided by a parser. The tree 101 includes word nodes 103 a , 103 b , 103 c , 103 d , 103 e , 103 f , 103 g , and 103 h . Each word node 103 a , 103 b , 103 c , 103 d , 103 e , 103 f , 103 g , and 103 h contains data for the individual strokes that make up a corresponding word W. More particularly, if the parser has determined that a group of strokes make up a word W, then the data for those strokes are contained in (or referenced by) the word nodes 103 a , 103 b , 103 c , 103 d , 103 e , 103 f , 103 g , and 103 h representing the word W.
If multiple words W are associated by the parser with a single line L, then the word nodes 103 a , 103 b , 103 c , 103 d , 103 e , 103 f , 103 g , and 103 h for the words W are arranged as children of a line node 105 a , 105 b , 105 c , 105 d , and 105 e corresponding to the line L. The line nodes 105 a , 105 b , 105 c , 105 d , and 105 e may include data common to all of its children, such as the color or thickness of the ink making up the words W in the line L. Line nodes 105 a , 105 b , 105 c , 105 d , and 105 e , corresponding to lines L that the parser has associated into a block B, are then arranged as children of a block node 107 a , and 107 b corresponding to the block B. The block nodes 107 a , and 107 b in turn serve as children of a page node 109 , which, in the illustrated example, is the root node for the tree 101 . Of course, if the parser recognized multiple page boundaries, then the page node 109 might itself be a child of a root node corresponding to the entire document.
A number of different program threads may seek to concurrently access the information provided in the tree 101 . For example, if a user is editing the electronic ink with a notetaking application, then the notetaking application will employ a user interface thread that changes the organization of the tree 101 to correspond with the user's edits. Thus, the user interface thread will attempt to execute read or write operations on one more nodes of the tree 101 . On the other hand, the notetaking application will also employ a parser thread that may be continually refining the structure of the tree 101 in the background, as noted above. The parser thread may thus also attempt to execute a read or write operation on one or more nodes of the tree 101 at the same time as the user interface thread. Of course, other software applications may also employ threads that could concurrently attempt to access one more nodes of the tree 101 for various reasons.
Moreover, even a single software thread may attempt to sequentially execute one or more read or write operations on one or more nodes of the tree 101 . For example, in order to move a word W to a line L, the user interface thread may need to execute a read operation on the line node 105 a , 105 b , 105 c , 105 d , or 105 e corresponding to the line L, and execute a write operation on the subtree formed by the word node 103 a , 103 b , 103 c , 103 d , 103 e , 103 f , 103 g , and 103 h corresponding to the word W.
As will be appreciated by those of ordinary skill in the art, it would be very undesirable to allow different threads to concurrently execute conflicting read or write operations on the same node. Accordingly, a thread seeking to access a node of a data structure must first initiate a “lock” on that node, to prevent a conflicting read or write operation of another thread from being executed on that node before its own read or write operation is complete. While the use of locks prevents conflicting read or write operations from concurrently executing on the same node, it creates new problems that can potentially stop the operation of the computer.
For example, referring to FIG. 2 , a user interface thread may act to move a word W corresponding to the subtree 201 into the line L represented by the line node 203 , as graphically illustrated by the dotted line 205 . To complete this task, the user interface thread must request a write lock on the subtree 215 . The user interface thread would then also request a write lock on the subtree 207 (that is, the subtree that includes the line node 203 ). Similarly, the parser thread may act to move the word W corresponding to the subtree 209 into the line L represented by the line node 211 , as graphically illustrated by the dotted line 213 . In order to complete its task, the parser thread would request a write lock on the subtree 207 , and request another write lock on the subtree 215 (that is, the subtree that includes the line node 211 ).
A problem arises if, for example, the user interface thread obtains a write lock on the subtree 215 , but cannot obtain a write lock on the subtree 207 before the parser thread obtains a write lock on the subtree 207 . In this situation, the user interface thread will wait for access to the subtree 207 until the parser thread's lock on the subtree 207 is lifted. The parser thread, however, will maintain its write lock on the subtree 207 until it can acquire a write lock on the subtree 215 . Because the user interface thread will maintain its lock on the subtree 215 until it can also obtain a lock on the subtree 207 , both the user interface thread and the parser thread will reach a deadlock. That is, neither the user interface thread nor the parser thread will be able to complete its task until the other finishes. This situation will effectively stop the operation of both the user thread and the parser thread, and may even impact the operation of other software applications being run by the computer.
One solution to this problem is to allow a single software thread to obtain a lock on the entire data structure. Thus, the user interface thread would be able to obtain a lock on the entire tree 101 . The user interface thread could then execute read and write operations as necessary, without interference from other threads. While this solution avoids the problem of deadlocks between different threads, it reduces the performance of other operations requiring access to the data structure. That is, allowing only one thread to use the data structure at any given time unnecessarily delays the operation of other threads that need the information in the data structure. For example, if the parser thread obtains a lock to the entire tree 101 in order to access the subtree 201 , then the user interface thread may not simultaneously access the subtree 217 , even though accessing the subtree 217 would not interfere with the parser thread's access to the subtree 201 . Instead, the user interface thread must first wait for the parser thread to release the lock on the entire tree 101 before it can access the subtree 217 , which may substantially delay the operation of the user interface thread.
Another solution to avoid deadlock is to allow a thread executing a write operation to obtain a lock on the entire data structure, while permitting different threads executing read operations to obtain concurrent locks. With this arrangement, a thread attempting to execute a write operation must either wait until all currently executing read operations are completed, or preempt (that is, prematurely end) the executing read operations. Thus, this solution also unnecessarily reduces the performance of operations requiring access to the data structure.
In addition to avoiding unnecessary performance reduction, it may actually be desirable to allow multiple threads to concurrently execute both read and write operations on a data structure. For example, as noted above, it may be useful to have the parser thread invisibly operate as a background process, even while the user is employing the user interface thread to manipulate the electronic ink. If the parser thread cannot execute both read and write operations on the tree 101 concurrently with, for example, the user interface thread, then the parser thread may noticeably prevent or delay the user interface thread from executing write operations.
It thus would be desirable to have a locking system that prevents deadlocks from occurring between different threads, but which does not unnecessarily reduce the performance of those threads. More particularly, it would be desirable to have a locking system for a data structure that allows different threads to concurrently obtain locks on different nodes of the data structure for both read and write operations.
SUMMARY OF THE INVENTION
Advantageously, various aspects of the invention provide a locking arrangement for data structures that prevent deadlocks, but which still allows different threads to simultaneously obtain locks on different nodes of a data structure for both read and write operations. The locking system according to the invention differentiates locks based on a priority hierarchy. The locking system will fail a request to lock one or more resources in a data structure if those resources have already been locked with a non-preemptable, conflicting lock of an equal or higher priority.
More particularly, if a preemptable lock with a lower priority has locked the resources, then the locking system will preempt the lower priority lock in favor of a conflicting higher priority lock. Alternately, if a non-preemptable lock with a lower priority has locked the resources, then the locking system will wait until the lower priority lock is removed before implementing a requested conflicting higher priority lock. Thus, high priority threads that require higher performance and efficiency, such as user interface threads, may receive preferential access to a data structure without preventing lower priority threads, such as a parser thread operating as a background process, from accessing the data structure. In addition, the locking technique still prevents deadlocks from occurring between different threads.
These and other features and aspects of the invention will be apparent upon consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 show a schematic diagram of a tree data structure for organizing data relating to an electronic ink document.
FIG. 3 shows a schematic diagram of a general-purpose digital computing environment that can be used to implement various aspects of the invention.
FIG. 4 shows a locking system for providing access to a data structure according to an embodiment of the invention.
FIG. 5 illustrates a flowchart showing a process for implementing a locking technique according to an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Introduction
A locking system according to the invention differentiates locks based on a priority hierarchy. Some embodiments of the invention may also distinguish locks for two types of operations on a data structure: a write operation and a read operation. A lock for a write operation (sometimes referred to as a “write lock”) by one thread will prevent any other operation by another thread from obtaining a lock on the locked up resources. A lock for a read operation (sometimes referred to as a “read lock”) by one thread will then prevent a write lock from being obtained on the locked up resources by another thread.
Thus, two concurrent write locks from different threads to the same resources will conflict with each other, as the modification of the resources by the write operation of one thread will affect the results produced by the write operation of the other thread.
Likewise, a concurrent write lock and a read lock from different threads on the same resources will conflict with each other for the same reason.
Two concurrent read locks, even to the same resources and from different threads, typically will not conflict. That is, because the execution of one read operation will usually not interfere with the results obtained by another read operation, then a locking system may classify all concurrent read locks, regardless of their source, as non-conflicting in order to optimize access to the data structure. If, however, a thread does employ read operations that may interfere with the read operations of another thread, then two concurrent read locks from different threads to the same resources may also be considered conflicting locks. Alternately, a locking system may forego efficiencies obtained by distinguishing read locks from write locks, and simply treat all locks as conflicting.
In addition to locking the resources specified in a lock request, a lock may also restrict access in some way to other resources. For example, with a tree data structure, operations on a given node may advantageously be applied to all of that node's descendants. This frees a thread from having to obtain a separate lock each time that it accessed a different node in a subtree. Moreover, this facilitates consistently applying an operation to an entire subtree. Similarly, an operation on a node should also be respected on any of the nodes in the chain of parents leading from a locked node to the root of the entire tree. For example, if one thread executes a write operation on a child node while another thread executes a read operation on a parent node, then the results of the read operation may be invalid.
Thus, with some embodiments of the invention, a lock on a node will also prevent a conflicting lock from being obtained on both ancestors of that node and descendants of that node. More particularly, for some embodiments of the invention, a lock on a specified node will also lock all of its descendants (that is, the subtree of nodes defined by taking the specified node as the root node), and prevent conflicting locks from being obtained on the ancestors of the specified node. With other embodiments of the invention, however, a lock on a specified node may simply prevent conflicting locks from being obtained on the ancestors or descendants of the specified node.
By differentiating locks according to priority, the locking system of the invention will prevent a request for a lock from waiting for resources that are already locked up by a lock with an equal or higher priority. This allows different threads to concurrently access different portions of a data structure without causing a deadlock, as will be explained in detail below.
Exemplary Operating Environment
As will be appreciated by those of ordinary skill in the art, a locking technique according to the invention may be implemented using software. That is, a locking system according to the invention may be described in the general context of computer-executable instructions, such as program modules, executed by one or more computing devices. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Typically the functionality of the program modules may be combined or distributed as desired in various embodiments.
Because the invention may be implemented using software, it may be helpful for a better understanding of the invention to briefly discuss the components and operation of a typical programmable computer on which various embodiments of the invention may be employed. FIG. 3 illustrates an example of a computing device 301 that provides a suitable operating environment in which various embodiments of the invention may be implemented. This operating environment is only one example of a suitable operating environment, however, and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Other well known computing systems, environments, and/or configurations that may be suitable for use with the invention include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
The computing device 301 typically includes at least some form of computer readable media. Computer readable media can be any available media that can be accessed by the computing device 301 . By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, punched media, holographic storage, or any other medium which can be used to store the desired information and which can be accessed by the operating environment 301 .
Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism, and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above should also be included within the scope of computer readable media.
With reference to FIG. 3 , in its most basic configuration the computing device 301 typically includes a processing unit 303 and system memory 305 . Depending on the exact configuration and type of computing device 301 , the system memory 305 may include volatile memory 307 (such as RAM), non-volatile memory 309 (such as ROM, flash memory, etc.), or some combination of the two memory types. Additionally, device 301 may also have mass storage devices, such as a removable storage device 311 , a non-removable storage device 313 , or some combination of two storage device types. The mass storage devices can be any device that can retrieve stored information, such as magnetic or optical disks or tape, punched media, or holographic storage. As will be appreciated by those of ordinary skill in the art, the system memory 305 and mass storage devices 311 and 313 are examples of computer storage media.
The device 301 will typically have one or more input devices 315 as well, such as a keyboard, microphone, scanner or pointing device, for receiving input from a user. The device 301 will typically also have one or more output devices 317 for outputting data to a user, such as a display, a speaker, printer or a tactile feedback device. Other components of the device 301 may include communication connections 319 to other devices, computers, networks, servers, etc. using either wired or wireless media. As will be appreciated by those of ordinary skill in the art, the communication connections 319 are examples of communication media. All of these devices and connections are well know in the art and thus will not be discussed at length here.
A Data Structure System
FIG. 4 illustrates a data structure system 401 according to one embodiment of the invention. As shown in this figure, the data structure system 401 communicates with one or more threads 403 - 407 . More particularly, the threads 403 - 407 request access to information resources maintained by the data structure system 401 . In the illustrated embodiment, each of the threads 403 - 407 is generated by the same software application, but two or more of the threads 403 - 407 may alternately be generated by different software applications.
The data structure module 409 maintains information in the data structure 411 . The data may be any type of information such as, for example, data relating to an electronic ink document. It should be noted that, while FIG. 3 schematically illustrates the data structure 411 as a tree structure, the data structure module 409 may also maintain data in an alternate structure of any desired typed or configuration. The data may physically be stored in the system memory 305 , the removable storage 311 , the non-removable storage 313 or a combination thereof using, for example, any suitable database software application.
The data structure system 401 also includes a lock request evaluation module 413 . The lock request evaluation module 413 receives requests to access one or more resources of the data structure 405 from the threads 403 - 407 . Typically, a request to access resources will identify the node (or nodes) for which access is requested (sometimes referred to hereafter as the “requested node”), and the type of access requested (that is, whether the thread will access the requested node with a read operation or a write operation). The access request will also include a request to lock the requested node, along with a priority for the requested lock. In addition, the access request may specify whether the requested lock will be a preemptable lock or a non-preemptable lock.
In response to receiving a lock request, the lock request evaluation module 413 determines whether the lock request will succeed or fail. If the lock request evaluation module 413 decides to approve a requested lock, it then passes the lock request to the lock maintenance module 415 . The lock maintenance module 415 tracks existing locks. Thus, when the requested node becomes available, the lock maintenance module 415 will initiate the requested lock so that the thread can obtain the specified access to the requested node. The lock maintenance module 415 will then keep track of the new lock as well.
Operation of the Data Structure System
The operation of the lock request evaluation module 413 and the lock maintenance module 415 will now be discussed in more detail with reference to the flowchart illustrated in FIG. 5 . In step 501 , a thread 403 , 405 or 407 submits a request to access one or more resources (for example, to access to a subtree) in the data structure 409 . The access request identifies the resources for which access is requested, and the type of access requested. That is, the access request will specify whether the access is to execute a read operation or a write operation. It will also request a lock on the root node of the subtree, along with a priority for the lock.
Upon receiving a lock request, the lock request evaluation module 413 first determines if the requested lock is a write lock. If the requested lock is not a write lock (that is, if the requested lock is a read lock), then in step 505 the lock request evaluation module 413 determines if access to the requested node has been restricted by a conflicting lock. That is, the lock request evaluation module 413 determines if there is an existing write lock on the requested node. The lock request evaluation module 413 also determines if there are any conflicting write locks on any of the ancestors or descendants of the requested node that would prevent a write lock from being obtained on the requested node. As previously noted, a write operation on a node by one thread may also affect the results of a read or write operation on an ancestor or descendant of that node by another thread. Accordingly, while the ancestors or descendants of the node may not be identified in the read lock request, the lock request evaluation module 413 also determines if a conflicting write lock has already been obtained for these resources. Thus, the lock request evaluation module 413 determines if the requested lock will conflict with an existing lock that would restrict access to any of the requested resources.
If none of the requested node, its ancestors and its descendants have been locked up by a conflicting lock, then the lock request evaluation module 413 immediately approves the requested lock in step 507 , and passes the approved lock request onto the lock maintenance module 415 . If the requested node, one of its ancestors or one of its descendant has already been locked by a conflicting write lock, however, then the lock request evaluation module 413 determines if the priority of the requested read lock is a high priority in step 509 . With the illustrated embodiment of the invention, the lock request evaluation module 413 recognizes only two priorities of locks, high and low. Accordingly, if the priority of the requested read lock is not high, it must be low, and thus equal to or lower than the priority of the conflicting write lock on the requested lock, its ancestor or descendant. As a result, the lock request evaluation module 413 fails the requested lock in step 511 .
If, however, the requested read lock has a high priority, then in step 513 the lock request evaluation module 413 checks to confirm that all of the conflicting write locks on the requested node, its ancestors and its descendants are low priority. If one of these conflicting write locks are high priority, then again the requested read lock is equal to this conflicting high priority write lock, and the requested read lock is failed in step 511 . If all of the conflicting write locks on the requested node, its ancestors and its descendants are low priority (and thus lower in priority than the requested read lock), then in step 515 the lock request evaluation module 413 will approve the requested read lock. In step 517 , the lock request evaluation module 413 passes the requested read lock onto the lock maintenance module 415 , which notes that the requested read lock is waiting for the existing conflicting write locks to complete and should be implemented when these locks are completed.
Returning now to step 503 , if the lock request evaluation module 413 determines that a thread has requested a write lock (that is, that the requested lock will conflict with any existing lock from another thread), then in step 519 the lock request evaluation module 413 determines if there are any conflicting non-preemptable read locks or write locks that would restrict access to the requested node. That is, the lock request evaluation module 413 determines if there is an existing conflicting lock on the requested node. It also determines if there are any existing, conflicting non-preemptable read locks or write locks on the ancestors or descendants of the requested node. If there are not (that is, if there are no existing locks or if the only existing locks are preemptable), then in step 521 the lock request evaluation module 413 voids any existing preemptable read locks on the requested nodes, its ancestors and its descendants. Then, in step 507 , it approves the requested write lock and passes the requested write lock onto the lock maintenance module 415 to be implemented.
If, however, there is one or more conflicting non-preemptable read locks or write locks on a requested node, one of its ancestors or one of its descendants, then in step 523 the lock request evaluation module 413 determines if any of these conflicting locks has a high priority. Again, because the lock request evaluation module 413 in this embodiment only recognizes two priorities, if any of these conflicting locks has a high priority, then the priority of the requested lock must be equal to or lower than the priority of these conflicting locks. Thus, in step 511 , the lock request evaluation module 413 fails the requested write lock.
On the other hand, if none of the conflicting locks on the requested node, its ancestors or its descendants has a high priority, then in step 525 the lock request evaluation module 413 determines the priority of the requested write lock. If it is low, then again it must be equal to the priority of the conflicting locks, and is failed in step 511 . If, however, the priority of the requested write lock is high, it is greater than the priority of any conflicting lock on the requested node, its ancestors and its descendants, and in step 515 the lock request evaluation module 413 will approve the requested read lock. In step 517 , the lock request evaluation module 413 passes the requested read lock onto the lock maintenance module 415 to be implemented when the existing conflicting write locks are completed.
In the illustrated embodiment, the locking system uses only two priorities. It should be noted, however, that other embodiments of the invention may employ a priority hierarchy with any number of desired priorities. As in the embodiment described above, with these alternate embodiments of the invention a requested lock will not wait on a conflicting, non-preemptable lock of equal or higher priority. For example, if the locking system according to the invention employed three priorities, high, medium and low, then a lock request for a medium priority lock would not wait for an existing conflicting lock with a high or medium priority to complete, but would wait for an existing conflicting lock with a low priority to complete. Similarly, a lock request for a high priority lock would not wait for an existing conflicting lock with a high priority to complete, but would wait for an existing conflicting lock with a medium or low priority to complete. Of course, the implementation of still greater numbers of different priorities will be apparent from the foregoing description.
In the foregoing illustrated embodiment, any write lock will preempt a preemptable lock, regardless of the relative priority of the different locks. It should be appreciated, however, that alternate embodiments of the invention may only allow a write lock to preempt a preemptable read lock of lower priority. Also, it should be noted that, to facilitate an understanding of the invention, the invention has been explained above with particular emphasis on prioritizing locks between different threads of a single software application. As will be appreciated by those of ordinary skill in the art from the foregoing description, however, the invention may also be employed to prevent lock conflicts between threads of different software applications. Still further, while the above discussion of the invention distinguishes locks for read operations from locks for write operations, various embodiments of the invention need not make that distinction. Instead, as previously noted, these embodiments of the invention may characterize all locks from different threads as conflicting locks.
Conclusion
Although the invention has been defined using the appended claims, these claims are exemplary in that the invention may be intended to include the elements and steps described herein in any combination or sub combination. Accordingly, there are any number of alternative combinations for defining the invention, which incorporate one or more elements from the specification, including the description, claims, and drawings, in various combinations or sub combinations. It will be apparent to those skilled in the relevant technology, in light of the present specification, that alternate combinations of aspects of the invention, either alone or in combination with one or more elements or steps defined herein, may be utilized as modifications or alterations of the invention or as part of the invention. It may be intended that the written description of the invention contained herein covers all such modifications and alterations. For instance, in various embodiments, a certain order to the data has been shown. However, any reordering of the data is encompassed by the present invention. | 4y
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RELATED APPLICATIONS
This is a divisional application of U.S. patent application Ser. No. 10/459,113, filed Jun. 10, 2003, which is a continuation of U.S. patent application Ser. No. 09/560,670, filed Apr. 27, 2000, now U.S. Pat. No. 6,578,004, all incorporated by reference.
COPYRIGHT NOTICE
©2003-2005 ProSight, Ltd. A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR §1.71(d).
FIELD OF THE INVENTION
The present invention relates to the field of information management. More specifically, the present invention relates to management of Information Technology (IT) investments.
BACKGROUND INFORMATION
Ever since the invention of computer, enterprises, business or otherwise, have used computers to improve the productivity of their workers and efficiency of their business operations. In the beginning, enterprises tended to focus in a handful of high priority operation areas, such as financial management, general ledger, payroll and so forth. While these projects were often important, and the investments were not insignificant, the investment often represented only a small portion of the enterprises' investment in infrastructure or research and development, and the overall success of the enterprises was not perceived to be critically dependent on these projects. Accordingly, except perhaps for periodic briefing for management of the organizational units that were directly impacted, senior management were seldom involved, and management of these projects were typically relegated to data processing professionals, and managed in an ad hoc manner.
Over time, continuing advances in computer and other related technology, such as networking and telecommunication, have made it economically as well as technically feasible to make available computing power to virtually every single worker of an enterprise, and support virtually every aspect of an enterprise's operations. As a result, the number as well as the type of applications have broaden, from individual worker productivity, such as word processing, email, and the like, to mission critical operations, such as reservation and flight scheduling in the case of the airline industry. The typical size and scope of many of these applications have also increased. In fact, not only the success of increasing number of conventional business enterprises are increasingly dependent on the success of their IT projects, we have new business enterprises, such as Internet access providers, Internet portals, e-Commerce companies, emerging that are made possible by information technology, which otherwise would not have existed.
With the increase in significance as well as in amount of investment, increasingly senior management of these enterprises are actively involved in the management of their enterprises' investment in IT. Unfortunately, while the significance and the investment in IT have skyrocketed in recent years, little advances have been made in the area of managing IT. Project managers, mid-level managers as well as senior executives continue to rely on a hodgepodge of non-integrated or poorly integrated individual software applications such as spreadsheet and project management applications.
Thus, increasingly there are interest and desire in having automated tools to assist management of all levels to manage these ever more critical IT projects.
SUMMARY OF THE INVENTION
A method and apparatus to facilitate management of IT investments includes, in one embodiment, storing data associated with performance metrics of a number of information technology (IT) projects, generating a number of scorecards for a number of IT portfolios, using the stored data, with each scorecard showing where IT projects of an IT portfolio stand on the performance metrics, and each IT portfolio having a subset of the IT projects. The method/apparatus further includes generating one or more investment maps of the IT portfolios, using also the stored data, with each investment map showing at least where a subset of the IT portfolios stand on a number of performance metrics. The method/apparatus further includes facilitating navigation from an investment map to a corresponding one of the scorecards for a selected IT portfolio by a user of the investment map through selection of a representation of the IT portfolio.
In another embodiment, the method/apparatus further includes generating a number of dashboards for the IT projects, using also the stored data, with each dashboard graphically illustrating one or more aspects of at least one IT project. The method/apparatus further includes facilitating navigation from a scorecard to a corresponding one of the dashboards for a selected IT project by a user of the scorecard through selection of a representation of the IT project.
Additional aspects and advantages will be apparent from the following detailed description of preferred embodiments, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will be described by way of exemplary embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:
FIG. 1 illustrates an overview of the present invention, in accordance with one embodiment;
FIG. 2 illustrates an organization of project data of FIG. 1 , in accordance with one embodiment;
FIGS. 3 a - 3 c illustrate the dashboard, the scorecard and the investment map of FIG. 1 , in accordance with one embodiment each;
FIGS. 4 a - 4 c illustrate the relevant operational flows of the dashboard generator/viewer, the scorecard generator/viewer, and the investment map generator/viewer of FIG. 1 , in accordance with one embodiment each;
FIGS. 5 a - 5 b illustrate additional relevant operational flows of the investment map generator/viewer and the scorecard generator/viewer of FIG. 1 , in accordance with one embodiment each;
FIG. 6 illustrates a networking environment suitable for practicing the facilitation of IT management of the present invention, in accordance with one embodiment; and
FIG. 7 illustrates a computer system suitable for use as an IT executive, a portfolio manager or a project manager's computing device or a server of FIG. 6 , in accordance with one embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following description, various aspects of the present invention will be described. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some or all aspects of the present invention. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the present invention. However, it will also be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well known features are omitted or simplified in order not to obscure the present invention.
Parts of the description will be presented in terms of operations performed by a computer system, using terms such as data, flags, bits, values, characters, strings, numbers and the like, consistent with the manner commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. As well understood by those skilled in the art, these quantities take the form of electrical, magnetic, or optical signals capable of being stored, transferred, combined, and otherwise manipulated through mechanical and electrical components of the computer system; and the term computer system include general purpose as well as special purpose data processing machines, systems, and the like, that are standalone, adjunct or embedded.
Various operations will be described as multiple discrete steps in turn, in a manner that is most helpful in understanding the present invention, however, the order of description should not be construed as to imply that these operations are necessarily order dependent. In particular, these operations need not be performed in the order of presentation.
Referring now FIG. 1 , wherein a block diagram illustrating the integrated facilitation of IT management of the present invention, in accordance with one embodiment, is shown. As illustrated, in accordance with the present invention, data associated with IT projects 102 are collected and stored. More particularly, as will described in more detail below, project data 102 are associated with a number of performance metrics of IT projects. Also illustrated, in accordance with the present invention, “integrated” dashboard generator/viewer 112 , scorecard generator/viewer 114 and investment map generator/viewer 116 are provided to generate IT project dashboards 122 , IT portfolio scorecards 124 and IT investment mapsmap 126 respectively. IT project dashboards 122 are designed to assist IT project managers to manage their respective projects, whereas IT portfolio scorecards 124 are designed to assist “mid-level” IT portfolio mangers to manage their respective IT portfolios. IT investment map 126 in turn are designed to assist an IT executive (or its business partners) to manage the entire IT investment of his/her enterprise. More particularly, project dashboards 122 , portfolio scoreboards 124 and investment maps 126 are logically integrated (as denoted by arrows 132 and 134 ) to facilitate more in-depth understanding of issues surfaced by investment maps 126 and by scorecards 124 .
FIG. 2 illustrates an organization of project data 102 in accordance with one embodiment. As alluded to earlier, in accordance with the present invention, project data 102 are associated with performance metrics designed to show where IT projects stand. In one embodiment, the performance metrics are key performance categories (KPC). In one embodiment, these performance metrics (or KPC) include budget metrics, staffing metrics, project size and quality metrics, and progress metrics. In one embodiment, the budget metrics include expense to budget ratios for a number of expense categories, such as personnel expenses, overhead expenses and the like. In another embodiment, the staffing metrics include current staffing level to staffing requirement ratios for a number of staffing categories, such as senior analysts, software engineers with web design skills, software engineers with C++ programming skills, engineers with networking skills and the like. In yet another embodiment, project size and quality metrics include metrics measuring the quantity of code and documentation being developed, the amount of defects encountered or removed from these code and documentation. In yet another embodiment, the progress metrics includes metrics measuring a number of task completion to schedule milestone indicators for a number of project phases, e.g. feasibility phase, design phase, unit test phase, functional test phase and system test phase. In alternate embodiments, data may also be stored for other performance metrics (or KPC) in addition to or in lieu of some or all of the above enumerated example metrics/categories.
For the illustrated embodiment, project data 102 are stored in tables 202 of a relational database, with each table storing a subset of the data (in columns) for a subset of the projects (in rows). The data may be organized into the various tables in any one of a number of application dependent manner, taking into consideration the number projects, the number of performance metrics as well as other factors. In alternate embodiments, project data 102 may also be stored employing other data organization techniques, including but limited to flat files, hierarchical databases and the like. In one embodiment, historic data are also stored and maintained for some or all of the metrics for which data are being stored. In one embodiment, user annotations for all or selected ones of the metrics are also stored.
In one embodiment, the data to be stored, and whether historical and/or annotations are to be stored, are user defined. The user definition may be provided through any one of a number of “input dialogues” known in the art.
FIGS. 3 a - 3 c illustrate a dashboard, a scorecard, and an investment map of FIG. 1 in further detail, in accordance with one embodiment each. As described earlier, dashboard 122 is designed to assist a project manager in managing a project. As shown in FIG. 3 a , for the illustrated embodiment, dashboard 122 includes a number of graphical depictions 302 a - 302 d for a number of aspects of a project (as indicated by one or more of the earlier described performance metrics). The graphical depictions 302 a - 302 d may include the illustrated non-linear graph 302 a , histogram 302 b , pie chart 302 c , linear graphs 302 d , as well as other depictions. The various graphical depictions 302 a - 302 d are “tiled” in the illustrated presentation. In other embodiments, the graphical depictions 302 a - 302 d are arranged in a cascaded overlapping manner instead. Further, a dashboard 122 may present graphical depictions for multiple projects instead.
In a preferred one of the embodiments, a project manager may select the subject matters (i.e. the projects and their performance metrics/categories) to be graphically depicted, the graphical depictions to be employed, as well as the manner in which the graphical depictions are to be presented. These selections may be specified by the project manager through any one of a number of “selection dialogues” known in the art.
As described earlier, scorecard 124 is designed to assist a portfolio manager in managing the portfolio of IT projects he/she is responsible for. As shown in FIG. 3 b , for the illustrated embodiment, each scorecard 124 is a tabular presentation of where the projects of a portfolio stand on various performance indicators, with measurements of the various performance indicators of the projects occupying columns 306 of corresponding rows 304 . Each performance indicator may correspond to a performance metric or may be an aggregate, weighted or otherwise, of a number of performance metrics (which may or may not be individually depicted in the subject scorecard). Additionally, in lieu of conventional numerical and/or textual presentation, the measurements may be advantageously depicted in symbols 308 (in color or otherwise) to enable the current standing of a performance indicator of a project to be easily highlighted for a portfolio manager. Furthermore, for selected ones of the performance indicators, corresponding cross project composite measures are automatically computed and presented in columns of a cross project row (the top row, for the illustrated embodiment). Likewise, the cross project composite measures may be “aggregated” in a weighted or non-weighted manner, as well as presented in symbolic fashion (color or otherwise). Similarly, the contributing projects for the computation of the cross project composite measures may or may not be part of the subject scorecard. Most importantly, the presented projects are logically linked to their dashboards 122 , to facilitate a portfolio manager to drill down or focus on a project if necessary.
In one embodiment, scorecards 124 may be used to present the status of portfolios of portfolios (as opposed to projects) instead. But, for ease of understanding, the remaining description will primarily focus on scorecards 124 being used to present the status of portfolios of projects.
Similar to dashboard 122 , in a preferred one of the embodiments, a portfolio manager may select the projects of a portfolio and the performance indicators of the projects to be included, the manner the performance indicators are to be “aggregated”, whether any cross project composite measures are to be computed, the manner in which the cross project composite measures are to be computed, as well as the manner in which the measurements are to be presented. These selections may too be specified by the portfolio manager through any one of a number of “selection dialogues” known in the art.
As also described earlier, investment maps 126 are designed to assist an IT executive in managing IT investments of his/her enterprise. As shown in FIG. 3 c , for the illustrated embodiment, an investment map 126 graphically depicts a selected subset of the IT portfolios in accordance with risk, technology type, their size and their soundness. Each IT portfolio is graphically represented by a “bubble”. In alternate embodiments, other graphical representations may be employed instead. The size and soundness of a portfolio are depicted by the size and color of the “bubble”. The risk and technology type of the portfolio determines the placement of the “bubble”, e.g. with risk determining the y-axis value and the technology type determining the x-axis value. In alternate embodiments, the technology type, risk, size and soundness may be conveyed through other visual attributes instead. Again, most importantly, the portfolios are logically linked to their scorecards 124 to facilitate an IT executive to drill down or focus on a portfolio if necessary.
In one embodiment, the technology type of each portfolio is characterized by the portfolio manager as being evolutionary in nature, or instrumental in establishing a new computing platform or technologically transforming in nature. In one embodiment, the characterization may be accomplished through quantified indices (which in turn are employed to generate the normalized x-coordinates). Similarly, the risk of each portfolio is characterized by the portfolio manager as being high, medium or low. In one embodiment, the characterization may also be accomplished through quantified indices (which in turn are employed to generate the normalized y-coordinates). In like manner, a portfolio manager also specifies how the size of a portfolio is to be measured, e.g. in terms of total dollars budgeted, total staffing, total number of lines of code to be written and so forth, as well as how “soundness” of a portfolio is to be measured, e.g. by the number of critical performance indicators in an “alert” state, or by the number of projects having at least one critical performance indicators in the “alert” state, or both. These specifications may too be made by the portfolio managers through any one of a number of “selection dialogues” known in the art.
In alternate embodiments, investment maps 126 may depict the status of a selection of IT portfolios relative to other performance metrics/categories (as opposed to risk, technology type etc.). Again, the performance metrics/categories to be referenced in the depiction of the status of IT portfolios may be user specified, through any one of a number of known “specification dialogues” known in the art.
FIGS. 4 a - 4 c illustrate the relevant generation operational flows of the dashboard generator/viewer, the scorecard generator/viewer, and investment map generator/viewer of FIG. 1 , in accordance with one embodiment each. As illustrated by FIG. 4 a , for dashboard generator/viewer 112 , upon start of the dashboard generation process for a project, at 402 , dashboard generator/viewer 122 selects one of the specified graphs for generation. At 404 , dashboard generator/viewer 122 generates the selected graph for the specified performance metrics. The manner of generation is graph dependent, i.e. whether it is a histogram or a pie chart and so forth, to be generated. The generation of these types of graphs are known in the art, accordingly will not be further described. At 406 , upon generation of the selected graph, dashboard generator/viewer 122 determines if additional graphs are to be generated. If so, dashboard generator/viewer 122 returns to 402 , otherwise, dashboard generator/viewer 122 continues at 408 , where it arranges the graphs for presentation. For the earlier described embodiment, dashboard generator/viewer 122 places and tiles the generated graphs.
As illustrated by FIG. 4 b , for scorecard generator/viewer 114 , upon start of the scorecard generation process for a portfolio, at 412 , scorecard generator/viewer 124 selects one of the project of the portfolio for generation. At 414 , scorecard generator/viewer 124 selects one of the specified performance indicators. At 416 , scorecard generator/viewer 124 determines the measurement value of the selected performance indicator for the selected project. The manner of determination is performance indicator dependent. For some performance indicators, the determination may simply involve determining whether a performance metric is higher or lower than a threshold value, for others, the determination may involve any one of a number of intermediate computations such as additions, subtractions, multiplications or divisions known in the art. At 418 , upon determining the measurement value of a performance indicator for a project, scorecard generator/viewer 124 determines if measurement values for additional performance indicators are to be determined. If so, scorecard generator/viewer 124 returns to 414 , otherwise, scorecard generator/viewer 124 continues at 420 . At 420 , scorecard generator/viewer 124 determines if the portfolio has additional projects to be processed. If so, scorecard generator/viewer 124 returns to 412 , otherwise, scorecard generator/viewer 124 continues at 422 . At 422 , scorecard generator/viewer 124 determines the cross project measure values for applicable ones of the performance indicators. Finally, at 424 , scorecard generator/viewer 124 displays the generated scorecard.
As illustrated by FIG. 4 c , for investment map generator/viewer 114 , upon start of the map generation process, at 432 , map generator/viewer 126 selects one of the portfolios for generation. At 434 , map generator/viewer 126 selects a project of the selected portfolio. At 436 , map generator/viewer 126 “aggregates” the performance metric values for the selected project. The manner of “aggregation” is performance metrics dependent. For some performance metrics, the “aggregation” may simply involve summation of performance metric values, for others, the “aggregation” may involve a number of intermediate transformation or normalization operations known in the art. At 438 , upon aggregating the performance metrics for a project, map generator/viewer 126 determines if the selected portfolio has more projects to be processed. If so, map generator/viewer 126 returns to 434 , otherwise, map generator/viewer 126 continues at 440 . At 440 , map generator/viewer 126 determines color of the bubble representation, to appropriately represent the soundness of the portfolio. Additionally, map generator/viewer 126 determines the size of the bubble representation, to appropriately represent the total investment of the portfolio, as well as the proper placement of the bubble representation, to appropriately depict the technology type and risk associated with the portfolio. At 442 , map generator/viewer 126 determines if additional portfolios are to be processed. If so, map generator/viewer 126 returns to 432 , otherwise map generator/viewer 126 continues at 444 , and displays the generated map.
FIGS. 5 a - 5 b illustrate the relevant viewing operational flows of the scorecard generator/viewer and investment map generator/viewer of FIG. 1 , in accordance with one embodiment each. As illustrated by FIG. 5 a , for map generator/viewer 116 , upon being notified of the selection of a portfolio by a user (e.g. by way of clicking on the bubble representation using a cursor control device such as a mouse), map generator/viewer 116 determines the identity of the selected portfolio, 502 . Upon determining the identity of the selected portfolio, at 504 , map generator/viewer 116 invokes scorecard generator/viewer 114 to display the scorecard for the selected portfolio, thereby facilitating an IT executive in drilling down and focusing on a portfolio of interest.
As illustrated by FIG. 5 b , for scorecard generator/viewer 114 , upon being notified of the selection of a project by a user (e.g. by way of clicking on the row of a project using a cursor control device such as a mouse), scorecard generator/viewer 114 determines the identity of the selected project, 512 . Upon determining the identity of the selected project, at 514 , scorecard generator/viewer 114 invokes dashboard generator/viewer 112 to display the dashboard for the selected project, thereby facilitating an IT executive/a portfolio manager in drilling down and focusing on a project of interest.
FIG. 6 illustrates a network environment suitable for practicing the present invention, in accordance with one embodiment. As illustrated, network environment 600 includes data server 602 , IT executive computing device 604 , portfolio manager computing devices 606 , and project manager computing devices 608 . Server 602 and computing devices 604 - 608 are coupled to each other via networking fabric 610 . Further, server 602 and computing devices 604 - 608 are incorporated with the earlier described teachings of the present invention. More particularly, server 602 is employed to store project data 102 , and provided with dashboard, scorecard and investment map generator/viewer 112 - 116 to facilitate generation and viewing of the earlier described dashboards, scorecards and investment map for an enterprise, by IT executives, portfolio managers, and project managers as described earlier, using computing devices 604 - 608 .
Server 602 is intended to represent one or more servers coupled to each other through a local or a wide area network. In one embodiment, dashboard, scorecard and investment map generator/viewer 112 - 116 may execute exclusively on server 602 with the results transmitted to display on computing devices 604 - 608 through networking fabric 610 . In other embodiments, part or all of dashboard, scorecard and investment map generator/viewer 112 - 116 may be executed on computing devices 604 - 608 instead. Further, there may be more than one executive computing device 604 , as well as having computing devices that serve as a computing device with more than one role, e.g. for an IT executive as well as a portfolio manager or a project manager. Networking fabric 610 is intended to represent a wide range of interconnected private and public networks, each constituted with networking equipment such as gateways, switches, routers and the like, such as the Internet.
FIG. 7 illustrates a computer system suitable for use as either server 602 or computing devices 604 - 608 of FIG. 6 in accordance with one embodiment. As shown, computer system 700 includes one or more processors 702 (typically depending on whether it is used as server 602 or one of computing devices 604 - 608 ) and system memory 704 . Additionally, computer system 700 includes mass storage devices 706 (such as diskette, hard drive, CDROM and so forth), input/output devices 708 (such as keyboard, cursor control and so forth) and communication interfaces 710 (such as network interface cards, modems and so forth). The elements are coupled to each other via system bus 712 , which represents one or more buses. In the case of multiple buses, they are bridged by one or more bus bridges (not shown). Each of these elements perform its conventional functions known in the art. In particular, system memory 704 and mass storage 706 are employed to store a working copy and a permanent copy of the programming instructions implementing the teachings of the present invention. The permanent copy of the programming instructions may be loaded into mass storage 706 in the factory, or in the field, as described earlier, through a distribution medium (not shown) or through communication interface 710 (from a distribution server (not shown). The constitution of these elements 702 - 712 are known, and accordingly will not be further described.
Thus, a novel method and apparatus for facilitating management of IT investment has been described. While the present invention has been described in terms of the above illustrated embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. The present invention can be practiced with modification and alteration within the spirit and scope of the appended claims. For example, in addition to the above described dashboard, scorecard and investment map, the present invention may also be practiced with a “management notebook” encapsulating the various project data for a project manager, and navigationally coupling e.g. the dashboards to these “management notebooks”. The description is thus to be regarded as illustrative instead of restrictive on the present invention.
It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the present invention should, therefore, be determined only by the following claims. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation of U.S. patent application Ser. No. 13/065,104, filed Mar. 15, 2011, the entirety of which is incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is in the field of photovoltaic panels. More particularly, the present invention is in the technical field of photovoltaic panel mounting systems.
2. Description of the Related Art
Photovoltaic, or solar, systems have emerged as a popular source of alternative energy. However, numerous deficiencies exist in current mounting devices and methods of installation. Striking a balance between customizability and efficiency of installation is paramount to the design and implementation of a successful photo voltaic system.
While many available photovoltaic systems are highly customizable, they lack in efficiency. Current installation methods, commonly referred to as build-on-site, require multiple steps taking place over several days of construction. First, workers must attach mounting devices to the surface or underlying substructure. Each additional mounting device requires penetration of the roof surface with a lag bolt, which compromises the roof's weather resistant barrier. Measurements are then taken and framing members are cut to length and mounted. Next, workers must measure, cut and install large amounts of wiring and component connections. Finally, photovoltaic modules are added individually until a completed photovoltaic array is formed. Each photovoltaic module must also be secured to the framework by additional mounting hardware. In many methods, this requires the added steps of inserting, positioning and tightening several nuts, bolts and washers per panel. Furthermore, addition of an aftermarket panel cleaning system results in added labor costs and risks possible damage to the installed photovoltaic panels.
In addition, the on-site installation of electrical wiring and power conversion elements creates unsafe working conditions for installers. When conventional string inverters are used as part of the system, the photovoltaic panels must be electrically connected in series as they are installed resulting in live, high-voltage, DC current on the roof The use of string inverters also requires that extreme measures be taken to insure that all elements of the framing system are securely grounded. The installers must work around this live power to install additional strings of panels and their associated components. The large array of tools and components that must be loaded onto the sloped roof surface and controlled during installation makes build-on-site construction a complex and hazardous process.
Once installed, photovoltaic arrays are subjected to varying climates and must be able to withstand high winds and snow accumulation. Current systems, such as the one described above, are entirely dependent on the underlying roof surface to maintain their form. Additional mounting points can marginally increase the stability and load capacity of these build-on-site systems, but require additional penetrations to the roof surface. One of the major disadvantages to build on-site construction is that framing members exist as independent components rather than as an integrated framework. During installation the framing members are secured directly to the mounting devices without the added benefit of stabilizing cross members. Each row of photovoltaic panels is therefore mechanically independent from the adjacent rows. Because of this, many roof surface mounting points are required and there is no system wide load sharing. The inability to create an integrated framework makes build-on-site systems inefficient for carrying high wind and snow loads.
The increased demand for solar systems brings with it a need for a safer and more efficient means of producing and deploying them. Therefore, a need exists in the industry for a new and useful integrated, multi-module, photovoltaic mounting system capable of off-site prefabrication, transportation and installation as a unitized assembly.
BRIEF SUMMARY OF THE INVENTION
The present disclosure is directed to an apparatus and method for fixing photovoltaic modules within a unitized photovoltaic assembly and installing on a roof or other surface. Central to the unitized photovoltaic assembly is a unitary frame support structure. The unitary frame is formed from horizontal rails and vertical struts positioned in uniform rows and columns respectively. The unitary frame is discussed herein in the context of being installed on a sloping residential roof In this context, the term “horizontal” used in connection with the rails means that each rail extends laterally along the sloping roof without a substantial change in inclination along its length, and the term “vertical” used in connection with the struts means that each strut is inclined along its length so that one end of the strut is vertically higher than the other end. The rails are solidly affixed to the struts by welding or other means. Each rail is a uniform structure having a double “I” cross-section and receiving slots. Opposing edges of the photovoltaic panels are retained within these receiving slots. Retaining brackets and spacer clips are provided for maintaining the photovoltaic panels within the receiving slots. Unlike existing systems, the unitized photovoltaic assembly is not solely dependent on the support of the underlying surface to maintain its form. As a result, less mounting hardware is required to obtain a rigid structure, which reduces the number of roof surface penetrations and installation time. This has the added benefit of reducing damage to the roof surface caused by workers walking on it.
Installation is further streamlined with the inclusion of additional elements during the off-site fabrication process. Power conversion elements are affixed to the unitary frame and pre-wired to the photovoltaic panels. The wiring includes polarized connector elements at the terminal ends allowing adjacent unitized photovoltaic assemblies to be easily connected to one another. Also, a spray head is installed for cleaning the photovoltaic panels and tubing is connected for carrying cleaning fluids. By pre-assembling these systems, workers will no longer be subjected to hazardous conditions while maneuvering tools, materials and themselves around live wires on a sloped roof surface.
The unitized photovoltaic assembly is designed to integrate with adjacent assemblies to form a completed array. Various assembly configurations are possible including, but not limited to, IX2, IX3, 2X2 and 2X3 depending on the size and shape of the installation surface. Adjacent assemblies are structurally joined with mounting interlocks adding to the rigidity and load carrying capacity of the completed system. Mounting interlocks are attached to the end of a strut or rail and engage with corresponding mounting interlocks on adjacent assemblies. Electrical wiring and tubing are also connected between adjacent assemblies to complete the system.
In order to form a completed system, each unitized photo voltaic assembly is installed from above with the use of a specialized lifting frame. Since larger unitized photo voltaic assemblies are not sufficiently rigid to stand alone, the lifting frame provides additional support to prevent the assembly from flexing and causing damage to the photo voltaic panels. Use of the specialized lifting frame in conjunction with a crane alleviates the need for photovoltaic panels to be individually carried up a ladder to the roof surface. The lifting frame includes a plurality of tabs and in some instances a “U” channel, which engage and stabilize the horizontal rails of the unitary frame. Cables attached to the lifting frame are adjustable to match the slope of the roof surface. Once positioned, the unitized photovoltaic assembly is lowered onto the roof surface and secured to conventional mounting devices that have been pre-installed on the roof or other surface. The type of mounting devices will vary depending on the installation surface.
The foregoing is intended to provide a broad description of the present invention in order to demonstrate its contributions to the art and better understand the descriptions to follow. These and other features of the present invention will be readily apparent to persons of ordinary skill in the art upon reading the entirety of this disclosure.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view of a unitized photovoltaic assembly 100 according to the present invention.
FIG. 2 is a perspective view of unitary frame 110 according to the present invention.
FIG. 3 is a perspective view of horizontal rails 104 according to the present invention.
FIG. 4A is an exploded view of retaining bracket 140 a according to the present invention.
FIG. 4B is a perspective view of retaining brackets 140 a, b according to the present invention.
FIG. 5A is an isolated view of spacer 160 according to the present invention.
FIG. 5B is a cross-sectional view of spacer 160 according to the present invention.
FIG. 6 is a perspective view of struts 106 according to the present invention.
FIG. 7A is an isolated view of mounting interlock 170 a according to the present invention.
FIG. 7B is a perspective view of mounting interlocks 170 a,b according to the present invention.
FIG. 8 is a perspective view of lifting frame 190 according to the present disclosure.
FIG. 9 is a perspective view of lifting frame 190 engaged with a unitized photovoltaic array 100 according to the present invention.
FIG. 10 is a cross-sectional view of lifting frame 190 engaged with a unitized photovoltaic array 100 according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present disclosure describes an apparatus for mounting photovoltaic modules, herein referred to as a unitized photovoltaic assembly 100 . The preferred embodiment as shown in FIGS. 1 through 11 , comprises a unitary frame 110 constructed to retain multiple photovoltaic modules 102 and various other elements. The unitized photovoltaic assembly 100 is designed for off-site fabrication, and can be transported and installed as a single unit, thereby reducing the time and resources required for build on-site construction.
In the preferred embodiment of unitized photo voltaic assembly 100 , shown in FIG. 1 , a unitary frame 110 provides the structural framework for the mounting of various elements. As shown, nine photovoltaic modules 102 are arranged into three rows defined by unitary frame 110 . Alternatively, unitary frame 110 can be adjusted to accommodate more or less photovoltaic modules 102 , depending on the application requirements. The Photovoltaic modules 102 are maintained within unitary frame 110 by a plurality of retaining brackets 140 a, b at the ends of each row in addition to spacers 160 between adjacent photovoltaic modules 102 .
The unitized photovoltaic assembly 100 is secured to a surface 150 with repositionable mounting brackets 152 . More specifically, mounting brackets 152 are attached to the unitary frame 110 and bolted to mounting devices 156 . The mounting devices 156 are preinstalled to the surface 150 in accordance with local building codes. In the present embodiment, mounting devices 156 are bolted to rafters 154 . Various types of mounting devices 156 , common within the industry, may be utilized. In some instances, mounting devices 156 may not be necessary, in which case mounting brackets 152 can be secured directly to the surface 150 .
Also shown in FIG. 1 , are mounting interlocks 170 a, b . Mounting interlocks 170 a, b are secured to the unitary frame 110 and are used to mechanically interconnect adjacent unitized photovoltaic assemblies 100 to form a complete system. Because of mounting interlocks 170 a, b, various arrangements of unitized photovoltaic assemblies 100 can be created, which have the added benefit of increased load sharing across the completed system.
FIG. 2 shows unitary frame 110 in further detail, without photovoltaic modules 102 . The unitary frame 110 is comprised of a plurality of rails 104 mounted above and welded to a plurality of struts 106 at cross points 108 . Brackets or fasteners could also be used in place of welding to mount rails 104 to struts 106 . Fabrication in this manner creates a unified framework central to the formation of the unitized photo voltaic assembly 100 . In the preferred embodiment, additional elements are attached to unitary frame 110 prior to installation. Additional elements may include, but are not limited to, power conversion elements 112 , spray head 118 , wiring 114 , tubing 120 , retaining brackets 140 a, b , mounting interlocks 170 a, b and mounting brackets 152 .
In the preferred embodiment, power conversion elements 112 are micro-inverters, which are attached to unitary frame 110 beneath photovoltaic modules 102 . The micro-inverters convert power from unregulated direct current (DC) to alternating current (AC) or to regulated DC depending on the installation requirements. Each power conversion element 112 is electrically connected to a corresponding photovoltaic module 102 . Individual power conversion elements 112 are also connected to one another by wiring 114 . Wiring 114 is generally attached to unitary frame 110 and terminates at the perimeter of unitized photovoltaic assembly 100 with polarized power connectors 116 a, b . Polarized power connector 116 a can be connected to 116 b of an adjacent unitized photovoltaic assembly 100 permitting a plurality of unitized photovoltaic assemblies 100 to aggregate their power by providing feed in and feed out paths for electrical power and control signals. The polarized power connectors 116 a, b can also be connected to a power collection unit when unitized photovoltaic assembly 100 is an original or terminal assembly. In this manner, minimal effort is required to wire the completed system.
The preferred embodiment also includes at least one assembly spray head 118 attached to unitary frame 110 . Spray head 118 directs cleaning fluids into a spray pattern covering photovoltaic modules 102 . Spray head 118 is connected to tubing 120 by a “T” spray connector 122 . In an alternate embodiment, when spray head 118 is the final sprayer, spray connector 122 is an elbow instead of a “T”. Tubing 120 supplies alternately, clear and soapy water from a pressure source (not shown). Tubing 120 is also generally attached to the unitary frame 110 and terminates at the perimeter of unitized photovoltaic assembly 100 with fluid connectors 124 a, b . Fluid connectors 124 a, b allow cleaning fluid to flow to and from adjacent unitized photovoltaic assemblies 100 .
The addition of elements to the unitary frame 110 in this manner provides for a plug-and-play unitized photovoltaic assembly 100 . This system allows for additional unitized photovoltaic assemblies 100 to be added with minimal connections and little or no additional wiring or tubing. Also, pre-wiring and the use of low-voltage power conversion elements 112 eliminates hazardous live wiring on the roof surface 150 creating a safer working environment.
As referred to above, the main structural components of unitary frame 110 are rails 104 and struts 106 . FIG. 3 illustrates the uniform structural cross-section of rails 104 . An extrusion process forms rails 104 with a uniform double “I” cross section designed to resist flexure. In the preferred embodiment, rails 104 are made from aluminum alloy, but other material having similar strength to weight properties could also be used. The structure of rails 104 provides U-shaped receiving slots 130 for retaining photovoltaic modules 102 . In the preferred embodiment, rails 104 are oriented laterally and substantially parallel to one another. When arranged in this manner, photovoltaic modules 102 can be slideably retained by their opposing edges within slots 130 . In the illustrated embodiment the slots 130 present smooth support surfaces upon which photovoltaic module edges can slide. The retained opposing edges of photovoltaic modules 102 can be either the long or short edges. Accordingly, the length and arrangement of rails 104 are determined by the dimensions, orientation and number of photovoltaic modules 102 to be retained. Additionally, rails 104 provide U-shaped receiving slots 132 for accepting mounting interlocks 170 a,b and retaining brackets 140 a, b . Rails 104 also include holes 136 for the securing of mounting interlocks 170 a, b and retaining brackets 140 a, b.
FIGS. 4A and 4B more closely illustrate retaining brackets 140 a, b , shown generally in FIG. 1 . Retaining brackets 140 a,b , laterally retain photovoltaic modules 102 within slots 130 . In the present embodiment, individual retaining bracket assemblies 140 a,b comprise a retaining element 142 that engages the outer edge of the end most photovoltaic modules 102 in each row so as to block the photovoltaic modules from sliding out of the unitary frame 110 . Retaining element 144 is attached to an L bracket 144 by fastener 146 . L bracket 144 includes a threaded hole 148 for receiving fastener 146 . Removal of fastener 146 allows retaining element 142 to be disengaged from photovoltaic module 102 . This will allow partial or complete removal of photovoltaic modules 102 from unitary frame 110 . Furthermore, L bracket 144 is affixed to the ends of rails 104 within receiving slots 132 . Specifically, L bracket 144 includes holes 158 , which align with holes 136 on rails 104 . A bolt or other fastener engages holes 158 and holes 136 to secure L bracket 144 to rails 104 . The main deference between retaining brackets 140 a and 140 b is the orientation of L bracket 144 , depending on which side of rail 104 it is positioned.
Additionally, during installation of unitized photovoltaic assembly 100 it may be helpful to disengage the retaining element 142 and slide photovoltaic modules 102 partially out of the unitary frame 110 in order to gain access to mounting brackets 152 or to additional elements of the system described above. As shown in FIGS. 3 and 5B , the surfaces of the U-shaped receiving slot 130 in each rail 104 are flat and smooth, as are surfaces of the edges of the photovoltaic module 102 , thus enabling the photovoltaic modules 102 to slide relative to the unitary frame 110 .
FIGS. 5A and 5B show spacer 160 . Spacer 160 comprises a clip 162 , which attaches to photovoltaic modules 102 . Spacer 160 includes fins 164 . Fins 164 contact the edges of adjacent photovoltaic modules 102 thereby maintaining a gap 180 . Gap 180 is useful for allowing the expansion and contraction of photovoltaic modules 102 during temperature changes. Spacer 160 is sufficiently resilient to allow such expansion and contraction of the photovoltaic modules 102 . Additionally, gap 180 provides a space for lifting frame 190 to engage unitary frame 110 , discussed below.
FIG. 6 shows the uniform structural cross-section of struts 106 , shown generally in FIG. 2 . An extrusion process forms struts 106 with an “I” cross-section designed to resist flexure. Struts 106 are preferably made from aluminum alloy, but other material having similar strength to weight properties could also be used. The design of struts 106 provides U-shaped receiving slots 134 for accepting interlock elements 170 . Struts 106 also provide mounting surfaces for additional elements attached to unitary frame 110 , discussed above. In the present embodiment, struts 106 are oriented generally in the vertical direction to align with the roofs underlying rafters 154 . It is important to note that struts 106 must not be aligned with gaps 180 as this will prevent lifting frame 190 from engaging with unitary frame 110 .
The preferred embodiment includes interlocks 170 a, b , shown in FIGS. 7A and 7B , in order to maintain a mechanical relationship between adjacent unitized photovoltaic assemblies 100 , thereby contributing to the structural integrity and load sharing capacity of the completed system. Interlocks 170 a, b are attached to the ends of rails 104 and struts 106 within receiving slots 132 and 134 , respectively. Mounting interlocks 170 a,b include holes 178 , which align with holes 136 or 138 depending on whether they are mounted to rails 104 or struts 106 . As shown in FIG. 7A , interlocks 170 also provide a ledge 174 . Ledge 174 is positioned face up or face down in order to engage a corresponding adjacent ledge 174 . The interaction between adjacent interlocks 170 a,b is more clearly demonstrated in FIG. 7B . Interlocks 170 a, b also include a locking hole 176 to accept a fastener 202 , thereby mechanically joining adjacent unitized photovoltaic assemblies 100 . Mounting interlocks 170 a and 170 b are mirrored so that corresponding locking holes 176 will align during the joining of unitized photovoltaic assemblies 100 .
Also shown in FIG. 7B , are mounting brackets 152 for securing unitized photovoltaic assembly 100 to a surface. Mounting brackets 152 are attached to rails 104 or struts 106 of the unitary frame 110 . During installation, mounting brackets 152 are secured to standard mounting devices 156 using bolts 208 . Prior to installation of the unitized photovoltaic assembly 100 , mounting devices 156 , are installed to the surface 150 and secured with lag bolts 206 to underlying rafters 154 . FIG. 1 more broadly illustrates the use of mounting brackets 152 for securing unitary frame 110 to a surface 150 . In some instances, mounting devices 156 may not be required, in which case mounting brackets 152 can be directly attached to surface 150 or underlying rafters 154 , depending on the local building code.
FIGS. 8 , 9 and 10 relate to the structure and use of lifting frame 190 . Unitary frame 110 is designed to maintain the general structure of unitized photovoltaic assembly 100 , but it is not significantly rigid to support photovoltaic modules 102 independently. Merging lifting frame 190 with unitized photovoltaic assembly 100 provides the necessary rigidity to inhibit bending of unitary frame 100 and thereby prevents damage to photovoltaic modules 102 during installation.
Lifting frame 190 comprises a framework having a plurality of tabs 192 and rail supports 194 a, b for engaging unitary frame 110 . More specifically, tabs 192 pass through gaps 180 to engage corresponding horizontal rails 104 . Vertical rail supports 194 a are comprised of two “C” channels oriented back to back with tabs 192 positioned between them. Tabs 192 are secured to rail supports 194 a with bolts 212 , as shown in FIG. 10 . Horizontal cross rail supports 194 b , also “C” channels, are attached to the horizontal rail supports 194 a with bolts 210 . Bolts 210 and 212 are used to allow for lifting frame 190 to be adjusted for unitized photovoltaic assemblies 100 of varying sizes. For large assemblies 100 additional rail supports 194 a can be added including additional tabs 192 .
In the preferred embodiment, lifting frame 190 is connected to a crane hook 200 by cables 198 attached to holes 196 , as shown in FIG. 9 . The cables 198 can be attached to different holes 196 and repositioned in relation to the crane hook 200 to achieve varying angles in order to match the slope of the installation surface 150 . After unitized photovoltaic assembly 100 is installed on the roof or other surface 150 , lifting frame 190 is disengaged from unitized photovoltaic assembly 100 and re-used.
Although the present invention has been described in accordance with the embodiments shown and contains many specifics, these descriptions should not be construed as limiting the spirit of the invention or scope of the appended claims. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to the transmission of data from the bottom of a bore hole to the surface and, more particularly, to a device for creating information-carrying pressure pulses in the circulating flow of fluid between a drill bit and the surface by selectively controlling the fluid flow patterns.
2. Discussion of the Prior Art:
For reasons of economy and safety it is highly desirable that the operator of a drill string be continually aware of such down-hole parameters as drill bit position, temperature and bore hole pressure. Knowledge of the drill bit position during drilling can save significant time and expense during directional drilling operations. For safety it is of interest to predict the approach of high pressure zones to allow the execution of proper preventive procedures in order to avoid blowouts. In addition, efficient operation of the drill string requires continuous monitoring of down-hole pressure. The pressure in the bore hole must be maintained high enough to keep the walls of the hole from collapsing on the drill string yet low enough to prevent fracturing of the formation around the bore hole. In addition the pressure at the bit must be sufficient to prevent the influx of gas or fluids when high pressure formations are entered by the drill bit. Failure to maintain proper down-hole pressure can and frequently does lead to loss of well control and blowouts.
Any system that provides measurements while drilling (MWD) must have three basic capabilities: (1) to measure the down-hole parameters of interest; (2) to telemeter the resulting data to a surface receiver; and (3) to receive and interpret the telemetered data. Of these three essential capabilities, the ability to telemeter data to the surface rapidly is the current limiting factor in developing MWD systems.
Four general methods have been studied that would provide transmission of precise data from one end of the well bore to the other: mud pressure pulse, hard wire, electromagnetic waves, and acoustic methods. At this time, mud pulsing has proven to be the most practical method.
In a typical mud pulsing system pressure pulses are produced by a mechanical valve located in a collar above the drill bit. The pulses represent coded information from down-hole instrumentation. The pulses are transmitted through the mud to pressure transducers at the surface, decoded and displayed as data representing pressure, temperature, etc. from the down-hole sensors. Of the four general methods named above, mud pulse sensing is considered to be the most practical as it is the simplest to implement and requires no modification of existing drill pipe or equipment.
Mechanical mud pulsers, known in the art, are inherently slow, producing only one to five pulses per second, are subject to frequent mechanical breakdown, and are relatively expensive to manufacture and maintain. An example of such a device is disclosed in U.S. Pat. No. 3,958,217 (Spinnler) disclosing a valve mechanism for producing mud pulses.
U.S. Pat. No. 4,418,721 (Holmes) discloses the use of a fluidic valve to rapidly change the flow of mud from radial to vortical and back again, altering the flow pattern of the fluid and producing pressure pulses therein. Mud flow through the valve transits a vortex chamber and diffuser assembly in a generally radial flow pattern, exiting the valve through an outlet located at the center of the chamber on one side of the assembly. A small tab is selectively extended from a recessed position into, and retracted from, the vortex chamber by a solenoid responding to encoded sequences of electrical impulses from measurements made by down-hole sensors. The insertion of the tab into the vortex chamber disturbs the fluid flow and transforms the radial flow to vortical, producing a pressure pulse that is radiated through the mud back up the drill pipe to the surface transducer. The activation energy for the tab is relatively low and the permissible pulse rate is therefore much higher than can be achieved with mechanical valves. Disadvantageously, such devices are characterized by relatively restrictive flow channel sizes requiring parallel connection of multiple valves with accompanying energy and volume requirement penalties and clogging potential. In addition, areas within the assymetrical vortex chamber suffer high pressure and wear, necessitating frequent inspection and maintenance and requiring costly reinforced construction.
OBJECTS AND SUMMARY OF THE INVENTION
The primary object of the present invention is to overcome the disadvantages of prior art mud pulsers by providing a vortex chamber mud pulser capable of producing a high signal rate and requiring very low activating energy.
It is a further object of the present invention to provide a durable and rugged mud pulser with an increased flow channel to minimize clogging.
Still another object of the present invention is to provide a mud pulser having a simple configuration and no pressure loaded moving parts.
Still another object of the present invention is to increase the flow rate through a mud pulser and increase the useful life by minimizing areas of high pressure and erosion.
Some advantages of the present invention over the prior art are that the mud pulser of the present invention: simplifies mud pulse telemetry by reducing the number of valves and the number and mass of actuator parts required to generate signal pulses; adds reliability and economy to mud pulse telemetry by providing a mud pulser with increased shock and vibration resistance and fewer areas of high wear and erosion; and is of simple and inexpensive construction.
In accordance with the present invention a flow disturbing tab extends from a recessed position into a vortex chamber and is withdrawn therefrom by an opposed pair of solenoids responding to signals received from a transducer or sensor. Drilling mud flows through an inlet in the top of the mud pulser valve module along the axis of the drill hole into an annular vortex chamber and exits through a pair of outlet nozzles axially aligned normal to the drill hole axis on opposite sides of the vortex chamber. The flow is radial through the symmetrical vortex chamber until the tab selectively disturbs the chamber symmetry and creates "free" vortex motion in the fluid flow. The swirling vortex path increases the tangential velocity of the fluid and reduces the static pressure driving the mud through the outlet nozzles. A rapid flow rate decrease results producing a positive pressure pulse each time the tab is inserted and a negative pulse each time the tab is withdrawn from vortex chamber flow. The sequencing and timing of the pressure pulses can be selectively controlled to encode and transmit binary data through the mud to a receiving sensor located in the flow pipe at the surface.
Other objects and advantages of the present invention will become apparent from the following description of the preferred embodiment taken in conjunction with the accompanying drawings wherein like parts in each of the several figures are identified by the same reference characters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the vortex chamber mud pulser device of the present invention as an element of a drill string employing a circulating mud system.
FIG. 2 is a front view in section of the vortex chamber mud pulser according to the present invention.
FIG. 3 is a side view in section of the vortex chamber mud pulser according to the present invention.
FIG. 4 is a perspective cross-section view of the vortex chamber of the present invention taken along the vortex chamber plane of symmetry.
FIG. 5 is a simplified side cross-section diagram illustrating fluid flow through the vortex chamber of the invention with its actuator tab withdrawn into a recess.
FIG. 6 is a simplified front cross-section diagram illustrating fluid flow.
FIG. 7 is a simplified side cross-section diagram illustrating fluid flow through the vortex chamber with the tab extended into the chamber.
FIG. 8 is a simplified front cross-section diagram illustrating fluid flow as in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A drill string 20 shown in FIG. 1 includes a drill pipe 22 supported and operated from above ground, a measurement while drilling (MWD) package 24 contained within an enlarged lower section 26 of the drill pipe and a drill bit 28. Drilling mud, a fluid used to remove cuttings and stabilize down-hole pressure, is circulated as shown by the arrows along the drill pipe 22, over and through the MWD package 24, through nozzles in the drill bit 28 and back along the annular space between the drill pipe and the bore hole. Feed and return lines 32 and 34, respectively, connect the drill pipe with a pump 36 and a mud pit 38 where cuttings are separated out of the fluid. The MWD package 24 contains instrumentation 39 to sense physical parameters around the drill head, a signal processing package 40 to convert sensor output to electrical impulses, a power supply 42 and a vortex chamber fluid pulser 44 to convert the electrical impulses into pressure waves, detected on the surface by a pressure transducer 45 in the wall of feed line 32.
The vortex chamber mud pulser 44, FIGS. 2 and 3, has an actuator module 46 and a valve module 48. The actuator module is smaller in diameter than the drill pipe, allowing drilling mud to flow between the module and the pipe. The actuator module converts electrical impulses received from the signal processing package into movement of a control rod 50 extending into the valve module. A pair of coaxial opposed solenoids 52 and 54 are housed in the actuator module. The plungers of the two solenoids (not shown) are connected to a linkage arm 56 pivotably fixed on one end to the actuator module housing 58 by a first pin 60 and pivotably connected on the opposite end by a second pin 62 to the rigid control rod 50 extending through a passage 66 in the housing 84 of valve module 48. Energization of the first solenoid urges linkage 56 and control rod 50 a short distance (on the order of 0.20 inches) toward the valve module 48 into an extended position; alternate energization of the second solenoid returns the linkage and rod toward the actuator module 46 into a retracted position. The actuator module 46 is filled with hydraulic fluid 68 surrounding the solenoids. A diaphragm assembly 70 is attached to the external surface of the actuator module housing and communicates with the hydraulic fluid 68 through an orifice 72. A pressure compensation diaphragm 74 expandably seals the fluid in the actuator module, allowing pressure to be equalized across the walls of the housing and compensating for changes in the internal volume of the actuator module due to movement of the plungers, linkage and control rod, expansion from solenoid heating and changes in ambient pressure. A flexible rubber bellows 76 sealingly surrounds the control rod between the actuator module and the valve module. Alternative configurations and assemblies, for instance, piezo-electric stacks, bi-morph materials and state changing fluids, may be used to translate the electrical impulses from the signal processor into mechanical movement of the control arm.
The valve module 48 is sized to fit tightly in the drill pipe and has a circumferential groove 78 machined into the outer surface to seat an O-ring 80 used to provide a seal between the upper inlet portion 82 of the valve module housing 84 and the lower outlet portion 86. An inlet duct 88 having an axis along the axis of the drill pipe 22 is located on the upper portion of the valve module and communicates with the radial wall of an annular chamber 90. Annular chamber 90 has an axis of revolution lying normal to the axis of the drill pipe 22. Two outlet ducts 92 and 94 are coaxial with the annular axis of revolution and communicate with the vortex chamber through an open cylindrical chamber 96, coaxial with outlet ducts and extending radially to the annular vortex chamber. The axial outlet ducts 92 and 94 can be machined to an efficient nozzle shape or to threadingly receive commercially available drill bit nozzles.
The control rod 50 linking the actuator module 46 to the valve module 48 extends through passage 66 into the annular chamber 90 in a direction parallel to the axis of the drill pipe. Passage 66 and control rod 50 are offset from but adjacent the radial inlet duct 88, perpendicular to the axis of revolution of annular chamber 90 and centered thereto. A perpendicular tab 102 is attached to the free end of control rod 50 and extends in each direction a distance less than half the width of annular chamber 90 forming a "T" junction with the control rod. A groove or slot 104 is machined into the interior wall of the annular chamber 90 and sized to accept tab 102 in a recessed position flush with the contour of the chamber wall when control rod 50 is in the retracted position. When control rod 50 is in the extended position, tab 102 is displaced into the vortex chamber by a distance corresponding to the distance control rod 50 is urged by linkage 56.
The composite geometry of the annular chamber 90, the axial outlet ducts 92 and 94, the cylindrical chamber 96, passage 66 and slot 104 form a vortex chamber 105, shown in FIG. 4, having geometric symmetry on either side of the plane passing through the axes of inlet duct 88 and outlet ducts 92 and 94.
The valve module housing 84 is tapered on opposite sides at 93 and 95 in the vicinity of the two axial outlet ducts 92 and 94, respectively, to permit free flow between the housing and the drill pipe of drilling mud passing through the vortex chamber 105. A downwardly converging flow guide 106 can be used to channel the annular flow of drilling mud past the actuator module 46 into inlet duct 88 of the valve module 48.
The symmetry of the vortex chamber 105 greatly simplifies fabrication of the valve module. Each identical half of the chamber, as shown in FIG. 4, is machined from a piece of solid stock, the two halves are assembled together into a unit, and the unit is turned on a lathe to achieve the required diameter and to cut O-ring groove 78. Tapered sections 93 and 95 are then milled into the sides of the unit. The two halves are disassembled, the retractable control rod 50 and tab 102 assembly is positioned and the halves are reassembled to each other by bolts, brazing or other means. These simple fabrication techniques are generally well suited to modern numerical control machine shop practice.
In use, the vortex chamber mud pulser 44 is positioned in the drill pipe 22 near the instrumentation 39, signal processor 40 and power supply 42. Electrical impulses are fed from the signal processor to the actuator module 46 in sequences containing data encoded into binary form and applied alternately to a first and second coaxial solenoid 52 and 54 to magnetically move the plunger and, through linkage 56, to selectively extend and retract a control rod 50 alternatively toward and away from the valve module 48. The mass and travel distance of the control rod and tab are small; consequently less actuator power is required and system response time is faster than in typical mechanical systems. Moreover, the simplicity of movement and minimal inertia of the control rod and tab assures a rugged shock-resistant device well suited to the down-hole environment.
Drilling mud propelled down the drill pipe by pump 36 passes around the actuator module and into inlet duct 88 in the valve module 48. Passage of mud around the valve module is prevented by O-ring 80 sealingly compressed between the valve module and the drill pipe. The mud flows through the inlet into the vortex chamber 105. When the control rod 50 is in the retracted position, tab 102 is recessed in groove 104 and does not interfere with the flow of the drilling mud. Undisturbed flow encircles the vortex chamber 105 in a relatively symmetric pattern resulting in radial flow into the axial outlet ducts 92 and 94 as shown in FIGS. 5 and 6, with a plane of essentially zero flow formed midway between the two outlet ducts along the vortex chamber plane of symmetry. In prior art single outlet devices this plane is formed by a back plate and is subjected to high pressure and wear. Here the pressure is equalized as the fluid is free to flow symmetrically in both directions. When control rod 50 is extended in response to an electrical impulse sent to the actuator module 48 from the signal processor 40, tab 102 is projected into the vortex chamber 105 and the chamber ceases to have symmetry about the axis of the radial inlet duct 88. The obstruction produced by tab 102 initiates a vortical flow pattern, shown by the arrows in FIGS. 7 and 8, following the chamber walls away from the disturbance and producing a "free" vortex. In a "free" vortex the angular momentum of the fluid is conserved and the angular velocity of the fluid increases as the flow swirls toward the centrally located outlet ducts 92 and 94. The increasing velocity produces a large pressure gradient between the slower moving and higher pressure flow near the chamber walls and the faster moving and lower pressure flow approaching the outlets. The magnitude of the throttling effect of the gradient is determined by the geometry of the chamber. The vortex increases the tangential velocity of the flow, reduces the static pressure normally driving the fluid through the outlets and produces a rapid reduction in flow rate, known as a "water hammer". The sudden flow restriction produces a pressure pulse propagating through the fluid at the speed of sound. A similar pulse is initiated by the withdrawal of tab 102 from the chamber as the flow returns to an unperturbed radial flow pattern with an attendant rapid increase in flow rate. Pressure pulses thus generated travel up the drilling mud and are sensed by a pressure transducer 45 in feed line 32 on the surface where the data encoded in the sequences or patterns of pressure pulses are interpreted.
In view of the foregoing, it is apparent that the present invention makes available a mud pulser capable of viably telemetering down-hole sensor signals to operators located at the surface. The ability to produce a high signal rate from a rugged, reliable and inexpensive pulser has not been heretofore possible in the prior art.
Inasmuch as the present invention is subject to many variations, modifications and changes in detail, it is intended that all subject matter discussed above or shown in the accompanying drawings be interpreted as illustrative only and not be taken in a limiting sense. | 4y
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This invention is a continuation-in-part of U.S. Application Ser. No. 217,953, filed Dec. 19, 1980 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a particular kind of router bit used with earth-moving equipment, e.g., tractor scrapers, bucket loaders, a dozer, and the like, for use in cutting into underlying terrain. More particularly, the present invention relates to an improved router bit having two parts, one of which may be permanently affixed to the earth-moving apparatus, while the other is separable from the former in order, inter alia, to reduce the ordinarily high cost of repair and replacement normally required when conventional unitary router bits become worn and ineffective.
2. The Prior Art
Most earth-moving apparatus includes a horizontally-elongated cutting edge for the purpose of cutting into the underlying terrain. This cutting edge is normally located in front of what is commonly called a scraper bowl, which is used to collect and hold the dirt sheared by the cutting edge. Secured to each side of the scraper bowl, adjacent and generally perpendicular to the cutting edge, are devices known as router bits. Router bits are used to slice vertically through the earth, perpendicular to the cutting edge, as the earth-moving equipment is being moved forwardly to ensure a clean cut and to protect the lower leading edges of the scraper bowl sides and the adjacent lateral ends of the cutting edge. If router bits are not provided, or if they are worn excessively, the lower leading edges, as well as the ends of the cutting edge, wear excessively, necessitating frequent time-consuming and expensive repair and, all too often, very costly replacement.
Conventional router bits are unitary in construction, normally manufactured by forging or casting, and are bulky because of the strength required for the bits. Normally, router bits are secured by bolts to the scraper side walls in order to perform their intended purpose, as aforesaid. Most conventional types of router bits will also include a metallic bar, or a thickened integrally formed rib which acts as a shield to protect the bolts from excessive wear due to the continuous passage of earth.
Conventional router bits, primarily because of their unitary construction, are often difficult to remove and expensive to repair and replace when they wear out. Replacement of router bits of a unitary structure involves taking the equipment out of service and loosening the bolts, known as plow bolts, and replacing the router bit. Since the router bits are of a unitary structure, a major portion of the bit is discarded. Normally four to five plow bolts hold each bit and the bolts are not readily accessible, are usually tightly installed requiring significant manual labor to loosen. Bolt threads may be damaged and bolt heads or nuts partially rounded, even though there may be bars or thickened edges which are intended to protect the bolt assembly. When such damage occurs to the bolt assembly because of the passage of dirt and rocks, replacement of the router bits may become a difficult chore.
Usually, the major portion of the upper section of a conventional router bit does not experience the degree of excessive wear that would require the need for constant repair and replacement of that particular part. Yet, because of its unitary construction, the entire router bit must be removed for repair and/or replacement even though only the lower portion is the only area affected and usually worn. In these situations, it is often necessary to replace, as well, the bolts used to secure the router bits to the scraper bowl sides. Naturally, this adds to the high cost of maintenance. Moreover, because router bits are usually formed of forgings, which are relatively expensive to fabricate and, thus, to replace, the constant expense and effort required to attend to their maintenance is rather high.
A typical prior art structure is that of U.S. Pat. No. 4,208,817 issued June 24, 1980 and the prior patents cited therein.
SUMMARY OF THE INVENTION
The present invention overcomes many of the problems associated with the maintenance and use of conventional router bits. Instead of a unitary construction, the present invention comprises a router bit having two separable portions, one being affixed to each of the side walls of the scraper bowl, while the other is separable therefrom and may be entirely disposed of when worn. The upper portion may be bolted or welded onto the side walls and may be used over a long period of time despite the fact that only the lower portion may require frequent repair or replacement.
The two portions may be joined through means of interlocking fingers and are further secured to one another by means that will be explained in more detail below. Lateral movement of the lower portion is prevented through the use of a metallic bar or similar device which may be welded or otherwise affixed onto each side thereof. When the two portions are joined together, the bars partially overlap and traverse the interlocking fingers in order to stabilize the lower portion to prevent against lateral movement. The bars also act to protect the bolts, when used in place of a weld.
Thus, there is a substantial reduction in material and labor expense in the event the router bit of the present invention becomes worn, since only the lower portion, rather than the entire device, including the usually much larger upper portion, will require replacement or repair. Since only the relatively smaller lower portion is replaced, the part may be fabricated of less expensive flat metal plate instead of expensive castings or forgings used to fabricate the bulkier conventional one-piece router bits. It is recognized in the art that the fabrication of router bits from flat metal plate, in contrast to expensive forgings and castings, offers significant economic advantages. Where economic savings in initial manufacture are added to the economic savings in replacement and repair, the improved router bit of this invention offers significant economic advantages.
Although the device of this invention is fabricated of flat metal sheet, the strength and effectiveness of the router bit of the present invention is not sacrificed. For example, when joined together, the two portions of the bit derive substantial strength from the interlocking finger arrangement. The bars which may be formed of relatively large diameter steel reinforcing rods which may be welded in place and which function to provide greater stabilization and to prevent lateral movement of the lower portion, in addition to protecting the bolt assembly.
In an alternative, easier to make embodiment a replaceable wear-edge router bit has a mounting member having a forward end and a rear end, and is adapted to be mounted as by welding to a piece of earth-moving machinery such as a bulldozer. A lower insert element which is detachable from the mounting member includes a portion which defines an earth-cutting edge. The mounting member and the insert each have a plurality of interlocking finger means and finger apertures. The finger means of the mounting member extend downwardly and forwardly, that is, point toward the ground and in the direction of forward movement of the earth-moving machine to which the router bit is to be mounted. The finger means of the insert point upwardly and rearwardly so as to interlock with finger means of the mounting member. Side plates are removably affixed to both sides of either the mounting member or the insert in an interference fit between the side plates to thereby prevent both lateral and forward movement of the insert relative to the first member.
In operation the greatest loads imposed upon the router arise from the downward weight of the earth-moving machine to which the router bit is mounted, which causes the router bit to cut into the underlying soil, and a horizontal force applied by forward motion of the machine which forces the router bit to plow forwardly through the soil. The primary forces on the insert are therefore in an upward and rearward direction. The disposition of the interlocking finger means is such that these primary forces urge the interlocking fingers against each other into firm engagement. Other forces operating on the router bit are lateral loads on the insert and forwardly directed forces acting on the insert, each of which forces alone would tend to bring about a disengagement of the interlocking fingers. In a preferred embodiment of the invention, these additional forces are counteracted by a pair of said plates, one plate being bolted to each side of the mounting member of the router bit so as to cover at least the interlocking portions of the both sets of fingers and thus hold the insert against lateral loads relative to the mounting member. The side plates may be curved and shaped so as to bite into the side surfaces of the insert and thereby retain the insert against forces acting forwardly on the insert which would separate the insert from the mounting member.
In a preferred embodiment of the invention the side plates are elongated members having a pair of long edges which are cut so as to form a corner of the line at intersection between the side surface and the long edge surface of each plate. The plates are shaped by a slight crowning so as to impart a concave bow to the plates between the long edges of the side plates on the side facing the interlocking fingers of the router bit. The side plates are mounted with the concave side against the side surfaces of the mounting member and insert, with the long edges lying transversely to the direction of the interlocking fingers. When the side plates are tightened against the mounting member and the insert by means of suitably mounting hardware, the inturned corners of the long edges grip the side surfaces on the insert.
The insert may be readily detached from the mounting member by loosening the bolts which tighten the side plates and hitting the rear end of the insert with a sledge hammer to bring about disengagement of the interlocking fingers, following which the insert drops away from the mounting member or can be easily removed.
This quick change replaceable router bit further improves over the prior art in that all of its major components can be constructed by cutting relatively inexpensive flat stock, such as steel plate, to make the mounting member, the insert, and the side plates. Only conventional bolts and nuts are required in addition to those components to make a complete router bit.
Other objects and advantages of the present invention will become apparent from the following specification taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of earth-moving equipment, namely, a tractor scraper, employing an embodiment of the present invention;
FIG. 2 is an enlarged view of the router bit of the present invention shown attached to each of the vertical sides of the scraper bowl used with earth-moving equipment;
FIG. 3 is an enlarged fragmentary side elevation of the router bit of the present invention;
FIG. 4 is an enlarged fragmentary side elevation of the router bit of the present invention wherein the two sections are shown separately; and
FIG. 5 is an isometric view of the lower section of the device of the present invention.
FIG. 6 is a perspective view of a quick change replaceable router bit according to this invention mounted to a piece of of earth-moving equipment, namely, the scraper bowl of a tractor, shown only in part.
FIG. 7 is a view taken in side elevation of the quick change replaceable router bit.
FIG. 8 is an exploded perspective view illustrating the component parts of the quick change replaceable router bit.
FIG. 9 is a front elevational view of the assembled router bit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention may be attached to earth-moving equipment, such as the tractor scraper shown in FIG. 1. However, it will be understood that the present invention is not limited to use with tractor scrapers, but may also be employed as effectively in a variety of other earth-moving apparatus, such as, for example, dozers, bucket loaders, etc. The earth-moving equipment shown in FIG. 1 includes a tractor 10 and a trailing scraper bowl 12. The lower edge of the bowl 12 at the forward end 14 is provided with a horizontally-elongated scraper blade 16, which can be engaged with the underlying terrain by lowering the bowl 12 about a pivot axis defined by the centers of its rear wheels 18 in the conventional manner.
The bowl 12 has upstanding sidewalls 22. The blade 16 extends between the walls 22.
Referring to FIG. 2, each sidewall 22, near the forward end 14 of the bowl, has a downwardly-extending lower edge 30. Along the length of the edge 30, on each of the sidewalls 22, a router bit 40 is provided. According to the invention, the router bit 40 is comprised of two parts 42, 44. Upper part 42 is generally affixed along edge 30 of sidewalls 22 by use of conventional means, such as plow bolts 46. Alternatively, section 42 may also be welded to edge 30. The lower part 44, also referred to as an insert, is separable from upper part 42 and may be of equal size to part 42, through the size of either section may vary depending on the circumstances.
Referring now to FIGS 3-5, the router bit of this intention is generally in the shape of a parallelogram when installed and includes a lower formed edge portion 48 which forms the forwarded cutting edge of the router bit. As wear takes place in normal usage of the router bit, it generally occurs in the area of the lower portion of vertical face 50 and the forward portion of the lower horizontal face 51 such that the cutting edge gradually becomes rounded and the wear tends to progress towards the rear. The type of wear pattern is typical of any router bit including that of the present invention.
In accordance with this invention, the router bit 40 is composed of two parts 42 and 44, as described, such that the cutting edge 48 is in the lower part or insert 44. Thus, when wear does take place, the lower part 44 of the router bit 40 is replaced, while the upper part 42 remains affixed to the side walls, as described.
One of the features of the present invention is the use of interlocking fingers to join the upper and lower parts of the router bit. Thus, as shown in FIG. 3, for example, the upper part 42 of the bit 40 includes a plurality of spaced fingers 52 extending generally in the direction of the lower forward edge portion 48 of the bit. Between the spaced fingers 52 are finger apertures 53 or portions of finger apertures. The lower part 44 of the bit also includes a plurality of spaced fingers 54, again with spaced finger apertures 56 therebetween.
As seen in FIG. 3, for example, the fingers and finger apertures of both the upper and lower parts of the bit are oriented such that the forces against the router bit, during its use, tend to urge the lower part 44 tightly against the upper part. Since the thrust forces are upwardly and rearwardly as shown by arrows in FIG. 3, the lower part 44 is forced upwardly and rearwardly, causing the lower part 44 to be urged upwardly and rearwardly in a locked position against the upper part 42.
To assure that the upper and lower parts 42, 44 of the bit remain together after assembly on the equipment, the finger surfaces and finger aperture surfaces of each part are formed parallel to the corresponding mating surfaces of the fingers and finger apertures, i.e., perpendicular to the plane of the router bit as shown, for example, in FIG. 5. Additionally, as mentioned, the fingers and finger apertures are oriented such that the rearward and upward forces generated during use tend to lock the two parts together.
Lateral movement of one part of the bit relative to the other, i.e., sidewise movement of the parts, is prevented by a pair of bars 60 and 61 which may, for example be a bent piece of reinforcing rod which is affixed to the fingers 54 of the lower part 44 or each side thereof, as shown in FIG. 5. As shown, the bars are formed to protect the plow bolts 46. Thus, when the lower part 44 is assembled to the upper part 42, fingers 52 of the upper part fit into the finger apertures 56, the latter bounded on each side by a portion 60a and 61a of the bars 60 and 61, respectively, which are located on each side of each of the finger apertures. When assembled, as seen in FIG. 3, the portions 60a and 61b of the bars overlying the finger apertures 56 operate to prevent sidewise movement of the fingers 52 in the corresponding finger apertures 56. One convenient way of affixing the bars, which function as side restraint guides to the lower part 44 of the bit 40 is by welding, although other means may be used.
While the bars are shown as being affixed to the lower part 44, they may just as easily be affixed to the upper part and still perform the same essential function. It is preferred, however, that the bars 60 and 61 be affixed to the lower part 44. Since the function of the bars in the present invention is twofold, i.e., to protect the plow bolts if used, and to prevent sidewise movement of the parts 42 and 44, it is preferred that the bars be part of the replaceable lower part 44 in order to assure proper protection to the plow bolts. Thus, as the bit and the bars are worn during use, there is an advantage to be able easily to replace both at the same time.
Another feature of this invention is the arrangement by which the upper and lower parts 42 and 44 of the bit are held together in use. While the fingers and finger apertures maintain the parts fixed against upward and rearward movement and the bars prevent lateral or sidewise movement as described, means also are provided to prevent forward movement of the lower part 44 relative to the upper part 42.
Referring to FIG. 3 and 4, at least two lock pins 65 and 66 are used. The lock pins may be in the form of "flex pins" which are separated elongated metal members with a resilient member such as rubber therebetween. The length of the flex pins is about equal to the cross-sectional thickness of the router bit. The flex pins are received in pin apertures 67 and 68 provided between the opposed faces of the sidewalls of the fingers and finger apertures. Half of each pin aperture 67a, 68a is formed in the finger and half 67b, 67b in the opposed finger aperture.
Referring to FIG. 4, the lower part 44 is assembled to the upper part by sliding the lower part from right to left as seen in FIG. 4, i.e., in the rearward direction.
When properly positioned, each half of the respective pin apertures are aligned and the pins are driven in place. The pins are proportioned to provide an interference fit in the apertures and as they are driven into the apertures, the resilient member is compressed and the pin is securely in place.
In order to prevent forward movement of the lower part 44 relative to the upper part, the pin apertures 67 and 68 are provided between the tip and base of the fingers, i.e., half the aperture is provided between the tip and base of finger 52 and the other half is provided between the end and the base of the finger apertures, each portion being located to be aligned when the parts 42 and 44 are assembled. Since forward movement of the lower part 44 relative to the upper part involves sliding movement of the fingers relative to the finger apertures, the pins 65 and 66 function to prevent such forward sliding movement. Rearward movement is prevented, as described, by the fingers which are bottomed against the base of the corresponding finger holes.
As will be apparent from the foregoing, replacement of the router bit in accordance with this invention is comparatively simple compared to prior art router bits. By this invention, only the lower part 44 of the bit is replaced, resulting in a significant savings because the entire router bit, including the unworn portion, is not replaced and discarded. The estimated savings of the replacement insert, i.e., the lower part, as compared to the entire bit, is about 60%. Further, the comparative simplicity of the replacement operation results in lower maintenance costs both in the actual installation and in the costs of the item replaced.
The replacement part is shown in FIG. 5 and is essentially the lower part 44 of the bit, and the locking pins. To replace a worn bit of in accordance with the present invention, the pins are driven out and lower part is moved left to right as shown in FIG. 4. Thereafter the new replacement lower part 44, shown in FIG. 5, is assembled by moving it right to left as shown in FIG. 4. The pins are then driven into place, the pins preferably oriented so that the metal ends face forward and to the rear, and replacement is complete.
Another practical advantage of the router bit of the present invention is the savings in cost and savings in manufacture thereof. In a preferred form, the router bit is formed of metal plate rather than being cast or forged. As compared to a casting or a forging, metal plate is currently less expensive. Further, the router bit of this invention is less bulky than the prior art castings which for strength reasons tend to be bulky.
In manufacture, the plate may be cut by a tracer torch with an electric eye to provide the parts, as decribed, or merely the lower part. The bars are of reinforcing rod, cut to length, formed and welded in place on the lower part, as described. As will be appreciated, the number, shape and size of the fingers and finger apertures may vary from those described here without departing from the present invention. It is also understood that the size and overall shape of the router bit of this invention may be varied as desired, e.g., more material at the cutting edge or an extended cutting edge. The router bit of this invention may be welded or bolted in place, as desired. The bars may be secured in place other than by welding.
While it is preferred to form the router bit out of plate for present reasons of economy, it may be advantageous to form the parts of the router bit by other fabrication techniques.
It will also be apparent that the router bit of the present invention may be sold as a complete assembly for replacement of current prior art bits or as original equipment. It is also apparent that the lower part of the router bit in accordance with this invention also possesses separate utility as a replacement part and may be separately made and sold.
An improved quick change replaceable router bit 110 shown in FIG. 6 includes an upper mounting member 112, which is welded along its upper edge 114 to a portion 116 of a piece of earth-moving machinery. A lower insert member 118 is secured in co-planar relationship to the mounting member 112 by means of side plates 120, 122 in a manner to be described. The router bit has a forward edge 124, a rear edge 126, and lower earth-cutting edge 128.
Turning now to FIGS. 7 and 8, the upper mounting member 112 has defined along its lower edge a plurality of downwardly and forwardly extending fingers 130, between which are defined finger apertures 132. The lower insert member 118 has defined along its upper edge a second plurality of fingers 134 between which are finger apertures 136. The fingers 134 extend upwardly and rearwardly and are shaped and configured so as to interlock with the fingers and finger apertures of the upper mounting member 112 as illustrated in dotted lines in FIG. 7. As best appreciated in FIG. 7, the rearward and upward loads imposed on thr insert 118 force the fingers into tighter interlocking engagement. The insert 118 is retained to the mounting member 112 by a pair of elongated side plates 120, 122 bolted to the mounting member 112 by means of a series of mounting bolts 138 which extend through holes 142 in the mounting member 112 and aligned with holes 144 in the side plates each bolt being secured by a corresponding nut 140.
Each side plate 120, 122 has a long upper edge 146 and a long lower edge 148 which may be parallel with the upper edge. The length of the side plates desirably extends across all of the interlocking fingers of the insert and mounting member i.e., from front to rear of the router bit, and the width of each side plate desirably at least covers the interlocked fingers 130, 134. It will be understood that while it is preferable to mount the side plates to the permamently attached mounting member 112, it is possible to construct a quick-change router bit with the side plates mounted to the insert 118.
Turning now to FIG. 9, it is seen that the side plates 120 and 122 seen edge-on from the front of the router bit are crowned or bowed in a vertical direction, that is, between the upper edge 146 and lower edge 148. The plates are otherwise straight along their long dimension, i.e., from front to rear of the router bit. The side plates are therefore concavely curved on the side facing the mounting member and the insert. The plates are preferably cut so as to form well-defined corners 150 at the intersection between the upper and lower edge surfaces 146, 148 and the concave inner surfaces of the side plates. These corners 150 desirably extend the full length of the upper and lower edges of the side plates. The side plates are fastened to the mounting member 112 by means of the mounting bolts and nuts 138, 140, respectively, which extend through bolt holes 144 situated generally midway between the upper and lower edges 146, 148. When the mounting bolts are tightened, inward pressure is applied to the corners 150, causing the relatively sharp corner lines along the lower edges 148 of the side plates to bite into the side surfaces of the lower insert 118.
The corner lines 150 slant upwardly in a forward direction so as to lie generally transversely to the direction of disengagement between the insert 118 and the mounting member 112. This direction of disengagement is generally suggested by the dotted lines in FIG. 8 connecting the fingers 134 of the insert 118 to corresponding finger apertures 132 of the mounting member 112. The angle of the corner lines 150 relative to the direction of the interlocking fingers 132, 134 may fall within a relatively wide range. Maximum retention of the insert by the clamping action of the side plates will be obtained when the corner lines 150 lie perpendicular to the direction of the interlocking fingers 132, 134. Departures from such a perpendicular relationship will normally provide adequate retaining force through a relatively wide range of angles.
All components of the quick change replaceable router can be made by cutting relatively inexpensive flat sheet stock, such as steel plate. Further, plate of similar thickness may be used for all components to minimize cost and complexity of of manufacture. The various parts may be flame cut by means of photocell guided automatic cutting torches. It will be appreciated that no welding of parts is required except for attachment of the mounting member 112 to a particular piece of earth-moving equipment. The crowning of the side plates 120, 122 may be accomplished with the aid of a press or any other suitable method. The bolt holes may be drilled with conventional drills, or may be flame cut with a torch.
It will, thus, be apparent to those skilled in the art that various changes, modifications and alterations may be made to the router bit herein disclosed, or to parts thereof, or to the method of making the same without departing from the scope of the present invention as set forth in the appended claims. | 4y
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FIELD
[0001] The technology described herein relates to an assay of measuring active molecular transport system out of the cells by ATP-binding cassette transporters.
BACKGROUND
[0002] Toxic side effects of drug have become the major obstacle in developing new block-buster pharmaceuticals. To improve the efficacy and in particular the safety of novel drug candidates, one has to assess the toxic effects of novel lead compounds in early phase in high-throughput mode. Toxicity relates also to specific transporter systems, which specifically pump small molecular compounds out from cells using ATP as energy source. In terms of adverse effect, the vital organs, such as liver, brain, heart muscles, has to be addressed.
[0003] ABC (ATP-binding cassette) transporters are one of the largest and most ancient (conserved) families of transporters present from prokaryotic organism to humans. These ABC transporters are transmembrane proteins that export structurally diverse hydrophobic compounds from the cell driven by ATP hydrolysis. One of the most studied ABC transporter is the P-glycoprotein (PGP) which is e.g. known to play central role in the absorption and distribution of drugs in many organisms and organs. PGP forms a major component of the blood-brain barrier. Its role is also to prevent the entry of potentially toxic compounds from the gut into the blood and protect sensitive internal organs. On the other hand, PGP and the other ABC transporters in general can also reduce the oral bioavailability of the therapeutic drug and the targeting of such drugs to the brain tissue, limiting the efficacy of treatment.
[0004] Many of the commonly used drugs are PGP substrates. Compounds that interact with PGP can function as stimulators or inhibitors of its ATPase activity. Over expression of ABC transporters has been also linked to efflux of chemotherapeutic drugs used for cancer treatment, sometimes leading to multidrug resistance problem. ABC transporters also play an important role in certain adverse drug-drug interactions.
[0005] ATP hydrolysis by transporters takes place at the two nucleotide binding (NB) domains located on the cytoplasmic face of the protein. ABC transporter consist of two homologous halves, each with six transmembrane (TM) segments and a cytosolic NB domain. The drug-binding site is formed by the TM regions of both halves of PGP. Substrates gain entry to this site from within the membrane. Nucleotide binding causes repacking of the TM regions of PGP, thereby opening the central pore to allow access of hydrophobic drugs directly form the lipid bilayer, leading to the proposal that ATP binding, rather than hydrolysis, drives the conformational changes associated with transport. First there is the catalytic cycle whereby ATP is hydrolyzed; this comprises ATP binding, formation of a putative nucleotide sandwich dimer, hydrolysis of ATP, dissociation of N and dissociation of ADP. The energy derived from this cycle is coupled to substrate movement across the membrane.
[0006] There are methods to measure specific transporters, none of which, however, is very efficient and suitable for high-throughput application.
[0007] The traditional monolayer efflux assay is regarded as the standard for identifying PGP substrates because this assay measures efflux in the most direct manner. However, monolayer assays are labour-intensive due to need of constant cell culturing and thus this assay is not amenable to automation.
[0008] ABC transporters can be also studied in membrane vesicles prepared from cells over expressing the wanted transporter. Inside-out membrane vesicles are good tools for calcein AM fluorescence based method monitoring the transporter efflux. Calcein AM is a substrate for the ABC transporters and it is intracellularly converted to a fluorescent product. However, this assay is not designed to distinguish PGP substrates from inhibitors, and do not directly measure transport. The method as such can be automated.
[0009] PerkinElmer has developed a non-radioactive heterogeneous GTP binding assay to monitor activation of G protein-coupled receptors. The assay exploits the unique fluorescence properties of lanthanide chelates. The assay is based on a GTP analogue labelled with a europium chelate and membrane fragments, all bound to a filtration plate. The labelled GTP derivative has an enhanced stability towards enzymatic hydrolysis. The same assay format could be adapted to the corresponding ABC transported assay by substituting the labelled GTP derivative with the corresponding ATP analogue.
[0010] The major drawback of heterogeneous assays is the requirement for extensive washings and prolonged incubations making their automation demanding.
[0011] Solvo Company has developed a homogeneous assay monitoring colorimetrically the release of inorganic phosphate by ATP hydrolysis. Instability of the signal makes the assay difficult to automate and to perform in high-throughput format although this assay is readily automated.
OBJECTS AND SUMMARY OF THE INVENTION
[0012] The main objective of the present invention is to provide an easily automated, high-throughput proximity assay for cellular transport system.
[0013] The homogenous assay format disclosed here takes advantageous of the fact that ABC transporters have two similar ATP binding sites. Accordingly, two ATP molecules are able to bind simultaneously to these adjacent NB sites.
[0014] According to one aspect of this invention, in addition to ATP derivatives, the assay can utilize other binding molecules binding to NB sites or adjacent to NB sites. Such molecules can be used as carrier of one partner of proximity assay, and such a molecule may comprise antibodies, oligopeptides, polypeptides, oligonucleotides polynucleotises, lectins or other natural or artificial polymers either mimicking ATP binding or recognizing adjacent motifs of NB sites.
[0015] According to one aspect this invention the signal detection is based on various forms of proximity assays. Examples of proximity assays include fluorescence energy transfer, fluorescence energy quenching, energy transfer between upconverted particles and fluorescent acceptors, fluorescence cross-correlation, luminescent oxygen channelling, and enzyme fragment complex formation upon proximity.
[0016] According to one aspect this invention concerns an assay where the energy transfer signal is detected between two labelled ATP derivatives when bound to ATP-binding cassette, wherein one of the ATP derivatives is labelled with an energy donor and the other one with an energy acceptor.
[0017] Thus, according to one aspect this invention concerns an assay wherein the energy acceptors are labelled ATP conjugates comprising a fluorometric or luminometric label.
[0018] According to another aspect this invention concerns an assay wherein the energy donors are labelled ATP conjugates comprising a fluorometric or luminometric label.
[0019] According to another aspect this invention concerns an assay wherein the energy acceptors are antibodies, oligopeptides, polypeptides, oligonucleotides polynucleotides, lectins or other natural of artificial polymers either mimicking ATP binding or recognizing adjacent motifs of NB sites labelled with fluorometric or luminometric label.
[0020] According to another aspect this invention concerns an assay wherein the energy donors are anti-transporter antibodies, lectins, polypeptides, polynucleotides, oligonucleotides, oligopeptides, anti-tag antibodies or other natural or artificial polymers either mimicking ATP binding or recognizing adjacent motifs of NB sites labelled with fluorometric or luminometric label.
[0021] According to another aspect this invention concerns an assay wherein the labelled ATP derivatives have an enhanced stability towards nucleases.
[0022] According to one aspect, the invention is based on a novel method to develop binding-domain compatible, non-hydrolyzable ATP conjugates containing a suitable label moiety enabling the measurement of transporter activation easily and quantitatively. The labeled ATPs bind to transporter binding domain when the transporter is activated with a drug or other molecule under examination, and since the ATP derivatives are not hydrolyzed, they allow the quantitation of activated transporter.
DETAILED DESCRIPTION OF THE INVENTION
[0023] As defined herein, “a transporter binding molecule” refers to a labelled ATP derivative, anti-transporter antibody, lectin, polypeptide, polynucleotide, oligonucleotide, oligopeptide, anti-tag antibody and other molecule capable in binding ATP binding sites and other natural and artificial polymers either mimicking ATP binding or recognizing adjacent motifs of NB sites
[0024] As defined herein, “ABC transporter” is a family of membrane transport proteins that use the energy of ATP hydrolysis to transport various molecules across the membrane.
[0025] As defined herein “ATP-binding cassette transporters (ABC-transporter)” are members of a superfamily with representatives in all extant phyla from prokaryotes to humans. These are transmembrane proteins that function in the transport of a wide variety of substrates across extra- and intracellular membranes, including metabolic products, lipids and sterols, and drugs. Proteins are classified as ABC transporters based on the sequence and organization of their ATP-binding domain(s), also known as nucleotide-binding (NB) domains. ABC transporters are involved in tumour resistance, cystic fibrosis, bacterial multidrug resistance and a range of other inherited human diseases.
[0026] As defined herein, “a stable ATP derivative” refers to a labelled ATP derivative with enhanced stability towards nucleases.
[0027] The invention disclosed herein comprises a homogenous non-radioactive proximity assay for ABC transporter activity wherein detection of the ABC transporter activity is based on a signal between two labeled ABC transporter binding molecules.
[0028] “The sites adjacent to ATP binding domains can be any suitable binding sites on the same transporter complex, which together with one reagent bound to ATP binding domain, allow direct monitoring of the transporter activation by energy transfer.”
[0029] “Proximity assay” means a situation, wherein labels through binding reaction (for example energy donoring chelate label and energy accepting organic fluorescence label) come so close to each other that non radiating (Förster) energy transfer can occur. This distance is in general less than 20 nm.
[0030] According to one embodiment, the labelled ABC transporter binding molecules are ATP derivatives, anti-transporter antibodies, lectins, polypeptides, polynucleotides, oligonucleotides, oligopeptides, or anti-tag antibodies. According to a preferable embodiment, the ABC transporter binding molecules are ATP derivatives.
[0031] According to another embodiment the signal detection is based on fluorescence energy transfer, fluorescence energy quenching, energy transfer between upconverted particles and fluorescent acceptors, fluorescence cross-correlation, luminescent oxygen channelling, and enzyme fragment complex formation upon proximity. In particular embodiment the signal detection is based on time-resolved fluorescence energy transfer or time-resolved fluorescence energy quenching.
[0032] According to another embodiment the ABC transporter binding molecules are labelled with luminescent lanthanide(III) chelates, quantum dots, nanobeads, upconverting phosphors or organic dyes. According to a preferable embodiment, the organic dye is selected from alexa dyes, cyanine dyes, dabcyl, dancyl, fluorescein, rhodamine, TAMRA and bodiby.
[0033] According to another embodiment one of the ATP derivatives is labelled with a luminescent lanthanide(III) chelate and one of the ATP derivatives is labelled with an organic dye. The lanthanide(III) chelate acts as a energy donor and the organic dye acts as an energy acceptor.
[0034] In a particular embodiment two ATP molecules bind to transporter in its activation. Because the binding domains are situated near each other, transporter activation bring the two labels in proximity allowing energy transfer between them in active complex when used in suitable concentrations.
[0035] It is desirable that the ATP derivatives have enhanced stability towards nucleases. This can be achieved by substituting one or more of the oxygen atoms of the triphosphate moiety by carbon, sulphur or nitrogen. Representative structures are ATPaS, ATPyS, ApCpp, AppCp, and AppNHp. These modified ATP derivatives are commercially available.
[0036] The label can be attached to the ATP molecule either directly or via a linker arm. Suitable sites are for labelling are C8 of the adenine moiety, O2′— or O3′— of the sugar moiety and γ-phosphate of the triphosphate moiety. Labelling at γ-phosphate also enhances the nuclease resistance of the said triphosphate.
[0037] In a particular embodiment the labelled ATP derivative is selected from a group consisting of
[0000]
BRIEF DESCRIPTION OF DRAWINGS
[0038] FIG. 1 . A dose-response curve of PGP transporter using verapamil as stimulating drug. 10 nM Eu-labelled ATP (donor; Example 1) and 10 nM Alexa647-labeled ATP (acceptor; Example 5) were used to detect the transporter activity. Energy transfer was measured in the plate reader after 2 h incubation. 2 μg of Sf9 membranes were used/well.
[0039] The invention will be illuminated by the following non-restrictive examples.
EXAMPLES
[0040] The invention is further elucidated by the following examples.
[0041] General. Electrospray mass spectra were recorded on an Applied Biosystems Mariner ESI-TOF instrument. HPLC purifications were performed using a Shimazu LC 10 AT instrument equipped with a diode array detector, a fraction collector and a reversed phase column (LiChrocart 125-3 Purospher RP-18e 5 μm). Mobile phase: (Buffer A): 0.02 M triethylammonium acetate (pH 7.0); (Buffer B): A in 50% (v/v) acetonitrile. Gradient: from 0 to 1 min 95% A, from 1 to 31 min from 95% A to 100% B. Flow rate was 0.6 mL min. −1
Example 1
Synthesis of the derivative between adenosine 5′[γ-thio]triphosphate and {2,2′,2′,2″-{[4′-(4′″-iodoacetamidophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}tetrakis(acetate)}europium(III)
[0042]
[0043] Adenosine 5′-[γ-thio]triphosphate tetralithium salt (1.2 mg) and {2,2′,2″,2′″-{[4′-(4′″-iodoacetamidophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylene-nitrilo)}tetrakis(acetate)}europium(III) (4.2 mg) were dissolved in water and stirred for 2.5 hours at room temperature. The product was purified with HPLC and was analyzed with ESI-TOF mass spectrometry.
Example 2
Amide of adenosine 5′[β,γ-methylene]triphosphate with {2,2′,2″,2″-{[4′-(4′″-aminophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}-tetrakis(acetate)}europium(III)
[0044]
[0045] Adenosine 5′[β,γ-methylene]triphosphate (2.9 mg) and {2,2′,2″,2′″-{[4′-(4′″-aminophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}tetrakis-(acetate)}europium(III) (3.4 mg) were dissolved in 0.5 M MES buffer, pH 5.5 (100 μL). EDAC (3.0 mg) was added and the reaction mixture was stirred overnight at RT. The product was precipitated with acetone. The precipitation was washed with acetone. The product was purified with HPLC and was analyzed with ESI-TOF mass spectrometry.
Example 3
Amide of adenosine 5′[α,β-methylene]triphosphate with { 2,2′,2″,2′″-{[ 4′-(4′″-aminophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}-tetrakis(acetate)}europium(III)
[0046]
[0047] The title compound was synthesized analogously with Example 2 using adenosine 5′-[α,β-methylene]triphosphate as a starting material.
Example 4
Amide of adenosine 5′-[β,γ-methylene]triphosphate with BODIPY-TMR
[0048]
[0049] Adenosine 5′[β,γ-methylene]triphosphate (2.0 mg), 2-(4-aminophenyl)ethylamine (10.4 mg) and EDAC (5.3 mg) were dissolved in MES buffer (200 μL, 0.5 M, pH 5.0), and the reaction was allowed to proceed overnight at room temperature. The product was precipitated with acetone, and the precipitation was washed with the same solvent. The precipitate was dissolved in a mixture of a carbonate buffer (500 μL, 0.1M; pH 8.6) and dioxane (500 μL). BODIPY-TMR NHS (0.7 mg) was added, and the mixture was stirred overnight. The product was precipitated with acetone and was washed with the same solvent. The product was purified with HPLC was analyzed with ESI-TOF mass spectrometry.
Example 5
Amide of adenosine 5′-triphosphate with Alexa 647
[0050]
[0051] Alexa-647 as active ester (Molecular Probes; 1.0 mg) and 2-(4-aminophenyl)ethylamine (0.18 mg) were dissolved in the mixture of 1,4-dioxane (50 μL), water (20 μL) and 0.1M sodium bicarbonate (10 μL). The mixture was stirred overnight and the product was precipitated with acetone. The precipitate, adenosine-5′-triphosphate disodium salt (0.9 mg) and EDAC (0.6 mg) were dissolved in MES buffer (240 μL, 0.5 M, pH 5.5), and the mixture was stirred overnight at room temperature. The product was precipitated with acetone and was washed with the same solvent. The product was purified with HPLC and was analyzed with ESI-TOF mass spectrometry.
Example 6
Amide of adenosine 5′-triphosphate with { 2,2′,2″,2′″-{[ 4′-(4′″-aminophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}tetrakis-acetate)}europium(III)
[0052]
[0053] Adenosine 5′-triphosphate trisodium salt (2.1 mg) and {2,2′,2″,2′″-{[4′-(4′″-aminophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}tetrakis-(acetate)}europium(III) (3.3 mg) were dissolved in MES buffer, pH 5.5 (100 μL). EDAC (3.0 mg) was added and the reaction mixture was stirred overnight at RT. The product was precipitated with acetone (3 mL). The precipitation was washed with acetone. The product was purified with HPLC and was analyzed with ESI-TOF mass spectrometry.
Example 7
Amide of adenosine 5′-[β,γ-S]triphosphate with {2,2′,2″,2′″-{[4′-(4′″-aminophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}tetrakis-(acetate)}europium(III)
[0054]
[0055] The title compound was synthesized according to the method disclosed in Example 2 but by using adenosine 5′-[β,γ-S]triphosphate as a starting material.
Example 8
Amide of adenosine 5′-[β,γ-imino]triphosphate with {2,2′,2″,2′″-{[4′-(4′″-aminophenyl)-2,2′: 6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}-tetrakis(acetate)}europium(III)
[0056]
[0057] The title compound was synthesized according to the method disclosed in Example 2 but by using adenosine 5′-[β,γ-imino]triphosphate as a starting material.
Example 9
Labelling of non-hydrolysable adenosine-5′-triphosphate derivative in 2′-position
[0058]
[0059] 2′-(6-Aminohexylsemicarbazide)adenosine 5′-[γ-thio]-triphosphate and {2,2′,2″,2′″-{[4′-(4′″-isothiocyanatophenyl)-2,2′:6′,2″-terpyridine-6,6″-diyl]bis(methylenenitrilo)}tetrakis(acetate)}europium(III) were dissolved in the mixture of pyridine, triethylamine and water (9:1.5:0.1, v/v/v), and. the solution was stirred overnight at room temperature. The product was purified with HPLC.
Example 10
Labelling of non-hydrolysable adenosine-5′-triphosphate derivative in 8-position
[0060]
[0061] The synthesis was performed according to the method disclosed in Example 9 but by using 8-(6-aminohexyl)adenosine 5′-[γ-thio]-triphosphate as the starting material.
Example 11
Homogeneous Assays
[0062] Eu-labeled ATP (donor, Example 1) and Alexa-647 labeled ATP (acceptor, Example 5) were used to measure the activation through energy transfer between these molecules bound to the adjacent NB sites of the same ABC transporter molecule. The assay was performed using Sf9 cell membrane preparations over-expressing ABC transporters MRP2 or PGP. The same cell line membranes transfected with same vector without transporter insert were used as controls. The membrane preparations (1 μg) in a MES buffer were incubated in lid covered 384-well microtitration plates (Wallac black plates or Wallac white Optiplates) at 37° C. for 5-20 min with varying concentrations of transporter specific substrates (probencid for MRP2 and verapamil for PGP) to get the efflux mechanisms activated. To diminish ATPase activity MgCl 2 was not included. After transporter activation, a reaction mixture containing 10 nM Eu-labeled ATP and 10 nM Alexa-647 labeled ATP were added, and the reaction mixture was incubated for further 2 hours. Duplicate reactions were performed using orthovanadate (Na 3 VO 4 , 1 mM) to measure the vanadate insensitive background. The reaction mixtures were measured directly without further separation by a time-resolved fluorometer (Victor 2) at 665 nm using 50 us delay and a 200 us counting window. To validate the eventual compound interference, measurements were performed also for the signal at 615 nm using the same time-window. These experiments were essential for the measurement of corrected energy-transfer signal. A dose-response curve with PGP transporter using verapamil as stimulating drug is given in FIG. 1 .
[0063] It will be apparent for an expert skilled in the field that other embodiments exist and do not depart from the spirit of the invention. Thus, the described embodiments are illustrative and should not be construed as restrictive. | 4y
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FIELD OF THE INVENTION
[0001] The invention relates to a support material for printing electronic circuits by means of the inkjet printing process with electrically conductive inks.
TECHNICAL BACKGROUND OF THE INVENTION
[0002] An essential step in the production of electronic devices and circuits is the manufacture of conductive connections between the components. These connections must follow a predetermined structure in order that the componentry or the device can carry out its intended function. Such structures can be manufactured from conductive materials in a variety of manners, usually from metals or carbon (graphite). Printing processes are particularly suitable for cheap mass production, whereby the circuits are produced by depositing printing inks which contain the conductive materials onto flat electrically insulating, preferably flexible support materials in a single operational step.
[0003] When manufacturing electronic circuits, inkjet printing technology can be employed. This means that electrically conductive structures can be deposited on insulating support materials, or components which have already been deposited can be conductively connected, whereby in contrast to other printing techniques such as screen printing, a previously prepared printing mask does not have to be produced; thus, it is possible to carry out manufacturing on a small mass-production scale, or even to manufacture single parts, simply and cheaply. Such applications have been described, for example, in the article by John B Blum, “Printed Circuit Design and Manufacture”, 1 Oct. 2007.
[0004] Metal-containing or carbon-containing preparations are usually employed as printing inks; the electrically conductive material is present therein in the form of particles. For inkjet printing, such particles must have very small dimensions, usually less than 1 μm, in order to prevent the printing nozzles from becoming blocked and to prevent the conductive particles from sedimentation in the low-viscosity ink. In order to stabilize the particles against agglomeration and sedimentation, such inks also have to be supplemented with additives such as surfactants or protective colloids, for example. Inks which contain finely divided metallic silver are frequently preferred. Inks of that type are, for example, available from ANP (Advanced Nano Products) in Korea under reference DGP and DGH, from Harima Chemicals Inc, Japan under reference NPS and from Cabot Corporation, USA, under reference CCI-300. The particle size of the silver particles in those inks is in the range from 5 nm to a few hundred nm.
[0005] In addition to using rigid support materials such as glass or ceramic as the support materials to be printed, flexible films formed from polymers, in particular polyesters, are preferably employed. Following inkjet printing on such support materials, the solvent contained in the ink evaporates and the non-volatile additives as well as the silver particles remain in the printed layer. Since the additives are electrical insulators, the conductivity of such printed structures is low. For this reason, as described in the data sheets from the ink manufacturers and in the article by John B Blum, “Printed Circuit Design and Manufacture”, 1 Oct. 2007, a thermal post-treatment is necessary at temperatures of at least 100° C. to over 400° C. in order to produce a metallic conductivity in the printed structures. Particularly at low temperatures, the time required for this necessary thermal post-treatment is long, normally more than 1 hour. If higher temperatures are employed in order to reduce the treatment time, however, it is not possible to use the cheap and easily manipulatable flexible films produced from thermoplastic polymers as a support material since the stability of such foils at the high temperatures required is insufficient and they deform.
[0006] In the article “Low Temperature Chemical Post-treatment of Inkjet-Printed Nano-Particle Silver Inks” (NIP 24 and Digital Fabrication 2008 Final Program and Proceedings, page 907), Werner Zapka et al describe a process wherein the printed structures are treated with a salt solution following drying. Following use, however, that salt solution has to be removed by washing again, thereby constituting a multi-step process with subsequent repeated drying.
[0007] U.S. Pat. No. 3,652,332 A describes the use of porous support materials, in particular coated offset printing paper, to print conductive structures. The printing process used in that case is the letterpress process. The printing inks described for producing the conductive structures are carbon black or flake silver printing inks with particle sizes of distinctly more than 1 μm, which are unsuitable for the inkjet printing process. That patent teaches that the printing medium must have a certain absorbency in order to be able to produce homogeneous printing surfaces with reproducible electrical conductivity. The support materials described in the patent, preferably standard graphical papers coated with clay pigment, do not, however, satisfy the special requirements of inkjet printing with low-viscosity inks containing conductive particles, since they have a coarse and irregular pore structure and low porosity.
[0008] US 2009/0087548 A1 describes a process whereby a metallic ink is applied to a support material having a porous layer. The porous layer prevents the printed structures from spreading, so that very fine structures are obtained. In that process, the metal particles enter the porous layer; the porous layer is then removed in the subsequent heat treatment. Even though very high resolution structures can be printed using that process, a subsequent additional process step for removing the porous layer is required. In addition, that process step involves the use of high temperatures of 300° C., which means that the invention cannot be applied to the preferred flexible support materials.
SUMMARY OF THE INVENTION
[0009] The object of the invention is to provide a support material for printing electronic circuits using printing inks, which contain electrically conductive particles having a mean particle size of less than 1 μm. It endows the printed structures with high electric conductivity even without thermal post-treatment of the printed material. This support material is especially suitable for inkjet printing with metal or carbon (graphite)-containing inks and means that high resolution printing of fine structures can be carried out.
[0010] It has now surprisingly been discovered that the thermal post-treatment of inkjet-printed structures of conductive particles can be dispensed with when the support material contains an outer microporous layer which has a mean pore size of less than 100 nm.
[0011] The invention also pertains to a process for producing an electrically conductive structure on the support material described above.
[0012] Finally, the invention pertains to a printed circuit, manufactured by printing the support material defined above using a printing ink containing electrically conductive particles using the inkjet printing process.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0013] In a preferred embodiment of the invention, the microporous layer has a mean pore size in the range 5 nm to 50 nm.
[0014] Particularly preferably, moreover, the surface of the microporous layer has a mean roughness of less than 1 μm, measured as the Rz parameter in accordance with DIN 4768.
[0015] In a particular embodiment of the invention, the outer microporous layer may be a polymer foam manufactured, for example, using a sol-gel process. Examples of such microporous layers have been described in WO 2007/065841 A1.
[0016] In a further preferred embodiment of the invention, the outer microporous layer contains fine inorganic and/or organic pigment particles and a hydrophilic binding agent. Examples of pigments which in the context of the invention are suitable for the microporous layer are aluminium oxide, aluminium hydroxide, aluminium oxide hydroxide, aluminium oxide hydrate, silicon dioxide, magnesium hydroxide, kaolin, titanium dioxide, zinc oxide, zinc hydroxide, calcium silicate, magnesium silicate, calcium carbonate, magnesium carbonate and barium sulphate. The quantity of pigments in the microporous layer may be 40% to 95% by weight, preferably 60% to 90% by weight, with respect to the weight of the dried layer.
[0017] The particle size of the pigment in the microporous layer is preferably less than 1000 nm, but in particular 50 to 500 nm.
[0018] The mean particle size of the primary particles is preferably less than 100 nm, in particular less than 50 nm.
[0019] The microporous layer contains a water-soluble and/or water-dispersible binding agent. Examples of suitable binding agents are polyvinyl alcohol, completely or partially saponified, cationically modified polyvinyl alcohol, polyvinyl alcohol containing silyl groups, polyvinyl alcohol containing acetal groups, gelatine, polyvinyl pyrrolidone, starch, carboxymethylcellulose, polyethylene glycol, styrene/butadiene latex and styrene/acrylate latex. Particularly preferably, completely or partially saponified polyvinyl alcohols are used. The quantity of binding agent may be 60% to 5% by weight, preferably 50% to 10% by weight, in particular however 35% to 8% by weight, with respect to the weight of the dried layer.
[0020] The microporous layer can contain the usual additives and auxiliary substances such as cross-linking agents, ionic and/or non-ionic surfactants, particle-binding substances such as polyammonium compounds, UV absorbers, antioxidants and other light stabilizing and gas resistance improving substances as well as other auxiliary substances.
[0021] The coat weight for the microporous layer may be 1 to 60 g/m 2 , preferably 5 to 40 g/m 2 , particularly preferably 10 to 30 g/m 2 .
[0022] The microporous layer can be formed as a single layer or in multiple layers.
[0023] The base material used as the support material over which the microporous layer is arranged can be a rigid flat material such as glass or a plastic. Preferably, however, a flexible base material is used, such as a plastic film, non-woven material or paper.
[0024] In a particularly preferred embodiment, the base material is a base paper. The term “base paper” as used in the context of the invention means an uncoated or surface-sized paper. As well as containing fibres of cellular material, a base paper can contain sizing agents such as alkyl ketene dimers, fatty acids and/or fatty acid salts, epoxided fatty acid amides, alkenyl or alkylsuccinic acid anhydride, wet-strength agents such as polyamine-polyamide-epichlorhydrin, dry strength agents such as anionic, cationic or amphoteric polyamides, optical brighteners, pigments, colorants, defoaming agents and other auxiliary substances which are known in the paper industry. The base paper may be surface-sized. Examples of sizing agents which are suitable for this purpose are polyvinyl alcohol or oxidized starch. The base paper may be produced on a Fourdrinier or Yankee paper machine (roll paper machine). The grammage of the base paper may be from 50 to 250 g/m 2 , in particular 50 to 150 g/m 2 . The base paper may be used in the uncalendered or calendered (smoothed) form.
[0025] Particularly suitable base papers are those with a density of 0.8 to 1.05 g/cm 3 , in particular 0.95 to 1.02 g/cm 3 .
[0026] Examples of fillers which may be used in base paper are kaolins, calcium carbonate in its natural form such as lime, marble or dolomite, precipitated calcium carbonate, calcium sulphate, barium sulphate, titanium dioxide, talc, silica, aluminium oxide and mixtures thereof.
[0027] In a further embodiment of the invention, at least one further layer may be arranged between the base paper and the microporous layer, which further layer contains a hydrophilic binding agent. Particularly suitable examples for this purpose are film-forming starches such as heat-modified starches, in particular corn starches or hydroxypropylated starches. In a preferred form of the invention, low-viscosity starch solutions are used which have Brookfield viscosities in the range 50 to 600 mPas (25% solution, 50° C./100 Upm), in particular 100 to 400 mPas, preferably 200 to 300 mPas. The Brookfield viscosity is measured in accordance with International standard ISO 2555. Preferably, the binding agent does not contain any synthetic latex. The absence of a synthetic binding agent means that waste can be re-utilized without having to be worked up.
[0028] In a further embodiment of the invention, at least one pigment is contained in the further layer containing a hydrophilic binding agent. The pigment may be selected from the group formed by metal oxides, silicates, carbonates, sulphides and sulphates. Pigments such as kaolin, talc, calcium carbonate and/or barium sulphate are particularly suitable.
[0029] A pigment with a narrow grain size distribution, wherein the dimension of at least 70% of the pigment particles is of less than 1 μm, is particularly preferred. In order to achieve the effect of the invention, the proportion of pigment with the narrow grain size distribution should be at least 5% by weight, in particular 10% to 90% by weight of the total quantity of pigment. Particularly good results are obtained with a proportion of 30% to 80% by weight of the total pigment weight.
[0030] A pigment with a narrow grain size distribution in accordance with the invention also comprises pigments with a grain size distribution whereby the dimension of at least approximately 70% by weight of the pigment particles is less than approximately 1 μm, and for 40% to 80% of these pigment particles, the difference between the pigment with the largest grain size (diameter) and the pigment with the smallest grain size is less than approximately 0.4 μm. Particularly preferably, this is a calcium carbonate with a d 50% of approximately 0.7 μm.
[0031] In a particular embodiment of the invention, a pigment mixture can be used which consists of the calcium carbonate defined above and kaolin. The calcium carbonate/kaolin proportion is preferably 30:70 to 70:30.
[0032] The binding agent/pigment proportion in the layer may be from 0.1 to 2.5, preferably 0.2 to 1.5, but in particular it is approximately 0.9 to 1.3.
[0033] The layer containing a hydrophilic binding agent may preferably contain further polymers such as polyamide copolymers and/or polyvinylamine copolymers. The polymer may be used in a proportion of 0.4% to 5% by weight with respect to the mass of the pigment. In a preferred embodiment, the proportion of polymer is 0.5% to 1.5% by weight.
[0034] The layer containing the hydrophilic binding agent may be arranged directly on the front face of the base paper or on the back face of the base paper. It may be deposited on the base paper in a single layer or in multiple layers. The coating mass may be applied using any in-line or off-line coating units, the quantity being selected so that after drying, the coat weight per layer is a maximum of 20 g/m 2 , in particular 8 to 17 g/m 2 , or in a particularly preferred embodiment 2 to 6 g/m 2 .
[0035] This further layer can be further smoothed using mechanical processes such as calendering or ferrotyping; however, it can also be deposited using cast coating.
[0036] In a particularly preferred embodiment of the invention, the base material is a base paper provided with at least one polymer layer on the front face or back face. The term “front face” as used here means that side of the base paper on which the conductive structure is printed.
[0037] In accordance with one embodiment of the invention, the polymer layers of the front and back face may contain the same polymer. In a further embodiment of the invention, the polymers employed in the polymer layers of the front and back face are different.
[0038] Preferably, the polymer layer arranged on at least one side of the base paper contains a polymer with a water vapour permeability of at most 150 g/m 2 . 24 h for a layer thickness of 30 μm, measured at 40° C. and 90% relative humidity.
[0039] The polymer is preferably a thermoplastic polymer. Examples of suitable thermoplastic polymers are polyolefins, in particular low density polyethylene (LDPE), high density polyethylene (HDPE), ethylene/α-olefin copolymers (LLDPE), polypropylene, polyisobutylene, polymethylpentene and blends thereof. However, other thermoplastic polymers such as (meth)acrylic acid ester homopolymers, (meth)acrylic acid ester copolymers, vinyl polymers such as polyvinyl butyral, polyamides, polyesters, polyacetals and/or polycarbonates may be employed.
[0040] In a preferred embodiment of the invention, the front face of the base paper is coated with a polymer layer which contains at least 50% by weight, in particular 80% by weight of a low density polyethylene with a density of 0.910 to 0.930 g/cm 3 and a melt-flow index of 1 to 20 g/10 min, with respect to the polymer layer.
[0041] In a further preferred embodiment of the invention, the back face of the base paper is coated with a polyolefin, in particular polyethylene. Particularly preferably, a polyethylene blend of LDPE and HDPE is used, wherein the LD/HD proportion is 9:1 to 1:9, in particular 3:7 to 7:3.
[0042] Furthermore, the polymer layers may contain white pigments such as titanium dioxide as well as other auxiliary substances such as optical brighteners, colorants and dispersing additives.
[0043] The coat weight of the polymer layers on the front face and back face may each be 5 to 50 g/m 2 , preferably 20 to 50 g/m 2 or particularly preferably 30 to 50 g/m 2 .
[0044] In a further embodiment of the invention, further layers such as protective layers or gloss-improving layers may be deposited on the outer microporous layer provided for printing with conductive particles using the inkjet printing process. The coat weight of such layers is preferably less than 1 g/m 2 .
[0045] The following examples are intended to further illustrate the invention.
EXAMPLES
Fabrication of Base Paper
[0046] Eucalyptus cellular material was used to manufacture the base paper. For beating, the cellular material was beaten as an approximately 5% aqueous suspension (thick matter) using a refiner to a degree of beating of 36° SR. The mean fibre length was 0.64 mm. The concentration of cellular material fibres in the thin matter was 1% by weight, with respect to the mass of the cellular material suspension. The thin matter was supplemented with additional substances such as a neutral sizing agent, alkyl ketene dimer (AKD), in an amount of 0.48% by weight, a wet-strength agent, polyamine-polyamide epichlorhydrin resin (Kymene®), in a quantity of 0.36% by weight, and a natural CaCO 3 in a quantity of 10% by weight. The quantities given are with respect to the mass of cellular material. The thin matter, the pH of which was adjusted to approximately 7.5, was transferred from the headbox onto the screen of the paper machine, whereupon sheets were formed by dewatering the web in the screen portion of the paper machine. In the press section, the paper web was further dewatered to a water content of 60% by weight with respect to the web weight. Further drying was carried out in the dryer section of the paper machine using heated drying rollers. A base paper was obtained with a gsm substance of 160 g/m 2 and a moisture content of approximately 7%.
Support Example A (Comparison)
[0047] The base paper was coated on the front face and back face with a coating mass consisting of a styrene acrylate binding agent and a pigment mixture formed from calcium carbonate and kaolin with a coat weight of 30 g/m 2 (front face) and 20 g/m 2 (back face), then dried and subsequently smoothed using a calender.
Support Example B (Comparison)
[0048] The front face of the base paper was coated with a resin blend formed by 100% by weight of a low density polyethylene (LDPE, 0.923 g/cm 3 ) with a coat weight of approximately 20 g/m 2 in a laminator at a speed of approximately 250 m/min.
[0049] The back face of the base paper was coated with a resin blend formed by 100% by weight of a low density polyethylene (LDPE, d =0.923 g/m 2 ) at a coat weight of 20 g/m 2 . Coating was carried out in a laminator at an extrusion speed of 250 m/min.
[0050] The front face of the support material was also treated by corona discharge and subsequently coated with a primer layer formed from a solution of polyvinyl alcohol (Mowiol® 04-98 from Kurarai) in water with a dry coat weight of 100 mg/m 2 then dried.
Support Example A1 (Invention)
[0051] Support Example A was coated with a coating mass having a solids content of 23% consisting of 80 parts boehmite pigment (Dispersal® HP14 from Sasol), 10 parts pyrogenic aluminium oxide pigment (Aeroxide® Alu C from Evonik Degussa), 8 parts polyvinyl alcohol (Mowiol® 40-88 from Kurarai) and 2 parts boric acid, then dried. The dry coat weight was 20 g/m 2 ; the mean pore size of the layer, measured using mercury porosimetry, was 30 nm.
Support Example B1 (Invention)
[0052] In the same manner as for support material Example A1, support Example B was provided with a microporous layer then dried. The dry coat weight was 30 g/m 2 ; the mean pore size of the layer, measured using mercury porosimetry, was 30 nm.
Support Example C1(Invention)
[0053] In the same manner as for support material Example A1, a commercially available polyester film (Mylar®) of 125 μm thickness was corona treated and subsequently coated with a microporous layer and then dried. The dry coat weight was 30 g/m 2 ; the mean pore size of the layer, measured using mercury porosimetry, was 30 nm.
Test of Printing Properties
[0054] The support materials A, B, A1, B1, C1 and an uncoated commercially available polyester film (Mylar®) were printed with “NPS” type silver ink from Harima Chemicals, Inc, Japan, using a DMP-2800 inkjet printer from Fujifilm DIMATIX®. To this end, 25 mm long and 2 mm wide silver conductive strips were produced 25 mm apart and dried at room temperature for 1 hour.
[0055] The electrical resistance of the printed silver conductive strips was measured using a GDM-8251A electrical multimeter manufactured by GWINSTEK, Taiwan, at 23° C. and 50% relative humidity, as well as the electrical resistance between two adjacent printed conductive strips. In addition, the print quality, in particular the uniformity and contour definition of the print, was visually assessed with the aid of a DPM-100 microscope from Fibro Systems AB, Sweden.
[0056] The results are summarized in the table below.
[0000]
Conductive
Resistance
Support
strip
between adjacent
Print
material
resistance
conductive strips
quality*)
Film
600
ohm
>100
Mohm
∘
(comparison)
A
480
ohm
2
Mohm
−
(comparison)
B
580
ohm
>100
Mohm
∘
(comparison)
A1
7
ohm
50
Mohm
+
(invention)
B1
9
ohm
>100
Mohm
+
(invention)
C1
7
ohm
>100
Mohm
+
(invention)
*)Print quality: −: unsatisfactory; ∘: satisfactory; +: good.
[0057] It can be seen that the materials of the invention exhibit a low electrical resistance for the printed conductive strips, a high insulative resistance between the conductive strips and a good print quality.
[0058] The preferred embodiments of the invention as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined herein and in the following claims. | 4y
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RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 61/783,905, filed 14 Mar. 2013, the entire content of which is incorporated herein by reference.
BACKGROUND
In this century, the shortage of fresh water will surpass the shortage of energy as a global concern for humanity; and these two challenges are inexorably linked, as explained, for example, in the “Special Report on Water” in the 20 May 2010 issue of The Economist . Fresh water is one of the most fundamental needs of humans and other organisms; each human needs to consume a minimum of about two liters per day. The world also faces greater freshwater demands from farming and industrial processes.
The hazards posed by insufficient water supplies are particularly acute. A shortage of fresh water may lead to a variety of crises, including famine, disease, death, forced mass migration, cross-region conflict/war, and collapsed ecosystems. Despite the criticality of the need for fresh water and the profound consequences of shortages, supplies of fresh water are particularly constrained. 97.5% of the water on Earth is salty, and about 70% of the remainder is locked up as ice (mostly in ice caps and glaciers), leaving only a fraction of all water on Earth as available fresh (non-saline) water.
Moreover, the earth's water that is fresh and available is not evenly distributed. For example, heavily populated countries, such as India and China, have many regions that are subject to scarce supplies. Further still, the supply of fresh water is often seasonally inconsistent. Meanwhile, demands for fresh water are tightening across the globe. Reservoirs are drying up; aquifers are falling; rivers are dying; and glaciers and ice caps are retracting. Rising populations increase demand, as do shifts in farming and increased industrialization. Climate change poses even more threats in many regions. Consequently, the number of people facing water shortages is increasing. Naturally occurring fresh water, however, is typically confined to regional drainage basins; and transport of water is expensive and energy-intensive.
Additionally, water can be advantageously extracted from contaminated waste streams (e.g., from oil and gas production) both to produce fresh water and to concentrate and reduce the volume of the waste streams, thereby reducing pollution and contamination and reducing costs.
Nevertheless, many of the existing processes for producing fresh water from seawater (or from brackish water or contaminated waste streams) require massive amounts of energy. Reverse osmosis (RO) is currently the leading desalination technology. In large-scale plants, the specific electricity required can be as low as 4 kWh/m 3 at 30% recovery, compared to the theoretical minimum of around 1 kWh/m 3 ; smaller-scale RO systems (e.g., aboard ships) are less efficient.
Other existing seawater desalination systems include thermal-energy-based multi-stage flash (MSF) distillation, and multi-effect distillation (MED), both of which are energy- and capital-intensive processes. In MSF and MED systems, however, the maximum brine temperature and the maximum temperature of the heat input are limited in order to avoid calcium sulphate, magnesium hydroxide and calcium carbonate precipitation, which leads to the formation of soft and hard scale on the heat transfer equipment.
Humidification-dehumidification (HDH) desalination systems include a humidifier and a dehumidifier as their main components and use a carrier gas (e.g., air) to communicate energy between the heat source and the brine. A simple version of this technology includes a humidifier, a dehumidifier, and a heater to heat the seawater stream. In the humidifier, hot seawater comes in direct contact with dry air, and this air becomes heated and humidified. In the dehumidifier, the heated and humidified air is brought into (indirect) contact with cold seawater and gets dehumidified, producing pure water and dehumidified air. As with MSF and MED systems, precipitation of scaling components can occur within the system with consequent damage if the temperature rises too high.
Another approach, described in U.S. Pat. No. 8,119,007 B2 (A. Bajpayee, et al.), uses directional solvent that directionally dissolves water but does not dissolve salt. The directional solvent is heated to dissolve water from a salt solution into the directional solvent. The remaining highly concentrated salt water is removed, and the solution of directional solvent and water is cooled to precipitate substantially pure water out of the solution.
Some of the present inventors were also named as inventors on the following patent applications that include additional discussion of HDH and other processes for purifying water: U.S. application Ser. No. 12/554,726, filed 4 Sep. 2009 (published as US 2011/0056822 A1); U.S. application Ser. No. 12/573,221, filed 5 Oct. 2009 (published as US 20110079504 A1); U.S. application Ser. No. 13/028,170, filed 15 Feb. 2011; and U.S. application Ser. No. 13/241,907, filed 23 Sep. 2011; and U.S. application Ser. No. 13/550,094, filed 16 Jul. 2012.
SUMMARY
Apparatus and methods for preventing scaling in desalination and other processes are described herein. Various embodiments of the apparatus and methods may include some or all of the elements, features and steps described below.
In accordance with embodiments of the methods, cations that can precipitate from an aqueous composition to produce scaling are sequestered by adding a multi-dentate ligand to the aqueous composition. The multi-dentate ligand bonds with the cation to form a non-scaling ionic complex; and at least a portion of the aqueous composition with the ionic complex present or removed is used in a process involving the production of substantially pure water from the aqueous composition, where the cation, absent formation of the ionic complex, is subject to scaling. The pH of the aqueous composition (or a brine including components of the aqueous composition) including the ionic complex is then reduced to release the cation from the multi-dentate ligand; and the multi-dentate ligand, after the cation is released, is then reused in a predominantly closed loop (where most, though not necessarily all, of the multi-dentate ligand is recirculated and reused in each iteration of the process).
Embodiments of the apparatus include a source of an aqueous composition including at least one type of cation that can precipitate from the aqueous composition to produce scaling. A first conduit is configured to feed the aqueous composition from the aqueous-composition source to a desalination system; and a second conduit configured to feed a multi-dentate ligand from a multi-dentate-ligand source into the first conduit to bond the multi-dentate ligand with cations in the aqueous composition to form a non-scaling ionic complex. A pH-reduction apparatus is coupled with a source of a pH-reducing agent and is configured to separate the cations from the multi-dentate ligand at low pH levels. Moreover, a third conduit is configured to feed the non-scaling ionic complex in the aqueous composition or in a brine produced from the aqueous composition to the pH-reduction apparatus.
By sequestering cations that can otherwise produce scaling in a high-temperature operation, such as desalination (including various forms of aqueous waste treatment), the methods and apparatus described herein can improve the efficacy of the operation (e.g., higher recovery) and prevent damage to the apparatus. Additionally, the methods and apparatus can be operated at higher temperatures absent the risk of scaling (and consequent harm) at high temperatures. Further still, these methods can reduce the cost of pre-treatment of aqueous feeds to about 1/10th the cost of previous techniques using soda lime to soften the aqueous feed before desalination to thereby reduce scaling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a molecular illustration of an Na 4 EDTA multi-dentate ligand.
FIG. 2 is a molecular illustration of an Na 4 EDTA multi-dentate ligand sequestering a cation.
FIG. 3 is a schematic illustration of a first embodiment of an apparatus for scaling-preventive desalination.
FIG. 4 is a schematic illustration of a second embodiment of an apparatus for scaling-preventive desalination.
FIG. 5 is a schematic illustration of a high-recovery desalination system that can be used in the apparatus of FIG. 3, 4 or 6 .
FIG. 6 is a schematic illustration of a third embodiment of an apparatus for scaling-preventive desalination.
In the accompanying drawings, like reference characters refer to the same or similar parts throughout the different views; and apostrophes are used to differentiate multiple instances of the same or similar items sharing the same reference numeral. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating particular principles, discussed below.
DETAILED DESCRIPTION
The foregoing and other features and advantages of various aspects of the invention(s) will be apparent from the following, more-particular description of various concepts and specific embodiments within the broader bounds of the invention(s). Various aspects of the subject matter introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the subject matter is not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.
Unless otherwise defined, used or characterized herein, terms that are used herein (including technical and scientific terms) are to be interpreted as having a meaning that is consistent with their accepted meaning in the context of the relevant art and are not to be interpreted in an idealized or overly formal sense unless expressly so defined herein. For example, if a particular composition is referenced, the composition may be substantially, though not perfectly pure, as practical and imperfect realities may apply; e.g., the potential presence of at least trace impurities (e.g., at less than 1 or 2%, wherein percentages or concentrations expressed herein can be either by weight or by volume) can be understood as being within the scope of the description; likewise, if a particular shape is referenced, the shape is intended to include imperfect variations from ideal shapes, e.g., due to manufacturing tolerances.
Although the terms, first, second, third, etc., may be used herein to describe various elements, these elements are not to be limited by these terms. These terms are simply used to distinguish one element from another. Thus, a first element, discussed below, could be termed a second element without departing from the teachings of the exemplary embodiments.
Spatially relative terms, such as “above,” “below,” “left,” “right,” “in front,” “behind,” and the like, may be used herein for ease of description to describe the relationship of one element to another element, as illustrated in the figures. It will be understood that the spatially relative terms, as well as the illustrated configurations, are intended to encompass different orientations of the apparatus in use or operation in addition to the orientations described herein and depicted in the figures. For example, if the apparatus 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 exemplary term, “above,” may encompass both an orientation of above and below. The apparatus may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
Further still, in this disclosure, when an element is referred to as being “on,” “connected to” or “coupled to” another element, it may be directly on, connected or coupled to the other element or intervening elements may be present unless otherwise specified.
The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting of exemplary embodiments. As used herein, singular forms, such as “a” and “an,” are intended to include the plural forms as well, unless the context indicates otherwise. Additionally, the terms, “includes,” “including,” “comprises” and “comprising,” specify the presence of the stated elements or steps but do not preclude the presence or addition of one or more other elements or steps.
Various ions (e.g., cations, such as Ca 2+ , Ba 2+ , Sr 2+ , Mg 2+ ) found in aqueous compositions (e.g., sea water, brackish water or produced or flowback water resulting from shale-gas or shale-oil extraction) can precipitate to form scaling compounds by, for example, combining with carbonates and sulfates. This scaling may occur at high temperatures due to inverse solubility (i.e., lower solubility of the scaling compound at higher temperatures) and may compromise the treatment of the aqueous compositions and/or may foul or damage the high-temperature components of the apparatus, which tend to be the most expensive components in the apparatus.
According to the methods described herein, these scaling ions can be sequestered and prevented from precipitating by capturing the ions 14 in a chelating multi-dentate ligand 12 , such as ethylenediamine tetra-acetic acid (H 4 EDTA). In one embodiment, the multi-dentate ligand 12 can be provided in the form of Na 4 EDTA, which forms EDTA 4− in solution. An illustration of the molecular structure of H 4 EDTA is provided in FIG. 1 . The hydrogen (H) atoms in the H 4 EDTA are released from the oxygen (O) atoms in the presence of the cations 14 , and the oxygen atoms to which the hydrogen atoms were bonded in the H 4 EDTA then bind to the cations 14 ; additionally, the free electron pair on each of the nitrogen (N) atoms also forms a bond with the cations 14 to sequester each of the cations 14 orthogonally on six sides.
The chemical reaction of this process can be expressed as follows:
Na 4 EDTA+Ca 2+ →CaEDTA 2− +4Na +
In the above expression, EDTA serves as the multi-dentate ligand (chelate), and calcium (Ca 2+ ) is the scaling ion. The capture of the calcium ion is facilitated by establishing a pH greater than 4 with K s substantially greater than 1 in the aqueous composition. As shown, above, one mole of EDTA traps one mole of metal-divalent or transition-metal ion. Specifically, in this case, when sequestered as CaEDTA 2− , the calcium ion is trapped and does not scale. The resulting new complex ion (CaEDTA 2− ) has a much higher solubility than even sodium chloride (NaCl) under the relevant temperatures.
The use of EDTA as the multi-dentate ligand is advantageous because of its high stability constant, though any of a variety of other ligands can be used. Examples of ligands that may be used in these methods are provided in Table 1, below, with their respective stability constants.
TABLE 1
Ligand
Stability Constant
EDTA
10.7
Triphosphate
6.5
nitrilotriacetic acid (NTA)
6.41
Tetrametaphosphate
5.2
Pyrophosphate
5
A schematic illustration of a first embodiment of an apparatus for scale-preventive desalination is provided in FIG. 3 . In this embodiment, the aqueous feed composition is produced water from oil or gas extraction. The aqueous composition can be fed from a source 22 , such as a tank or an open pool, into a high-recovery desalination system 28 via a first conduit 16 . The multi-dentate ligand 12 can initially be supplied by and replenished from a source 24 and injected into the first conduit 16 , where the multi-dentate ligand 12 captures the cation 14 to form a non-scaling ionic complex 15 , as shown in FIG. 2 (where hydrogen bonds are omitted from the illustration for simplicity), which is then injected with the produced water into a high-recovery desalination system 28 into which thermal energy 46 is also fed.
A schematic illustration of the components of an embodiment of the high-recovery desalination system 28 is provided in FIG. 5 . The aqueous composition 26 (e.g., produced water) is fed first via a conduit through a reverse-osmosis unit 62 , from which a first fresh-water output 32 ′ is extracted via a first output conduit. The remaining aqueous brine composition is then fed via a conduit through a mechanical vapor compression distillation unit 64 , from which second fresh-water output 32 ″ is extracted via a second output conduit. The remaining aqueous brine composition is then fed via a conduit through a crystallizer 66 , from which a third fresh-water output 32 ′″ is extracted via a third output conduit. The crystallizer 66 also outputs (a) a brine 34 including the cation 14 still sequestered by the multi-dentate ligand 12 in the form of the ionic complex 15 and (b) a solid (crystallized) output 30 of, e.g., NaCl, KCl, Na 2 SO 4 , and Na 2 CO 3 . Alternatively, or in addition, the high-recovery distillation system 28 can include units for multi-stage flash distillation (MSF), multiple-effect distillation (MED), extractive distillation (ED), membrane distillation (MD), humidification/de-humidification (HDH) distillation, etc. These distillation processes can be carried out in this method at temperatures (e.g., at least 50° C.) at which the cation 14 would precipitate from the aqueous composition 26 , were the cation 14 not captured by the multi-dentate ligand 12 .
Returning to FIG. 3 , the brine 34 including the ionic complex 15 from the high-recovery desalination system 28 , after the fresh (substantially pure) water 32 and solids 30 are removed, is fed via third conduit 20 into a pH-reduction chamber 36 , where the pH of the brine 34 can be reduced to below 2 via the addition of an acid (e.g., hydrochloric acid, sulphuric acid or oxalic acid) from a source 38 . In particular embodiments, where oxalic acid is added, the pH need only be reduced to a pH of about 5 (or less) because the oxalic acid can trigger the precipitation of calcium oxalate rather than EDTA from the ionic complex. This lowering of the pH causes the multi-dentate ligand 12 to disassociate from the cation 14 . The multi-dentate ligand 14 with remaining aqueous composition is then fed as a recycled feed 42 through a second conduit 18 back to the first conduit 16 through which the initial aqueous composition 26 is fed. En route, a neutralizing base, such as NaOH, is injected from a source 44 into the second conduit 18 to raise the pH of the recycled feed 42 to about neutral; and additional (replenishing) multi-dentate ligand 14 can be injected into the second conduit 18 from source 24 .
Brine (after the removal of multi-dentate ligand 12 in composition 42 ) that is output from the pH-reduction chamber 36 is fed to a chiller 54 that extracts thermal energy 46 from the brine (e.g., reducing the temperature of the brine to less than 20° C.). The thermal energy 46 extracted from the brine can then be transferred via a thermally conductive link and reintroduced into the high-recovery desalination system 28 . Cooling the brine in the chiller 54 results in the separation of additional multi-dentate ligand 12 (that was not released in the pH-reduction chamber 36 ) from the cation 14 in the brine. Composition 42 ′ with the additional release of multi-dentate ligand 12 is injected into the flow of composition 42 from the chiller 54 to recycle even more of the multi-dentate ligand 12 . The chiller 54 also outputs brine including the released ions (e.g., Na, Ca, Ba, Sr, and/or Mg, as well as Cl) to a reservoir 40 . A second embodiment of the apparatus without the chiller 54 and without the additional release of composition 42 ′ therein is illustrated in FIG. 4 .
A schematic illustration of a third embodiment of an apparatus for scale-preventive desalination is provided in FIG. 6 . In this embodiment, the aqueous composition feed 26 is fed via first conduit 16 through an ultra-filtration unit 48 , which can include a membrane having sub-1-μm pores through which the aqueous composition feed 26 flows. The ultra-filtration unit 48 removes the ionic complex 15 from the aqueous composition 26 before the remnant 52 of the aqueous composition is injected into the high-recovery desalination system 28 . The brine 34 with the ionic complex 15 that was filtered out of the aqueous composition 26 by the ultra-filtration unit 48 is directed via the third conduit 20 into the pH-reduction chamber 36 . The pH-reduction chamber 36 outputs a brine with the released cations to a reservoir 50 and also outputs a composition 42 including the multi-dentate ligand 12 for reinjection into the aqueous feed composition 26 via the second conduit 18 . Accordingly, this embodiment differs from the first and second embodiments (shown in FIGS. 3 and 4 ) in that the non-scaling ionic complex 15 is removed from the aqueous feed composition 16 before it reaches the high-recovery desalination system 28 .
In describing embodiments of the invention, specific terminology is used for the sake of clarity. For the purpose of description, specific terms are intended to at least include technical and functional equivalents that operate in a similar manner to accomplish a similar result. Additionally, in some instances where a particular embodiment of the invention includes a plurality of system elements or method steps, those elements or steps may be replaced with a single element or step; likewise, a single element or step may be replaced with a plurality of elements or steps that serve the same purpose. Further, where parameters for various properties or other values are specified herein for embodiments of the invention, those parameters or values can be adjusted up or down by 1/100 th , 1/50 th , 1/20 th , 1/10 th , ⅕ th , ⅓ rd , ½, ⅔ rd , ¾ th , ⅘ th , 9/10 th , 19/20 th , 49/50 th , 99/100 th , etc. (or up by a factor of 1, 2, 3, 4, 5, 6, 8, 10, 20, 50, 100, etc.), or by rounded-off approximations thereof, unless otherwise specified. Moreover, while this invention has been shown and described with references to particular embodiments thereof, those skilled in the art will understand that various substitutions and alterations in form and details may be made therein without departing from the scope of the invention. Further still, other aspects, functions and advantages are also within the scope of the invention; and all embodiments of the invention need not necessarily achieve all of the advantages or possess all of the characteristics described above. Additionally, steps, elements and features discussed herein in connection with one embodiment can likewise be used in conjunction with other embodiments. The contents of references, including reference texts, journal articles, patents, patent applications, etc., cited throughout the text are hereby incorporated by reference in their entirety; and appropriate components, steps, and characterizations from these references may or may not be included in embodiments of this invention. Still further, the components and steps identified in the Background section are integral to this disclosure and can be used in conjunction with or substituted for components and steps described elsewhere in the disclosure within the scope of the invention. In method claims, where stages are recited in a particular order—with or without sequenced prefacing characters added for ease of reference—the stages are not to be interpreted as being temporally limited to the order in which they are recited unless otherwise specified or implied by the terms and phrasing. | 4y
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FIELD OF THE INVENTION
The present invention relates to pest repellents and methods for repelling pests, especially suitable for repelling cockroaches.
BACKGROUND OF THE INVENTION
Pests such as cockroaches transmit diseases. The presence of these pests in environments wherein humans inhabit increase the chances to be exposed to diseases. Efficacious agents and methods which control pests from inhabiting the human environment have been desired. Since pests can adapt to exposure, it would be an advantage if a multiplicity of methods and agents are available for controlling these pests.
Aerosol compositions comprising of N,N-diethyl-m-toluamide have been utilized to repel mosquitoes and black flies. However, N,N-diethyl-m-toluamide may be insufficient as a pest repellent. The deficiency of sustaining any repelling activity after a long period of time has deemed N,N-diethyl-m-toluamide as an unpalatable candidate for a pest repellent. In addition, the efficacy of N,N-diethyl-m-toluamide is insufficient when certain pests such as cockroaches are targeted.
Japanese Laid-open patent No. sho56-92803-A discloses ester compounds such as empenthrin as an active ingredient of a cockroach repellent. These ester compounds may have the ability to repel pests for a given period, but also greatly decrease efficacy after a long period of time.
It is tedious to continually dispose an agent to repel pests. Therefore, it would be of advantage if a pest repellent can efficaciously repel pests for a long period of time with one disposal. It would also be of advantage if a pest repellent were developed to target a larger variety of pests and include pests which have been difficult to repel such as the cockroach.
SUMMARY OF THE INVENTION
The present invention sets forth a pest repellent that employs imiprothrin [2,4-dioxo-1-(2-propenyl)imidazolazin-3-ylmethyl (1R)-cis, trans-chrysanthemate], and a pest repelling method that utilizes imiprothrin.
DETAILED DESCRIPTION OF THE INVENTION
Imiprothrin may be produced by following U.S. Pat. No. 4,176,189.
The pest repellent of the present invention may be the active ingredient of imiprothrin itself, but providing imiprothrin as a formulation is generally standard. More specifically, a formulation wherein imiprothrin is supported on an appropriate carrier is standard. Sheet formulations, formulations wherein imiprothrin is kneaded into a resin, emulsifiable concentrates, oil formulations, wettable powders, flowable formulations, granules, dusts, enmicrocapsulated formulations, aerosols, heat volatile formulations, and so on are examples of possible formulations.
The sheet materials are not especially restricted when the pest repellent is formulated as a sheet. Papers, synthetic resins, cloths, and so on are set forth as examples of the said sheet materials. The formulated sheet may generally comprise about 0.01 to 10 g of imiprothrin for every 1 m 2 of the said sheet.
Furthermore, in the event the pest repellent takes the formulation of emulsifiable concentrates or oil formulation, the said formulations generally comprise about 0.01 to 10% by weight of imiprothrin.
In addition to imiprothrin, any other pest repelling ingredient may be incorporated to the pest repellent. Examples of the other pest repelling ingredients that may be additionally incorporated are N,N-diethyl-m-toluamide, carane-3,4-diol, 1-methylpropyl 2-(2-hydroxyethyl)-1-piperizinecarboxylate, p-menthane-3,8-diol, pest repelling plant essential oils and so on.
The pest repellent is generally utilized by disposing the pest repellent at the targeted area of pest repelling. The typical household, warehouse, dining areas, and so on areas wherein the pest may invade are examples of objective areas wherein the pest repellent generally may be disposed. It is especially effective to repel pests such as cockroaches by setting the sheet formulation of the pest repellent under intricate machinery such as a personal computer, copy machine, and telephone, or under vending machines, or so on. The pest repellent may also be utilized to repel pests such as mosquitoes (Culicidae), black flies (Simuliidae), stable flies (Stomoxyidae) by disposing onto the body or clothes when the pest repellent is formulated as an ethanol solution, isopropanol solution, lotion or cream formulation, or so on. The pest repellent may further be utilized to repel or stop the invasion of pests such as ants, pill bugs, sow bugs, millipedes (Anamorpha), millipedes (Epimorpha), centipedes, and so on by dispersing around the perimeter of a typical household, warehouse, dining areas, and so on.
When the pest repellent is formulated as emulsifiable concentrates, wettable powders, flowable formulations, enmicrocapsulated formulations, and so on, a water dilution is applied. When the pest repellent is formulated as granules, dusts, aerosols, oil formulations, or so on, the pest repellent is applied by itself. The amount of imiprothrin employed for the pest repellent does vary with the objective location, utilization method, variation of formulation, targeted pest, and so on, but usually is about 0.01 g to 10 g for 1 m 2 .
The pest repellent of the present invention may be employed in various methods but, a method wherein the pest is exposed with the present invention either directly or by previously preparing the pest repellent in an area that is possible for the pest to be exposed to the pest repellent is preferable. More specifically, the pest repellent may be applied in a pest repelling method such as dispersal, spraying, spreading, placing, pasting, or so on. In addition, the pest repellent may also be employed in a pest repelling method wherein the pest repellent is supported on the ingredients of household items by means of incorporation such as spreading, soaking, kneading and mixing, dripping/dropping, and so on before the said ingredient is formed to an household item. The utilization of the household item that was formed from the said ingredients that preserve the pest repellent will repel pests and is also a method to repel pests.
The pest repellent is not limited to repel just Dictyoptera such as German cockroach (Blattella germanica), smokybrown cockroach (Periplaneta fuliginosa), American cockroach (Periplaneta americana), brown cockroach (Periplaneta brunnea), oriental cockroach (Blatta orientalis), and so on; Lepidoptera such as casemaking clothes moth (Tinea pellionella), webbing clothes moth (Tineola bisselliella), Indian mean moth (Plodia interpunctella), and so on; Diptera such as Culex spp., Anopheles spp., Aedes spp., Muscidae, small fruit flies or vinegar flies (Drosophilidae), moth flies or sand flies (Psychodidae), Phoridae, and so on; Coleoptera such as the maize weevil (Sitophilus zeamais), adzuki bean weevil (Callosobruchus chinensis), black carpet beetle (Attagenus unicolorjaponicus), varied carpet beetle (Authrenus verbasci), Anobiidae, powderpost beetle (Lyctus brunneus), robe beetle (Paederus fuscipes), and so on; Hymenoptera such as ants (Formicidae), Bethylidae, and so on; Siphonaptera such as human flea (Pulex irritans), cat flea (Ctenocephalides felis), and so on; lice (Anoplura) such as body louse (Pudiculus humanus), crab louse (Pthrius pubis), and so on, Isoptera such as Reticulitermes speratus, Formosan subterranean termite (Coptotermes formosanus), and so on; and so on harmful insects, but is also efficacious in repelling mites and ticks (Acarina) such as house dust mites (for example, Acaridae, Dermanyssidae, Pyroglyphidae, Chetyletidae, and so on), ticks (for example, Boophilus microplus), Ornithonyssus spp., and so on; spiders; Scorpions (Scorpionida); Oniscoidea such as pillbugs and sow bugs; millipeds (Chilopoda) such as Anamorpha, Epimorpha, centipede, and so on; Gastropoda such as slugs and snails; leeches; and so on. Namely, the pests include arthropod, mollusca, annelida, and so on.
EXAMPLES
Example 1
A shelter was prepared by constructing an entrance/exit into a paper box (length 7 cm×width 10 cm×height 2 cm). A sheet formulation (7.6 cm×2.6 cm) was then prepared by spreading 0.4 ml of an acetone solution comprising of 0.25% by weight of imiprothrin onto a glass slide and then drying the formulation. The said sheet formulation was then located in a position on the floor in the said shelter wherein the said formulation follows the entrance/exit. Food, water, the obtained shelter containing the sheet formulation, and 10 male and female adult cockroaches were deposited into a plastic case (length 30 cm×width 20 cm×height 8 cm). The quantity of cockroaches in the said shelter was counted 24 hours later.
In addition, a shelter containing the sheet formulation was preserved for 2 weeks at 25° C. and wherein the humidity was at 60%. Food, water, the preserved shelter, and 10 male and female adult cockroaches were re-deposited into the emptied plastic case. The quantity of cockroaches in the said shelter was counted 24 hours later.
Furthermore, empenthrin and N,N-diethyl-m-toluamide (Deet) were similarly tested for the ability to repel German cockroaches from the shelter. A control was also performed by utilizing a shelter without repellent disposal.
The results are given in table 1. Within the table, a "-" represents that the invasion rate of cockroaches into the shelter was less than 30%, a "+" represents 30% or more to less than 50%, and a "++" represents 50% or more.
TABLE 1______________________________________ results right after disposal results 2 weeks later______________________________________imiprothrin - -empenthrin + ++Deet - ++No Compositional ++disposal______________________________________
The insect repellent of the present invention is effective in repelling insects such as cockroaches. Imiprothrin was able to repel insects 2 weeks after disposal while other well known pest repellents such as empenthrin and N,N-diethyl-m-toluamine were ineffective after such an elapse of time. The ability of imiprothrin to sustain repelling activity after a long period of time negates the necessity to tediously continue pest repellent disposal to efficaciously repel pests. In addition, the ability of imiprothrin to repel a difficult pest such as the cockroach also deems imiprothrin as an excellent repellent against a variety of pest. | 4y
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This invention was made with government support under Grant No. NHLBIHL34322 awarded by the National Institutes of Health. The government has certain rights in the invention.
FIELD OF THE INVENTION
This invention relates to certain dinucleotides, pharmaceutical formulations containing the same, and methods of removing retained mucus secretions from the lungs of a subject by administering dinucleotides to the subject.
BACKGROUND OF THE INVENTION
In cystic fibrosis several functions of airway epithelia are abnormal, and deficiencies in both Cl - transport and Na + absorption are well documented. See, e.g. Knowles et al., Science 221, 1067 (1983); Knowles et al., J. Clin. Invest. 71, 1410 (1983). Regulation of ion transport might have potential therapeutic benefit in lung diseases characterized by abnormalities in epithelial ion transport, e.g., cystic fibrosis.
One therapeutic goal in cystic fibrosis and other pulmonary diseases in which the water content of the mucous is altered is to hydrate the lung mucous secretions, so that the secretions may be thereafter more easily removed from the lungs by mucociliary action or simple coughing. The use of aerosolized amiloride to hydrate mucous secretions is described in U.S. Pat. No. 4,501,729. Amiloride appears to block Na + reabsorption by airway epithelial cells, and therefore inhibits water absorption from the mucous.
A different therapeutic approach for hydrating lung mucous secretions is exemplified by techniques that involve the administration of ATP or UTP, which appear to stimulate chloride secretion from respiratory epithelial cells. See, e.g., U.S. Pat. No. 5,292,498 to Boucher.
In view of the large numbers of people afflicted with cystic fibrosis, there is an ongoing need for new methods for providing methods of hydrating lung mucous secretions and thereby facilitating lung mucous clearance.
SUMMARY OF THE INVENTION
A first aspect of the present invention is a compound of Formula (I), or a pharmaceutically acceptable salt thereof: ##STR3## In a compound of Formula I: n is from 1 to 6. n is preferably from 2 to 4, and is most preferably 4.
X is --OH or --SH, and is preferably --OH.
A and B are each independently selected from the group consisting of: ##STR4## wherein R is H or Br.
A second aspect of the present invention is a pharmaceutical formulation comprising, in a pharmaceutically acceptable carrier (e.g., a solid or liquid carrier), a compound of Formula (I) as given above or a pharmaceutically acceptable salt thereof in an amount effective to hydrate lung mucous secretions. Optionally, the pharmaceutical formulation may further comprise a compound selected from the group consisting of amiloride, benzamil and phenamil in an amount effective to inhibit the reabsorption of water from lung mucous secretions.
A third aspect of the present invention is a method of hydrating mucous secretions in the lungs of a subject in need of such treatment, comprising administering to the lungs of the subject a compound of Formula I as given above, or a pharmaceutically acceptable salt thereof, in an amount effective to hydrate lung mucous secretions.
A fourth aspect of the present invention is the use of a compound of Formula I as given above, or a pharmaceutically acceptable salt thereof, for the preparation of a medicament for hydrating mucous secretions in the lungs of a subject in need of such treatment.
The foregoing and other objects and aspects of the present invention are explained in detail in the specification set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the effect of dinucleotide A 2 P 4 on Cl - secretion on the luminal surface of airway epithelia previously treated with forskolin.
FIG. 2 shows the effect of A 2 P 4 administration on Cl- secretion in airway epithelia prestimulated with UTP.
DETAILED DESCRIPTION OF THE INVENTION
The method of the present invention can be used to facilitate (i.e., enhance, speed, assist) the clearance of mucous secretions from the lungs of a subject in need of such treatment for any reason, including (but not limited to) retained secretions arising from airway diseases such as cystic fibrosis, chronic bronchitis, asthma, bronchiectasis, post-operative atelectasis (plugging of airways with retained secretions after surgery), and Kartagener's syndrome.
The present invention is concerned primarily with the treatment of human subjects, but may also be employed for the treatment of other mammalian subjects, such as dogs and cats, for veterinary purposes.
Compounds of Formula I and the pharmaceutically acceptable salts thereof (i.e., active compounds) may be prepared in accordance with the techniques described herein and variations thereof which will be apparent to those skilled in the art. As an example, synthesis of UppppU (U 2 P 4 ) may be carried out by condensation of UDP using the water soluble carboimide EDC (1-ethyl-3-[3-dimethyl-ammonio-propyl]-carboimide hydrochloride). See K. E. Ng and L. E. Orgel, Nucleic Acids Research 15(8), 3572-80 (1987).
Amiloride and its use in hydrating lung mucus secretions is known and described in U.S. Pat. No. 4,501,729 to Boucher and Knowles (all patent references recited herein are to be incorporated by reference herein in their entirety). Benzamil (also known as 3,5-diamino-6-chloro-N-(benzylaminoaminomethylene) pyrazinecarboxamide) and phenamil (also known as 3,5-diamino-6-chloro-N-(phenylaminoaminomethylene)pyrazinecarboxamide) are known compounds and are disclosed in U.S. Pat. No. 3,313,813 to E. Cragoe. The terms "benzamil", "phenamil", and "amiloride", as used herein, include the pharmaceutically acceptable salts thereof (i.e., salts as given above), such as (but not limited to) amiloride hydrochloride, benzamil hydrochloride or phenamil hydrochloride.
Active compounds of the present invention may, as noted above, be prepared as pharmaceutically acceptable salts thereof. Pharmaceutically acceptable salts are salts that retain the desired biological activity of the parent compound and do not impart undesired toxicological effects. Examples of such salts are (a) acid addition salts formed with inorganic acids, for example hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; and salts formed with organic acids such as, for example, acetic acid, oxalic acid, tartaric acid, succinic acid, maleic acid, fumaric acid, gluconic acid, citric acid, malic acid, ascorbic acid, benzoic acid, tannic acid, palmitic acid, alginic acid, polyglutamic acid, naphthalenesulfonic acid, methanesulfonic acid, p-toluenesulfonic acid, naphthalenedisulfonic acid, polygalacturonic acid, and the like; and (b) salts formed from elemental anions such as chlorine, bromine, and iodine.
The active compounds disclosed herein may be administered to the lungs of a subject by any suitable means, but are preferably administered by administering an aerosol suspension of respirable particles comprised of the active compound, which the subject inhales. The respirable particles may be liquid or solid.
Aerosols of liquid particles comprising the active compound may be produced by any suitable means, such as with a pressure-driven aerosol nebulizer or an ultrasonic nebulizer. See, e.g., U.S. Pat. No. 4,501,729. Nebulizers are commercially available devices which transform solutions or suspensions of the active ingredient into a therapeutic aerosol mist either by means of acceleration of compressed gas, typically air or oxygen, through a narrow venturi orifice or by means of ultrasonic agitation. Suitable formulations for use in nebulizers consist of the active ingredient in a liquid carrier, the active ingredient comprising up to 40% w/w of the formulation, but preferably less than 20% w/w. The carrier is typically water (and most preferably sterile, pyrogen-free water) or a dilute aqueous alcoholic solution, preferably made isotonic with body fluids by the addition of, for example, sodium chloride. Optional additives include preservatives if the formulation is not made sterile, for example, methyl hydroxybenzoate, antioxidants, flavoring agents, volatile oils, buffering agents and surfactants.
Aerosols of solid particles comprising the active compound may likewise be produced with any solid particulate medicament aerosol generator. Aerosol generators for administering solid particulate medicaments to a subject produce particles which are respirable, as explained above, and generate a volume of aerosol containing a predetermined metered dose of a medicament at a rate suitable for human administration. One illustrative type of solid particulate aerosol generator is an insufflator. Suitable formulations for administration by insufflation include finely comminuted powders which may be delivered by means of an insufflator or taken into the nasal cavity in the manner of a snuff. In the insufflator, the powder (e.g., a metered dose thereof effective to carry out the treatments described herein) is contained in capsules or cartridges, typically made of gelatin or plastic, which are either pierced or opened in situ and the powder delivered by air drawn through the device upon inhalation or by means of a manually-operated pump. The powder employed in the insufflator consists either solely of the active ingredient or of a powder blend comprising the active ingredient, a suitable powder diluent, such as lactose, and an optional surfactant. The active ingredient typically comprises from 0.1 to 100 w/w of the formulation. A second type of illustrative aerosol generator comprises a metered dose inhaler. Metered dose inhalers are pressurized aerosol dispensers, typically containing a suspension or solution formulation of the active ingredient in a liquified propellant. During use these devices discharge the formulation through a valve adapted to deliver a metered volume, typically from 10 to 150 μl, to produce a fine particle spray containing the active ingredient. Suitable propellants include certain chlorofluorocarbon compounds, for example, dichlorodifluoromethane, trichlorofluoromethane, dichlorotetrafluoroethane and mixtures thereof. The formulation may additionally contain one or more co-solvents, for example, ethanol, surfactants, such as oleic acid or sorbitan trioleate, antioxidants and suitable flavoring agents.
The aerosol, whether formed from solid or liquid particles, may be produced by the aerosol generator at a rate of from about 10 to 150 liters per minute, more preferably from about 30 to 150 liters per minute, and most preferably about 60 liters per minute. Aerosols containing greater amounts of medicament may be administered more rapidly.
The dosage of the compound of Formula I, or pharmaceutically acceptable salt thereof, will vary depending on the condition being treated and the state of the subject, but generally may be an amount sufficient to achieve dissolved concentrations of active compound on the airway surfaces of the subject of from about 10 -7 to about 10 -3 Moles/liter, and more preferably from about 10 -6 to about 3×10 -4 Moles/liter. Depending upon the solubility of the particular formulation of active compound administered, the daily dose may be divided among one or several unit dose administrations. The daily dose by weight may range from about 1 to 20 milligrams of respirable particles for a human subject, depending upon the age and condition of the subject. Amiloride, benzamil or phenamil administered concurrently with the compound of Formula I or salt thereof may be given in the same dosages as the compound of Formula I or salt thereof.
Solid or liquid particulate pharmaceutical formulations containing active agents of the present invention should include particles of respirable size: that is, particles of a size sufficiently small to pass through the mouth and larynx upon inhalation and into the bronchi and alveoli of the lungs. In general, particles ranging from about 1 to 5 microns in size (more particularly, less than about 4.7 microns in size) are respirable. Particles of non-respirable size which are included in the aerosol tend to be deposited in the throat and swallowed, and the quantity of non-respirable particles in the aerosol is preferably minimized. For nasal administration, a particle size in the range of 10-500 μm is preferred to ensure retention in the nasal cavity.
In the manufacture of a formulation according to the invention, active agents or the physiologically acceptable salts or free bases thereof are typically admixed with, inter alia, an acceptable carrier. The carrier must, of course, be acceptable in the sense of being compatible with any other ingredients in the formulation and must not be deleterious to the patient. The carrier may be a solid or a liquid, or both, and is preferably formulated with the compound as a unit-dose formulation, for example, a capsule, which may contain from 0.5% to 99% by weight of the active compound. One or more active compounds may be incorporated in the formulations of the invention, which formulations may be prepared by any of the well-known techniques of pharmacy consisting essentially of admixing the components.
Compositions containing respirable dry particles of active compound may be prepared by grinding the active compound with a mortar and pestle, and then passing the micronized composition through a 400 mesh screen to break up or separate out large agglomerates.
Amiloride, benzamil or phenamil used to prepare compositions for the present invention may alternatively be in the form of a pharmaceutically acceptable free base of benzamil or phenamil. Because the free base of the compound is less soluble than the salt, free base compositions are employed to provide more sustained release of benzamil or phenamil to the lungs. Amiloride, benzamil or phenamil present in the lungs in particulate form which has not gone into solution is not available to induce a physiological response, but serves as a depot of bioavailable drug which gradually goes into solution.
The pharmaceutical composition may optionally contain a dispersant which serves to facilitate the formation of an aerosol. A suitable dispersant is lactose, which may be blended with the benzamil or phenamil in any suitable ratio (e.g., a 1 to 1 ratio by weight).
The present invention is explained in greater detail in the following non-limiting Example.
EXAMPLE 1
Effect of dinucleotide A 2 P 4 on chloride (Cl - ) secretion
Normal airway cells were cultured on permeable supports and Cl - secretion assayed as previously described in M. J. Stutts, et al., Am. J. Physiol. 267, C1442-C1451 (1994). Cl - secretion was measured after administration of the dinucleotide A 2 P 4 (Sigma Chemicals, St. Louis, Mo.). Amiloride was added to block airway epithelial sodium absorption. A 2 P 4 had little effect when exposed to the basolateral surface of the airway epithelial preparation, but on the luminal surface stimulated additional Cl - secretion in airway epithelia that had been treated with forskolin. This result is shown in FIG. 1. Because forskolin maximally activates the CFTR-mediated cAMP-regulated Cl - channels of airway epithelia, this result suggests that A 2 P 4 stimulates luminal purigenic P2U receptors.
Moreover, the administration of A 2 P 4 had no effect on Cl - secretion in airway epithelia pre-stimulated with UTP, which is known to activate non-CFTR Cl - channels. These results, shown in FIG. 2, suggest regulation by A 2 P 4 of the non-CFTR Cl - channel that is controlled by purigenic receptors and further suggests that A 2 P 4 stimulates the same airway epithelial Cl - channels as UTP acting through P2U receptors. Stimulation of this receptor is a therapeutic strategy for certain lung diseases, including cystic fibrosis.
The foregoing Example is illustrative of the present invention, and are not to be construed as limiting thereof. The invention is defined by the following claims, with equivalents of the claims to be included therein. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 10/844,016, filed on May 12, 2004 now U.S. Pat. No. 7,302,775 and incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Barrier movement operators generally include power and control systems for responding to operator inputs and sensed conditions to move a barrier between open and closed positions with respect to an opening. The barrier may be a door, a gate, a window, a window shade/protector or similar apparatus. Garage door operators are a common form of barrier movement operator.
One type of garage door operator comprises a head end with control circuitry and a motor that extends and retracts a trolley connected to the door. The trolley moves along a rail connected between the head end and a support wall of a garage at a point above the garage opening. Such a trolley and rail type of garage door operator is generally supported from an overhead structure such as the ceiling joists of a garage. Support is often achieved by vertical metal support members from the housing of the head end to the ceiling joists which may result in a less than stylish connection.
Ancillary equipment or accessories can be used to improve the functionality of the garage in which the garage door operator is mounted. For example, additional lighting is often placed in the garage, which in some instances, may be controlled by the controller of the head end. Also, a readily available extension cord and/or a mechanic's light is sometimes provided in the garage. The garage door operator itself may gain advantage to having an attached security camera, monitor, motion sensor and other sensing equipment. In previous systems, the inclusion of such additional equipment results in a mix of non-similar items affixed throughout the garage.
In previous systems, the amount of current that an electrical outlet can supply to an operator and its accessories is limited by a circuit breaker. The current flows from the outlet to the operator and the accessories. When the barrier is moved, the movable barrier operator requires a large percentage of the current flowing from the outlet to operate. Both during the starting of the motor and situations where high force is required, the amount of current needed is at a peak. If during the starting of the motor, the sum of the operator current and the current supplied to the additional devices is above the threshold of the circuit breaker, the circuit breaker trips, current flow is halted, and the operator is unable to complete its operation. When the circuit breaker trips, the operation of the operator and the additional devices is impaired resulting in significant inconvenience to the user.
Previous systems do not deal with this situation effectively. Also, in previous systems the power made available to the ancillary devices is the same regardless of whether the operator is active or inactive or which of the ancillary devices is in operation. This results in an inefficient use an allocation of system resources.
SUMMARY OF THE INVENTION
A barrier operator includes a current limiting portion to limit the current supplied to additional or ancillary devices of a barrier operator system. The current limiting portion removes the possibility of tripping an external circuit breaker when a current surge occurs. The safety of the system is enhanced, and at the same time, the power available for the ancillary devices is customized depending upon whether the operator or one of the other ancillary devices is active.
In many of these embodiments, a barrier operator includes a barrier operator portion and a current limit portion. The current limit portion is coupled to a mains supply. The barrier operator portion is coupled to the current limit portion and the mains supply. The current limit portion limits the electrical current made available to at least one ancillary device.
The current limit portion of the operator may include a single current limit device or multiple current limit devices. In addition, the current limit portion may include a controller. The controller receives information indicative of the type of the at least one additional device.
If a controller is used, the controller can make decisions concerning the activation of the additional devices based upon the type of device or other factors. For instance, if a first device is a compressor, a second device is a florescent light, and the third device is a heater, the controller can activate the compressor and heater when the operator is activated but leave the light deactivated. In addition, the controller can leave on the florescent light but not turn on the work light, if the approach would lower the current. The controller can be flexibly programmed to make these decisions based upon the specific needs of a user and the quantity of available current.
The additional device may include a variety of different types of devices used in garages, for example, lights, heaters, sensors, security devices and compressors. The current limit device may be a secondary circuit breaker, positive temperature coefficient resistor, current detecting circuit, switch or fuse. Other examples current limiting devices are possible.
Thus, a system and method is provided that prevents the tripping of a circuit breaker supplying current to an operator. This approach allows for a more convenient use experience during the operation of the operator and effectively manages current surges. Since current surges are effectively managed, operating conditions for a user are made more safe. Also, power is managed mote effectively because the state of the operator is considered on determining the amount of power supplied to ancillary devices. This results in the smoother and more efficient operation of the system.
BRIEF DESCRIPTION OF DRAWING
FIG. 1 is a perspective view of a mounted prior art barrier movement operator;
FIG. 2 is a perspective view of an improved barrier movement operator mounting according to the present invention;
FIG. 3 is a front plan view of the mounting of FIG. 2 according to the present invention;
FIG. 4 is an end view of an elongate member and vertical support used in FIG. 2 according to the present invention;
FIG. 5 is an electrical block diagram illustrating power distribution according to the present invention;
FIG. 6 is a top view of the barrier movement operator according to the present invention;
FIG. 7 is a system for controlling in the distribution of current according to the present invention;
FIG. 8 is a system for controlling in the distribution of current according to the present invention;
FIG. 9 is a system for controlling in the distribution of current according to the present invention;
FIG. 10 is a system for controlling in the distribution of current according to the present invention;
FIG. 11 is a system for controlling in the distribution of current according to the present invention; and
FIG. 12 is a system for controlling in the distribution of current according to the present invention.
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of the various embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , a perspective view of the inside of a secure area such as a garage, having a known barrier movement operator is described. The area has a ceiling 16 and a front wall 14 with a doorway (not shown) therethrough which is opened and closed by a paneled garage door 24 . The position of the door 24 is controlled by a barrier movement operator head end 12 which moves a trolley 20 out and back along a rail 18 . The trolley 20 is connected to door 24 by a trolley/door arm 22 . The door 24 includes rollers at its edges which engage doorguides 26 and 28 and as the trolley 20 is drawn toward the head end 12 the door 24 is raised in the doorguides to a substantially horizontal position. The movement of the door may be controlled by user interaction with a wall control unit 31 which signals the head end of the user's requests. The head end 12 , which includes an electric motor, is powered from a maims voltage outlet 15 and is supported from the joists of the ceiling by support members 13 . Other sensors and signaling devices may be used to control barrier movement, but are not described because they are not necessary for an understanding of the present invention.
FIG. 2 is an upward perspective view of a combined barrier movement operator support and power busing system. The trolley of the FIG. 2 arrangement may be connected to a trolley/door arm 22 as shown in FIG. 1 to raise and lower a door or other barrier. FIG. 3 is a view of the same structure as FIG. 2 , but the view is from the front of the garage, along the trolley rail 18 . The structure of FIG. 2 includes an elongate member 33 which is supported by a plurality of vertical members 35 from an over head structure. The over head structure may be ceiling joists or another support member secured to the overhead structure of the garage. Elongate member 33 , which is shown in cross section in FIG. 4 , comprises an open trough 34 which may be fabricating by roll forming 16 gauge sheet steel. The open trough 34 runs the length of the elongate member and may be used to provide power to accessories attached to the elongate member as discussed below.
Vertical members 35 may comprise hollow tubes having a shoulder portion 37 at a bottom thereof Shoulder portion is affixed to the hollow tube vertical member 35 and includes female threads at the open end thereof. The elongate member 33 includes a plurality of mounting holes and the vertical members 35 are connected to the elongate member 33 by bolts 39 screwed into the female inner threads of shoulders 37 through the holes. The open ends of elongate member 33 may be closed by end caps 38 .
The operator 12 includes a current limit portion 12 a . The current limit portion 12 a controls current to the additional devices 53 , 54 , 55 , 56 and 57 . As described in greater detail below, the current limit portion 12 a may include a single current limit device or multiple current limit devices. In addition, the current limit portion 12 a additional may include a controller. In one example, the controller receives information indicative of the type of the at least one additional device.
FIG. 6 is a top plan view of the barrier movement operator 12 portion of the elongate member 33 and portion of the trolley tail 18 . The barrier movement operator 12 is secured to the elongate member 33 by means of a plurality of bolts 41 which extend through the elongate member 33 into threaded holes in the barrier movement operator. Similarly, the trolley rail 18 is secured to the top of barrier movement operator 12 by means of a pair of bolts 43 through the rail and into barrier movement operator, Also shown in FIG. 6 is a drive sprocket 45 which is rotated by a motor (not shown) to move a chain 47 which is attached to trolley 20 . Mains voltage may be provided to the barrier movement operator by a multi conductor power wire 49 which passed through one of the hollow vertical supports 35 and into the hollow trough 34 of elongate member 33 . Power wire 49 runs along the interior 34 of elongate member 33 and is passed to the barrier movement operator 12 via an opening 51 in the elongate member.
The elongate member 33 also includes a number of points at which accessories can be attached to provide additional functionality. As shown in FIG. 3 , light fixtures 53 and 54 are attached to a portion of the elongate member 33 to the left of the barrier movement operator 12 and light fixtures 55 and 56 are attached to the right. Further, a retractable cord, mechanic's light 58 is attached to the elongate member as is a retractable hose reel 59 for supplying compressed air from a compressor 52 . In other embodiments, other accessories such as a battery charger, security camera, CO monitor, motion detector etc., may be attached to the elongate member 33 .
FIG. 5 is an electrical block diagram illustrating the connection and distribution of electrical power using the arrangement of FIG. 2 . In FIG. 5 a portion of the elongate member 33 is shown to represent its power distribution or power bus function and barrier movement operator 12 is shown in block diagram form. Barrier movement operator 12 comprises power distribution apparatus 71 , a controller 73 , barrier movement apparatus 75 , a light assembly 77 , and the current limit portion 12 a . The current limit portion 12 a limits current to the additional or ancillary devices. Barrier movement apparatus 75 may include a motor and sensors (not shown) which cooperate with control unit 73 to open and close a barrier. Power distribution unit 71 is equipped to receive mains voltage and to distribute mains voltage, or another created voltage, under the control of controller 73 . The light 77 is a common part of barrier movement operators and is used to provide one source of illumination under the control of controller 73 .
Power wire 49 is connectable to a source of mains voltage and connects that voltage to power distribution unit 71 . Power distribution unit 71 distributes power within barrier movement operator 12 as is needed to provide barrier movement. Controller 73 is also responsible for controlling the application of mains voltage and other electrical power derived therefrom to accessories connected to barrier movement operator 12 .
The following are examples of power distribution via elongate member 33 . The mains power on power conductor 49 may be distributed directly to attached accessories on elongate member 33 by connection to the power conductor. For example, one accessory may be a “night light” which is continuously powered, but which senses light levels and turns on the “night light” when light levels drop below a predetermined level. Further, the mechanics' light and cord reel 58 and the compressor 52 may be permanently supplied with mains power by connection to power conductor 49 . A battery charger 61 may also be permanently connected to mains power. AC mains power may be selectively provided to accessories by the power distribution unit 71 under the control of controller 73 . For example, when a left hand garage door is being opened lights 54 and 53 may receive mains power from power distribution 71 via conductor 77 . Similarly, lights 55 and 54 may receive mains power from power distribution unit 71 via conductor 79 when a right hand garage door is being opened. Further, laser positioning devices 57 may receive power via conductor 81 or 82 to create a light spot only briefly when a vehicle is entering one side or the other of the garage. The power sent to a laser light 57 may be AC mains or DC created by power distribution 71 under control of controller 73 . In addition, conductors 91 may be employed by power distribution 71 to distribute low voltage power along elongate member 33 or potentially a lower mains voltage to dim the lighting.
In the preceding embodiments, elongate member is shown as being open at the top. The elongate member may be closed on its top to provide protection against improper contact with household voltage. The barrier movement operator is shown in the preceding, attached to the underside of the elongate member. In other embodiments, the barrier movement operator may be attached to the top of the elongate member and rest thereon. Mains power was supplied to the apparatus by a power cord 49 passing through a hollow vertical support 35 . In other embodiments, the power cord may be connected to mains power without passing through a vertical support and such power may be supplied directly to barrier movement operator 12 via a power cord as shown in FIG. 1 .
Referring to FIG. 7 , one example of an operator with a current limiting device is described. A power plug 710 is placed in a power outlet to supply power and current to the operator 702 via power lines 704 from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. A current limiting device 706 limits the current supply to additional or ancillary devices that are connected via an outlet 708 . The current limiting device 706 may be a secondary circuit breaker, positive temperature coefficient resistor, current detecting circuit or fuse. The current limitation for the additional devices is limited to the maximum current, which the operator 702 demands.
Referring now to FIG. 8 , another example of an operator with a current limiting device is described. A power plug 816 is placed in a power outlet to supply power and current to an operator 802 via power lines 803 . The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. Current limiting devices 804 , 806 , 808 supply and limit current to outlets 810 , 812 and 814 respectively. The current limiting devices may be a secondary circuit breaker, positive temperature coefficient resistor, current detecting circuit or fuse. The outlets 810 , 812 and 814 are connected to separate outside devices. The maximum current to each additional device is limited to the maximum current the operator 802 demands divided by the number of potential devices. The limit to the amount of current for each branch may be different and may be determined by a user.
Referring now to FIG. 9 , another example of an operator with a current limiting device is described. A power plug 910 is placed in a power outlet to supply an operator 902 with power and current. The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. The operator 902 includes a control circuit 904 , a current limiting device 906 and an outlet 908 to additional devices (not shown). The current limiting device 906 may be a secondary circuit breaker, positive temperature coefficient resistor, current detecting circuit or fuse. The control circuit 904 controls the operation of the barrier movement portion of the barrier operator.
The current that a motor is allowed to absorb is limited by the limiting device 906 . The limiting device 906 slows down the rate at which a motor (not shown) accelerates but allows for a higher amount of current for the additional devices. This approach may be used alone or in combination with other approaches described herein.
Referring now to FIG. 10 , an example of an operator with another current limiting approach is described. A power plug 1008 is placed in a power outlet to supply an operator 1002 . The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. A power control element 1004 controls the amount of current supplied to outlet 1006 . The outlet 1006 is connected to additional devices (not shown). In this approach, the power control element 1004 turns off the additional devices whenever the operator 1002 is required to move a barrier. This allows the barrier to have a full current supply, but at the same time, power the additional devices.
Referring now to FIG. 11 , another example of an operator with current limiting devices is described. A power plug 1112 is placed in a power outlet to supply power and current to an operator 1102 via power lines 1103 . The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. The operator 1102 includes switches S 1 , S 2 and S 3 that are connected to outlets 1108 , 1106 and 1104 respectively. The outlets 1104 , 1106 and 1108 and switches S 1 , S 2 and S 3 are connected to control logic 1110 . The control logic 1110 , in one example, may be in the form of a microprocessor. As an example, the switches S 1 , S 2 , and S 3 can be relays, triacs, other solid state relays or combinations of these devices.
The switches S 1 , S 2 and S 3 are operated by the control logic 1110 . The control logic 1110 causes the switches S 1 , S 2 and S 3 to be opened and closed depending upon how the control logic has been programmed.
The control logic 1110 may also be responsible for phasing-in the operation of the additional devices. For example, the control logic 1110 may determine to activate a first additional device at time t 1 , a second additional device a certain length of time later, and a third additional device another length of time later. Phasing-in the additional devices avoids current spikes that might be created at start-up if all the additional devices were activated at the same time. The additional devices may be any that have been described previously. In addition, the additional devices may include other barrier operators.
In this approach, information indicating the types of devices that are attached to the operator is supplied to the control logic 1110 . By knowing, for instance, that the first device is a compressor, the second device is a florescent light and the third device is a heater, the control logic 1110 can make an intelligent decision as to which devices to activate based upon certain predefined circumstances. For instance, the control logic 1110 can activate the compressor and heater when the operator is activated but leave the light deactivated. The control logic 1110 can leave on the florescent light but not turn on the heater, if the approach would lower the current. Those skilled in the art will realized that the control logic 1110 can be configured in any number of ways to act upon the additional devices depending upon the desires of a user.
Referring now to FIG. 12 , an example of an operator where information concerning additional devices is received by the operator is described. A power plug 1214 is connected to a power and current outlet and power and current is supplied to the operator via lines 1203 . The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. Outlets 1204 , 1206 , 1208 and 1212 are connected to additional devices.
The knowledge of the type of device can be given either through a third connection (information, power and ground) or through a specific connection to the additional device. The specific connection can be specific plugs or a specific wire connection for switched and unswitched power. The third connection (information) can be performed by a number of methods. Serial communication is one example as is having an impedance connected to that terminal to allow the impedance measurement to give the magnitude of current demanded by the products connected to the terminal.
While there has been illustrated and described particular embodiments of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true scope of the present invention. | 4y
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FIELD OF THE INVENTION
[0001] This invention relates generally to an electrical connection, and more particularly, to a connection between a tubular lead and a high voltage bushing, and a method of maintaining the connection.
BACKGROUND OF THE INVENTION
[0002] A high voltage bushing (“HVB”) can be used to conduct electric current from a stator winding connection of a generator through the generator frame to a buss external to the generator. In a gas-cooled generator (e.g., a hydrogen-cooled generator), the HVB isolates voltage from the generator frame and provides a gas tight connection. On higher rated generators, direct gas-cooled HVBs are used along with other electrical conductors and/or components to transmit the electric current from the winding to the external buss. In these generators, cooling gas flows through a hollow HVB conductor and a hollow tubular lead. Physical and/or electrical degradation of these and other electrical components can occur due to heat, vibration, or other factors, many of which occur during the course of normal use and aging. Degradation and/or failure of the electrical components can lead to overheating of the HVB, causing degradation and/or failure of the HVB. HVB degradation and/or failure can include, but is not limited to, degradation and/or failure of gas seal(s)/gaskets within the HVB which causes the HVB to leak hydrogen and/or corona resistant filler (e.g., asphalt), aging of the HVB flange bond, and electrical degradation and/or failure. HVB degradation and/or failure can necessitate HVB maintenance, repair, or replacement.
[0003] Routine inspections and maintenance can be scheduled, during which the need to repair or replace an HVB can be detected. Leaking asphalt is one possible indicator of a failing HVB. Asphalt can be used to fill air space in the HVB connection to prevent undesirable electrical discharge (e.g. arcing between components). The air-side (exposed side) of the HVB is an area where evidence of asphalt leaking is likely to be discovered. In the event the seals fail and asphalt leaks from the HVB, it is normally recommended that the HVB be rebuilt or replaced with a new HVB, to protect from hydrogen leakage.
[0004] HVB degradation and/or failure can also be indicated by in-service gas loss, in gas-cooled generators. Further, an HVB replacement can be prompted by generator uprating, resulting in the need for higher rated HVBs, or by other factors not associated with degradation, damage, or failure of the HVBs or other electrical components.
[0005] An HVB and/or an HVB connection can be repaired and/or replaced by disassembling and reassembling it. Before disassembly, a first winding resistance on each phase can be recorded to obtain baseline data. The disassembly of the HVB connection can be performed by removing insulation and putty between the HVB and the lower stud connector, unbolting the connection between the HVB, the lower stud connector, and a tubular lead, and removing the lower stud connector to free the HVB to be removed.
[0006] The tubular lead and the lower stud connector can be visually inspected for overheating and their silver plating integrity. The plating can be restored if desired. Usually, there is no evidence of overheating on the HVB conductor, the lower stud connector, or the tubular lead.
[0007] The reassembly of the HVB connection can be performed by the reverse of the disassembly process, except that the lower stud connector bolts can be replaced with new stainless steel hardware. Once the lower stud connector bolts are properly torqued, a second winding resistance can be recorded, and the connection can be re-insulated.
[0008] Attempts to repair and/or replace HVBs using current methods have resulted in ensuing failures of the HVBs. These failures have occurred either immediately after the maintenance, or relatively soon thereafter, in a time significantly less than the expected or average life of an HVB. For example, recent failures have surfaced over the past 1 to 3 years with replacement HVB's installed by more than one service provider. In each case, evidence of leaking asphalt was detected during inspections. Accordingly, current industry practices to repair and/or replace HVBs are insufficient in addressing the HVB failure and/or its cause.
[0009] In some cases of failure after repair or reassembly of an HVB the winding resistance was recorded, and the results were consistent with past maintenance outage measurements, and in both cases, measurements were consistent between phases. The results would appear to indicate that the HVB connections were acceptable per the industry acceptance criteria e.g., max. of 2% differential between phases when compared to one another). Accordingly, current industry practices to detect HVB connection deficiencies and/or HVB failure causes are insufficient.
[0010] It would be advantageous to perform maintenance, repair, or replacement of an HVB to avoid, prevent, or reduce the chance of, an ensuing failure that occurs sooner than the expected life of an HVB.
SUMMARY OF THE INVENTION
[0011] The present method provides an improved manner to maintain, repair and/or replace HVBs and/or HVB connections to prevent or reduce ensuing HVB failures.
[0012] In one embodiment of the invention, a method of maintaining a high voltage bushing is provided. The method comprises inspecting a high voltage bushing connection, the high voltage bushing connection comprising a tubular lead, a lower stud connector, and the high voltage bushing.
[0013] In one aspect of this embodiment, the method comprises restoring at least one of the tubular lead, the lower stud connector, and the high voltage bushing.
[0014] In another aspect of this embodiment, the method comprises disassembling the high voltage bushing connection and reassembling the high voltage bushing connection.
[0015] In another aspect of this embodiment, inspecting the high voltage bushing connection comprises visually inspecting at least one of a mating portion of the tubular lead, a mating portion of the lower stud connector, and a mating portion of the high voltage bushing.
[0016] In another aspect of this embodiment, inspecting the high voltage bushing connection comprises checking a contact surface of at least one of a mating portion of the tubular lead, a mating portion of the lower stud connector, and a mating portion of the high voltage bushing using a bluing agent.
[0017] In another aspect of this embodiment, inspecting the high voltage bushing connection comprises measuring diametrical dimensions of at least one of a mating portion of the tubular lead, a mating portion of the lower stud connector, and a mating portion of the high voltage bushing.
[0018] In another aspect of this embodiment, restoring at least one of the tubular lead, the lower stud connector, and the high voltage bushing comprises applying conductive material to at least one of a mating portion of the tubular lead and a mating portion of the high voltage bushing, machining an external diameter of at least one of the mating portion of the tubular lead and the mating portion of the high voltage bushing, and machining an internal diameter of at least one of a first mating portion of the lower stud connector and a second mating portion of the lower stud connector.
[0019] In another aspect of this embodiment, restoring at least one of the tubular lead, the lower stud connector, and the high voltage bushing further comprises measuring a length from an end of the tubular lead at a mating portion of the tubular lead to an insulation, and removing the insulation from the tubular lead.
[0020] In another aspect of this embodiment, restoring at least one of the tubular lead, the lower stud connector, and the high voltage bushing further comprises performing a restoration contact surface check using a bluing agent.
[0021] In another aspect of this embodiment, restoring at least one of the tubular lead, the lower stud connector, and the high voltage bushing further comprises silver plating at least a portion of at least one of a mating portion of the tubular lead, a mating portion of the lower stud connector, and a mating portion of the high voltage bushing.
[0022] In another aspect of this embodiment, reassembling the high voltage bushing connection comprises performing a post-restoration contact surface check using a bluing agent.
[0023] In another embodiment, a method of restoring a high voltage bushing connection is provided. The method comprises applying conductive material to at least one of a mating portion of a tubular lead and a mating portion of a high voltage bushing, machining an outside diameter of at least one of the mating portion of the tubular lead and the mating portion of the high voltage bushing to a predetermined outer diameter, and machining a mating portion of a lower stud connector to a predetermined inner diameter.
[0024] In one aspect of this embodiment, the method comprises disassembling the high voltage bushing connection and reassembling the high voltage bushing connection.
[0025] In another aspect of this embodiment, the method further comprises performing at least one contact surface area check using a bluing agent.
[0026] In another aspect of this embodiment, the method further comprises removing insulation from the tubular lead.
[0027] In another aspect or this embodiment, removing insulation from the tubular lead further comprises measuring a length from an end of the tubular lead at a mating portion of the tubular lead to the insulation.
[0028] In another aspect of this embodiment, the method further comprises cleaning the lower stud connector to remove putty, epoxies, or contaminants on the external or internal surfaces, the cleaning occurring before the step of machining a tubular lead end of a lower stud connector.
[0029] In another aspect of this embodiment, a mandrel is used in place of the high voltage hushing to simulate the mating portion of the high voltage bushing and to perform at least one of the at least one contact surface check.
[0030] In another aspect o this embodiment, the method further comprises plating at least one of the mating portion of the lower stud connector, the mating portion of the tubular lead, and the mating portion of the high voltage bushing.
[0031] In another embodiment, a high voltage hushing connection of a generator is provided. The high voltage bushing connection comprises a restored mating portion of a tubular connector and a restored lower stud connector. The restored mating portion comprises an added portion of conductive material machined to a final external diameter greater than an initial external diameter with which the tubular connector was previously used in operation with the generator, and the restored lower stud connector comprises a final internal diameter machined to a value larger than an initial internal diameter with which the lower stud connector was previously used in operation with the generator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 illustrates a gas-cooled generator, according to one exemplary embodiment.
[0033] FIG. 2 illustrates the internal components of the bushing box of FIG. 1 , according to one exemplary embodiment.
[0034] FIG. 3 illustrates an HVB connection 30 , according to one exemplary embodiment.
[0035] FIG. 4 illustrates a tubular lead with the lower stud connector disassembled.
[0036] FIG. 5 illustrates a disassembled lower stud connector.
[0037] FIG. 6 illustrates a tubular lead with mica-insulation entirely removed, and with applied copper incorporated to build out a mating portion, according to one exemplary embodiment.
[0038] FIG. 7 illustrates a mating portion of the tubular lead machined to a uniform, round surface at a desired diameter, according to one embodiment.
[0039] FIG. 8 illustrates a lower stud connector being machined, according to one embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0040] FIG. 1 illustrates a gas-cooled generator 10 , according to one embodiment. The generator 10 has attached a gas-cooled bushing box 20 , otherwise called a lower frame extension, under the generator 10 .
[0041] FIG. 2 illustrates the internal components of the bushing box 20 . Gas-cooled designs can utilize a large bushing box where access is via a manway in the wall of the box. Inside the bushing box 20 , from the top, or side closer to the generator 10 , to the bottom, or side farther from the generator 10 , the components can comprise connection rings 11 , flexible connectors 12 , gas-cooled tubular main leads 13 (e.g., a 3.5 or 4.0 inch diameter conductors), gas-cooled stand-off insulators 14 , lower stud connectors 15 , and gas-cooled HVBs 16 (e.g, 4 inch or 6 inch conductors). Of these components, the electrical current carrying components can include the connection rings 11 , the flexible connectors 12 , the tubular leads 13 , the lower stud connectors 15 , and the HVBs 16 .
[0042] FIG. 3 illustrates an HVB connection 30 . The HVB connection comprises a tubular lead 13 connected to a lower stud connector 15 , which is connected to an HVB 16 . The lower stud connector 15 is a clamshell design that is bolted around an end of the tubular lead 13 , and bolted around an end of the HVB 16 . Between the stand-off insulator 14 and the tower stud connector 15 , the tubular lead 13 is insulated with mica insulation. At the end where the lower stud connector 15 bolts around the tubular lead 13 , copper, which composes the hollow tube of the tubular lead 13 , is exposed, to mate with the lower stud connector 15 .
[0043] A comprehensive maintenance program, comprising inspection and repair of the HVB connection 30 , can be implemented to maintain reliability of the high voltage hushing and associated components. By utilizing a specialized inspection process, the electrical contact surfaces can be evaluated, and repairs can be performed to re-establish proper electrical surface contact, which can minimize the possibility of a high-resistance joint leading to a high voltage bushing failure.
[0044] The exemplary method of maintenance can involve disassembling the HVB connection 30 , inspecting the HVB connection 30 , restoring the tubular lead 13 , the HVB 30 , and/or the lower stud connector 15 , and reassembling the HVB connection 30 . Lead times to procure new replacement parts can be prohibitive to ordering new parts, from a production and operation standpoint.
[0045] The lower stud connector 15 can be disassembled from the HVB 16 and the tubular lead 13 . FIG. 4 illustrates the disassembled tubular lead 13 and HVB 16 , and FIG. 5 illustrates the disassembled lower stud connector 15 . Removing the lower stud connector reveals a mating portion 43 of the tubular lead, and a mating portion 46 of HVB 16 . A first mating portion 53 of the lower stud connector 15 which mates with the tubular lead 13 , and a second mating portion 56 of the loner stud connector 15 , which mates with the HVB 16 , are also revealed.
[0046] An exemplary method of maintenance can comprise inspecting the HVB connection 30 . A visual inspection of the conductor mating surfaces can be conducted. During the visual inspection, any cracks, electrical pitting, or other deformities or damage can be noted and/or recorded. These cracks, pitting, or other deformities or damage can be later repaired.
[0047] Following the visual inspection, a contact surface check using a bluing agent (e.g., machinist's blue, otherwise known as engineer's blue), such as Hi-Spot Blue, can be performed. A contact surface check can be performed by spreading the bluing agent on the contact surface of one component, and assembling and disassembling the second component with/from the first component. The bluing agent that transfers between the two components can reveal the portions of the two components that mated. Surface incongruences between two mating surfaces and high spots can be detected. Contact surface checks using a bluing agent have not been performed as normal industry installation practices for HVB replacement projects. During the contact surface check, a proper torque on the lower stud connector 15 can be applied in order to facilitate a proper determination or contact surface area mating. A proper torque can be determined by, for example, the generator manufacturer's specifications or industry standards.
[0048] A dimensional check can also be performed to verify the diametrical dimensions (e.g., 4 point check) on the mating portion 43 of the tubular lead 13 , where the lower stud connector 15 connects to the tubular lead 13 , and on the mating portion 46 of the HVB 16 , where the lower stud connector 15 connects to the HVB 16 . Dimensions can be recorded at the end or up to approximately ½ inch from the end of the tubular lead 13 . The dimensional check can be repeated by dividing the remaining length of the mating portion 43 into meaningful increments to determine its “roundness”. Similarly, the dimensions on the mating portion 46 of the HVB 16 can be recorded at the end or up to approximately ½ inch from the end of the HVB 16 , repeating the dimensional check by dividing the remaining length of the mating portion 46 into meaningful increments. Dimensional checks can also be performed on the first mating portion 53 and the second mating portion 56 of the lower stud connector 15 .
[0049] Investigating HVBs replaced by service providers that consequently failed found that mating components in each HVB revealed a potentially high resistance connection in-service between the tubular lead 13 and the lower stud connector 15 . The contact surface checks using a bluing agent revealed insufficient contact surface area between the tubular lead 13 and the lower stud connector 15 . In addition, diametrical dimensional checks performed along the axial length of the tubular connection revealed deformation (out of roundness) of the copper material making up the conductive components. The insufficient surface contact can increase electrical resistance, increase heat, and cause or promote failure of the HVB 16 .
[0050] The “roundness”, or contact surface of the mating portion 43 of the tubular lead 13 and the first mating portion 53 of the lower stud connector 15 can be restored to achieve acceptable or desirable contact surface area between the tubular lead 13 and the lover stud connector 15 .
[0051] To restore the contact surfaces, the length of the end of the tubular lead 13 , including the mating portion 46 of the tubular lead 13 , up to the beginning of the mica-insulation, can be measured and recorded. The existing mica-insulation can then be entirely stripped off the tubular lead 13 . The measured/recorded length of the exposed copper portion of the tubular lead 13 can be used to re-establish the insulation termination when the tubular lead is later re-insulated.
[0052] After stripping the mica-insulation, copper build material can be applied on the mating portion 43 of the tubular lead 13 . The copper can be applied via any known method, such as via a TIG welding, process. FIG. 6 illustrates the tubular lead 13 with the mica-insulation entirely removed, and with applied copper 61 incorporated to build out the mating portion 43 . The mating portion 43 of the tubular lead can be machined to a uniform, round surface at a desired diameter, as illustrated in FIG. 7 .
[0053] The lower stud connector 15 can undergo similar treatment to restore its contact surface. First, both halves of the lower stud connector 15 can be cleaned to remove any conforming putties, epoxies, or contaminants remaining on the external or internal surfaces. Glass bead cleaning, or any known cleaning method, can be performed. Then the first mating portion 53 of the lower stud connector 15 can be machined to a desirable internal diameter for connection with the mating portion 43 of the tubular lead 13 . FIG. 8 illustrates the lower stud connector 15 being machined. To allow the components to be repaired at a location remote from the generator 10 , and to allow the HVB 16 to remain on site with the generator 10 , an assembly for machining can be arranged using a temporary conductor on the HVB side of the lower stud connector 15 .
[0054] After the tubular lead 13 and the lower stud connector 15 are machined, the parts can be checked to ensure dim have all adequate amount of contact surface engagement. A restoration contact surface check using a bluing agent, between the newly machined tubular lead 13 and the lower stud connector 15 , can be performed. Again, to allow the components to be repaired remotely, a specified diameter mandrel can be used to simulate the HVB conductor. A repaired tubular lead 13 and lower stud connector 15 can have a minimum amount of contact surface engagement, as determined in each case by the generator type, the generator requirements, the electrical load, the generator manufacturer specifications, industry standards, and/or a variety of other factors. An acceptably repaired tubular lead 13 and lower stud connector 15 , for example, might have, at minimum, 2.5 inches length of engagement of the tubular lead 13 into the lower stud connector 15 and 50% or greater surface contact at the mating areas.
[0055] Following an acceptable restoration contact surface check using a bluing agent, the tubular lead 13 and the lower stud connector 15 can be silver plated (e.g., 0.0005-0.002 inch thickness). Silver plating can be applied to both ends of the tubular lead 13 . The plating on the mating portion 43 of the tubular lead 13 should be at least the length of engagement between the tubular lead 13 and the lower stud connector 15 . After the silver plating process, the tubular lead 13 can be re-insulated. The insulation build depends, at least in part, on the voltage of the generator.
[0056] The “roundness”, or contact surface of the mating portion 46 of the HVB 16 and the second mating portion 56 of the lower stud connector 15 can also be restored to achieve acceptable or desirable contact surface area between the HVB and the lower stud connector 15 , if the contact surface area between the HVB 16 and the lower stud connector 15 is unacceptable or otherwise insufficient.
[0057] As with the tubular lead 13 , copper build material can be applied on the mating portion 46 of the HVB 16 . The copper can be applied via any known method, such as via a TIG welding process. The mating portion 46 of the HVB 16 can be machined to a uniform, round surface at a desired diameter.
[0058] The second mating portion 53 of the lower stud connector 15 can be machined to a desirable internal diameter for connection with the mating portion 46 of the HVB 16 .
[0059] After the mating portion 46 of the HVB 16 and the lower stud connector 15 are machined, the parts can be checked to ensure they have an adequate amount of contact surface engagement. A second restoration contact surface check using a bluing agent, between the newly machined HVB 16 and the lower stud connector 15 , can be performed. As with the connection between the tubular lead 13 and the lower stud connector 15 , a repaired HVB 16 and lower stud connector 15 can have a minimum amount of contact surface engagement, as determined in each case by the generator type, the generator requirements, the electrical load, the generator manufacturer specifications, industry standards, and/or a variety of other factors.
[0060] Following an acceptable second restoration contact surface check using a bluing agent, the mating portion 46 of the HVB 16 and the second mating portion 46 of the lower stud connector 15 can be silver plated (e.g., 0.0005-0.002″ thickness). The plating on the mating portion 46 of the HVB 16 should be at least the length of engagement between the HVB 16 and the lower stud connector 15 . If the mating portion 46 of the HVB 16 is restored, the silver plating process can be performed on the HVB 16 , the tubular lead 13 , and the lower stud connector 15 after the machining of each of the tubular lead 13 , the lower stud connector 15 , and the HVB 16 .
[0061] The exemplary method comprises reassembling the HVB connection components. During reassembly, the HVB connection components can be reinstalled in the generator and a post-restoration contact surface check using a bluing agent can be performed with all the components assembled in their operating positions. With this post-restoration contact surface check, the desired minimum amount of contact surface engagement can be verified.
[0062] The implementation of this maintenance method in the field during routine maintenance and/or during forced outages of generators has resulted in increased service lives of HVBs in-service.
[0063] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. | 4y
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority of Provisional application Ser. No. 60/184,677, filed on Feb. 24, 2000.
GOVERNMENT RIGHTS
The invention disclosed herein may be manufactured, used, and licensed by or for the U.S. government for governmental purposes without the payment to us of any royalty thereon.
FIELD OF THE INVENTION
This invention relates to conductive and photonic polymer membrane articles, and methods to fabricate such articles.
BACKGROUND OF THE INVENTION
A number of studies have shown that conducting polymers processed into films and coatings can be used in a wide variety of applications. These applications include corrosion protection, static dissipation from polymer fibers, textile/fiber reinforcement to provide microwave-absorbing materials with stable radioelectric properties, radar absorbing composites and photovoltaic materials. The principal barrier to the commercial use of conductive polymers in these types of applications and others has been the lack of a viable and economically feasible processing technique that can fabricate these polymers into mechanically tough, stable and high surface area architectures.
Conducting polymer films are typically produced by casting or deposition from solution. Films produced in these manners are fragile, have a relatively low surface area, and are not porous.
Conductive polymers are also spin deposited into coagulating solutions to form conductive fibers. This process produces relatively gross fibers having diameters of around 10-100 um. These fibers are also weak, and have relatively low surface area.
SUMMARY OF THE INVENTION
It is therefore a primary object of this invention to provide conductive (electrical, ionic, and photoelectric) membrane articles that are lightweight and porous, yet have high surface area and are mechanically tough. Such articles can also be fabricated on flexible substrates, such as textiles.
It is a further object of this invention to provide conductive membrane articles that can be designed to have a wide range of electrical, ionic and photoelectric conducting properties.
This invention results from the realization that thin nanoporous conductive flexible articles having extremely high surface area, porosity and toughness can be fabricated by electrospinning at room temperature or thereabout a solution comprising of a matrix polymer and/or a conductor (such as a conducting polymer or conductive nanoparticles), to create a conductive (electrical, ionic, and photoelectric) membrane composed of a non-woven mat of fibers having diameters of less than one micron, corresponding to surface areas greater than 10 m 2 /g.
The invention describes new electrospun conducting polymer membranes and composites that have high surface areas and are lightweight, tunable and active (electrically, chemically and optically). A purpose of this invention is to develop a new technique to process conducting polymers into useful and more efficient architectures for applications including but not limited to, ionic and electrical conductivity, photovoltaic devices, electrostatic dissipation, chemical sensing, corrosion protection, electromagnetic interference shielding and radar attenuation. Another purpose of this invention is to improve the electrospinning process in general, as addition of just a small amount of soluble conducting polymer to the polymer solutions used for spinning (known in the art as “spin dopes”) improves fiber formation and morphology without imparting undesired effects to the final membrane. In this invention, conducting polymers (from organic or aqueous solution or as solid dispersions) are added directly into a spin dope mixture and applied to various surfaces, including but not limited to metals, semiconductors, glass and textiles, or processed as stand alone membranes, using electro spinning technologies.
The conducting polymer membranes of the invention have high surface areas and are lightweight, porous and permeable to vapor. These features are unique in the design and production of conductive thin films: the high surface area of the electrospun fiber enhances exposure of photo conductive compounds to important electrochemical reactions within the film; porosity enables the film to be infiltrated by getting liquids such as polyelectrolytes to improve performance and conductivity; increased interfaces allow for more efficient energy conversion; and vapor permeation enables the film constituents to be altered chemically by vapor reactions. These membranes have intrinsic electrical conductivities ranging from (but not limited to) 0.15 to 10 −6 S/cm depending on the level and concentration of the conducting polymer(s) used in the spin dope, other components added to the spin dope and the architecture of the membranes. Many different polymers and materials can be blended to form unique membranes with improved properties for use in an array of applications. For example, improved properties including but not limited to mechanical toughness, adhesion, conductivity (electrical, ionic and photoelectric), recognition for sensing, and electromagnetic shielding may be built into these membranes through judicious choice of components.
Recent test results have led to the development of electrospinning techniques for the processing of soluble conducting polymers (organic solvent and aqueous based and mixtures thereof) and dispersions into new conducting polymer fibrous membranes and composite structures. The membranes and composites formed with this invention are unique and desirable in that they are nanoporous structures that have extremely high surface area, porosity and tunability (i.e. properties that can be varied over a range of values). These enhancements to date have not been available for the processing of conductive polymers and are extremely valuable for each of the above-mentioned applications. In addition, these electro spun conducting polymer membranes are inexpensive as they can be easily prepared and modified to the desired size and substrate.
These fibrous membranes can be processed at ambient conditions adhering to and forming vapor permeable membranes on a variety of substrates such as clothing or other surfaces, as well as forming stand-alone membranes. The conducting materials can be readily incorporated into fibrous networks with high surface areas without problematic techniques involving solubility and polymer casting of traditional membranes using conducting polymers. These membranes are lightweight and can be tailored for specific properties depending on use. Single or combinations of various conducting polymers can be added to the spin dope thereby adding their novel properties to the membrane. The conducting polymers also have an effect on the electrospinning process itself by acting in the spin dope to optimize fiber formation.
There are numerous embodiments of the invention, as the membranes can be formulated with not only conducting polymers but with a wide variety of other interesting electronic materials. When solubility is an issue, insoluble conductive particulate compounds and inorganic semiconductor nanoparticles can also be captured by the electrospinning techniques described to impart the desired properties of the included material and yet maintain the similar properties of the nanofibrous membrane as described in this disclosure.
This invention can be used for the fabrication of novel conducting materials for electrostatic dissipation, corrosion protection, electromagnetic interference shielding, signature reduction, photovoltaic devices, lightweight batteries, conductive fabrics and chemical and biological sensing. Other potential applications of this invention include the use of a small amount of conducting polymer in the spin dope to improve electrospinning and fiber formation of other desirable polymeric materials.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiments, and the accompanying drawings, in which:
FIG. 1 shows the effect of Polyaninile/SPS (PANI/SPS) content, and the addition of oxidized carbon nanotubes (oxCNT) on the DC conductivity of electrospun fiber mats in accordance with the invention;
FIG. 2 shows the effect of PANI/SPS content, and the addition of furnace carbon nanotubes, on the AC conductivity of electrospun fibers of estane polyurethane in accordance with the invention; and
FIG. 3 illustrates the photovoltaic response from dilithium phthalocyanine with titanium dioxide particles electrospun onto indium tin oxide, in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention can be produced using a wide range of organic and aqueous soluble conducting polymers and dispersions thereof and inorganic conducting nanoparticles contained in a polymeric matrix material which are then electrospun together to form a non-woven fibrous mat or membrane. Non-limiting examples of conducting polymers include polyaniline, polypyrrole, polythiophene, polyphenol, polyacetylene, and polyphenylene. Non-limiting examples of inorganic semi-conductor nanoparticles include but are not limited to, titanium dioxide, zinc oxide, tin sulfide and tin oxide. Non-limiting examples of matrix polymeric materials include but are not limited to polyurethane (PU), polyethylene oxide (PEO), polyacrylonitrile (PAN), polylactic acid (PLA), polyvinyl acetate (PVA), and cellulose acetate, contained in a matrix of additional polymeric material which are then electrospun together to form a fibrous mat or membrane.
A preferred embodiment of the invention is to incorporate a water-soluble complex of polyaniline and sulfonated polystyrene (PANI/SPS) into a DMF (dimethyl formamide) solution of polyurethane and to electrostatically spin fibers from the solution onto a target substrate. The PANI/SPS complex is added to the polyurethane solution at a level of 10-60% percent by weight. The resulting fibers are 0.1-1 microns in diameter. These PANI/SPS/PU membranes show reversible electrical doping/dedoping processes consistent with those observed with traditional bulk cast films of polyaniline. These conducting polymer membranes also show increased surface areas, mechanical toughness and porosity when compared to traditional bulk cast films of polyaniline.
A second preferred embodiment of the invention is to incorporate chemical indicator (pH) dyes into a DMF solution of polyurethane and to electrostatically spin fibers from solution onto a target substrate. Non-limiting examples of the colorimetric dyes include but are not limited to, phenol red, thymol blue and phenolphthalein. The indicator dye is added to the polyurethane solution at a level of 1-10% by weight. The resulting fibers are 0.1-1 microns in diameter, corresponding to a surface area of about 10-50 m 2 /g. These indicator membranes incorporate the chemical dye within the nanofibers of the spun membrane and offer increased surface area, mechanical toughness and porosity. These indicator dye membranes demonstrate reversible color changes consistent with chemical environment exposures.
A third preferred embodiment of the invention is to incorporate photo-reactive compounds and semi conductive particles, both in the soluble and particulate forms, into a DMF solution of polyacrylonitrile and to electrostatically spin fibers from the solution onto a target substrate. In addition, layering or casting of these compounds may be used in combination with electrospun matrixes. Non-limiting examples of photo-reactive dyes include but are not limited to phthalocyanines, ruthenium complexes with organic ligands, porphyrins, and polythiophenes. The photo-reactive compounds (single or in combination) are added to the polymer solution at a level of 10-60% by weight. The resulting fibers from the electrospun form of the invention are 0.1-1 micron in diameter. These electrospun membranes show photoelectric conversion. The photo-reactive membranes show increased surface areas, flexibility, and porosity when compared to traditional solar cells.
This invention includes two classes of membrane articles comprising a non-woven mat of fibers having diameters of less than about one micron: electrically conductive articles having conductivities of at least about 10 −6 S/cm, and photoelectric conducting capabilities that produce voltages of at least about millivolts/cm 2 and currents of at least about microamps/cm 2 .
Electrospinning accomplishes smaller fibers (generally having diameters of about 20 nm to about 1 micron), that are more controlled in diameter as compared to melt spun fibers. Also, melt spinning operates at high temperatures that prevent the use of additives that would be destroyed or altered at such temperatures, while electrospinning operates at or around room temperature, thus accommodating a wider variety of additives, such as temperature sensitive and photo active biological dye compounds (e.g., bacteriorhodopsin).
The spun membranes comprise layers of non-woven fibers that directly incorporate the conductive polymer, the conductive nanoparticles, and/or the photoreactive compounds within the fibers themselves, so that the fibers have the conductive (electrical, ionic, and photoelectric) properties. The membranes thus formed are flexible, which allows them to be deposited on flexible substrates such as textiles, to accomplish an active textile material, or the membranes can stand alone.
The invention also provides for the incorporation of conductive nanoparticles such as particles of conductive or semiconductive materials, carbon nanotubes, or fullerenes and modified fullerenes. In the prior art, solar cell device processing using nanoparticles were sintered during manufacturing, requiring the use of high temperature materials only, and generally resulting in rigid devices. Conductivities of the membranes were measured thus:
Measurements were taken in the plane of the fibrous mat, with the charge carrier running parallel to the surface of the substrate. A van de Pauw measurement was made using four connections on the perimeter of the film; in this case it would be the corners of a rectangular section. It forces a current through two adjacent leads and measures the voltage across the other two.
The setup for photovoltaic current/voltage measurement is described as follows:
The current-voltage (I-V) characteristic of a solar cell was determined by a photovoltaic measurement system. An Oriel 1000-W Xenon lamp served as the standard light source, in combination with one ultraviolet long pass filter (cut-on wavelength 324 nm, Oriel 59458) and one heat-absorbing filter (Oriel 59060) to remove ultraviolet and infrared radiation. The Oriel Air Mass (AM) 0 filter (Oriel 81011) and AM 1.5 filter (Oriel 81075) were placed in the optical path to simulate AM 1.5 Direct solar irradiance. The light intensity was measured by an Oriel radiant power energy meter (70260) with a thermopile detector (70264). All experiments were performed at 1 sun of 100 mW/cm2 light intensity except special stated. A Keithley 2400 SourceMeter, which was controlled by a computer, was used to measure the I-V performance of the solar cell. The data was collected by a TestPointTM based program.
FIG. 1 illustrates the results of two experiments in accordance with the invention, wherein Polyaninile/SPS (PANI/SPS) 20% in a DMF solution was spun as described, with and without the addition of oxidized carbon nanotubes (oxCNT). The DC conductivity of the electrospun fiber mats was measured as described above, illustrating conductivities of at least about 10 −6 S/cm.
FIG. 2 shows the effect of PANI/SPS content (weight percent), and the addition of furnace carbon nanotubes (fCNT), on the AC conductivity of electrospun fibers of estane polyurethane in accordance with the invention.
FIG. 3 illustrates the photovoltaic response from dilithium phthalocyanine with titanium dioxide particles (diameters in the range of 20 to 150 nanometers) electrospun onto indium tin oxide, in accordance with the invention, illustrating the light intensity in the bottom curve and the photovoltaic response in the upper curve. The induced current density measured as described above was about 9 nanoamps per square centimeter.
Other embodiments will occur to those skilled in the art and are within the following claims. | 4y
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BACKGROUND OF THE INVENTION
Businesses spend billions of dollars on year on software and hardware-based technology systems. Technology systems range from simple software packages such as Microsoft Word to sophisticated hardware and software systems that automate strategic business and manufacturing processes. Whether the technology system is purchased from one or more outside vendors or is developed “in-house” the challenge that businesses face is getting the technology system implemented and deployed (within a reasonable timeframe and budget) such that the system is being utilized within the business and a return on investment is being recognized.
Unfortunately this challenge is not easily overcome by many businesses. As a result many technology systems that are purchased or developed are never implemented or are only partially implemented. Worse yet, most businesses grossly underestimate the implementation process which result in large schedule and budget overruns.
Traditionally businesses have looked to external consulting and professional service organizations to assist with and support the implementation of technology systems. However, in many cases the implementation services provided by external consultants and service organizations has proven to be very expensive and inconsistent in quality. This has caused many businesses to attempt the implementation of technology systems using “in-house” resources. Unfortunately this approach has also proven to be ineffective as internal resources generally do not have the experience or expertise to manage the implementation of technology systems. As a result, traditional implementation approaches are generally ineffective, costly and do not yield successful results.
Vendors of technology systems are also impacted by this problem as the long-term viability of a technology system vendor depends on the success of their customers and their ability to ensure that their technology systems are quickly and effectively implemented. The long-term viability of consulting and professional organizations also relies on the quality of the implementation services provided to their clients. Due to the shortage of qualified technical resources many consulting and professional services companies are having difficulty recruiting and retaining first class resources. This situation is forcing consulting and professional service organizations to hire less qualified and skilled resources while charging higher rates to their clients.
In order to alleviate these problems vendors and implementation service providers have developed “implementation methodologies and processes” for implementing various technology systems. The purpose of these methodologies and processes is to attempt to ensure that the implementation process for a particular technology system or class of systems is repeatable from business to business and consultant to consultant. Many vendors and implementation service providers have made these methodologies and processes available to their customers and clients for their own internal use. Several vendors such as Computer Associates with their Process Continuum product have developed software to augment and support the use of these methodologies. Libraries of “online methodologies” have been developed and are being sold by third party companies such as James Martin that work as an input to the Process Continuum software. The Process Continuum software and related libraries are marketed directly to businesses with the goal of enabling businesses to take advantage of proven methodologies and best practices.
Unfortunately, despite the number of methodologies and related products that are available on the market today, the technology system implementation and integration issues introduced previously are not being successfully addressed. This is because the methodologies that are available are developed to be “one size fits all” and, as a result, do not create an implementation plan and strategy which takes into consideration the specific technology system that is being implemented, the specific functionality of the system that will be implemented or the end user environment where the system will be implemented. They do not examine and take into consideration the specific cultural and “people” issues that impact technology system implementations. They do not enable users to draw upon encapsulations of implementation tools and historical “like kind” implementation data nor do they allow a user to encapsulate and share their own implementation data, tools and strategies with others. In today's business environment each technology system implementation is unique. As a result implementation plans, strategies and approaches must take into consideration the uniqueness of each individual implementation. The “one size fits all” methodology is limited in its usefulness in today's business environment.
The bottom line is that neither the use of consultants nor the use of existing packaged libraries of implementation methodologies is a sufficient solution to the challenges associated with implementing and integrating varied technology systems. What is needed is a universally accessible system which is designed to facilitate and manage the implementation and integration of technology systems as opposed to simply providing a methodology. This system should be able to support an unlimited number of technology system implementations over time and be able to address and handle each implementation as a unique entity. It should allow businesses that are implementing technology systems to encapsulate the knowledge and techniques garnered in a technology system implementation and then draw on those encapsulations for formulating implementation strategies for similar implementations. It should allow businesses to build an “implementation template” and strategy based upon their unique implementation and integration requirements. The system should facilitate access by and communication with outside consultants, technology vendors and other implementation experts in an efficient and cost-effective manner. This new system should take full advantage of computers, databases, and the Internet and related on-line networks to allow for entirely new features and quality of service that were previously unavailable.
SUMMARY OF THE INVENTION
To address the foregoing problems which exist in the prior art, the present invention provides a system in which the implementation and integration of technology systems is facilitated, managed and supported regardless of the type of technology system being implemented. An implementation plan and strategy is developed that will ensure the highest probability of success and will be time and cost effective. The creation of implementation deliverables such as project schedules and plans is streamlined. The invention allows users to access, communicate with and share implementation and integration strategies with each other. An “implementation template” is created based upon specific implementation requirements. A common framework, marketplace and community is provided where businesses, vendors, consultants and other experts can communicate and share implementation information data in a useful and workable manner. A mechanism is provided for pricing and billing of implementation templates and tools. The invention also provides expert analysis surrounding a specific technology system implementation using historical “like kind” implementation data and knowledge bases.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a first embodiment of the present invention.
FIG. 2 is a block diagram showing one embodiment of the Control Unit.
FIG. 3 illustrates an embodiment in which the computing resources of the Control Unit are distributed over a number of servers.
FIG. 4 is a block diagram showing an exemplary End-User interface.
FIG. 5 is a block diagram showing an exemplary Administrator interface.
FIG. 6 is a block diagram showing one embodiment of the Implementation Management System.
FIG. 7 illustrates an embodiment in which the computing resources of the Implementation Management System are distributed over a number of servers.
FIG. 8 is a block diagram showing one embodiment of the Implementation Data Capsule.
FIG. 9 illustrates an embodiment showing how a Control Unit Transaction is processed by the Control Unit.
FIG. 10 illustrates an embodiment showing how an IMS Transaction is processed by the Implementation Management System.
FIG. 11 illustrates an embodiment showing how a Control Unit Administration Transaction is processed by the Control Unit.
FIG. 12 illustrates an embodiment showing how an IMS Administration Transaction is processed by the Implementation Management System.
FIG. 13 illustrates an embodiment showing how a template Implementation Data Capsule is created by the administrator.
FIG. 14 illustrates an embodiment showing how a new implementation is created and registered by the Implementation Management System.
FIG. 15 illustrates an embodiment showing how implementation data is input and updated by the Implementation Management System.
FIG. 16 illustrates an embodiment showing the Implementation Planning process by the Implementation Management System.
FIG. 17 illustrates an embodiment showing how an Implementation Data Capsule is created by the Implementation Management System.
FIG. 18 illustrates an embodiment showing how an Implementation Data Capsule is transferred to the Control Unit.
FIG. 19 illustrates an embodiment showing how the Control Unit analyzes an Implementation Data Capsule.
FIG. 20 illustrates an embodiment showing the creation and updating of implementation deliverables.
FIG. 21 illustrates an exemplary embodiment a billing system related to the present invention.
FIG. 22 illustrates an exemplary embodiment for automatically calculating the price of an Implementation Data Capsule price.
DETAILED DESCRIPTION OF THE INVENTION
System Architecture
The system architecture of a first embodiment of the apparatus and method of the present invention is illustrated with reference to FIGS. 1 through 8. As shown in FIG. 1, the apparatus of the present invention comprises End User Interface 400 , Control Unit 200 , Implementation Management System 600 , and Administration Interface 500 (collectively the “nodes”). Each node interacts with another through a public and/or private network 110 , provided by a local or regional telephone company or alternatively provided by an internal organization within a business entity. Connection may also be provided by dedicated data lines, cellular, Personal Communication Systems (“PCS”), microwave, wireless or satellite networks. In a preferred embodiment, the nodes are connected via the Internet. End User Interface 400 and Administration Interface 500 are the input and output gateways for communication with the Control Unit 200 and the Implementation Management System 600 .
Implementation Data Capsule 800 is used to transfer implementation data between the Control Unit 200 and Implementation Management System 600 and end user interface 400 and administration interface 500 .
Using the above components, the present invention provides a method and apparatus for a commercial network system designed to facilitate, manage, and support the implementation and integration of technology systems.
Transactions fall into two categories: control unit transactions 120 and implementation management system transactions 130 . Each category of transaction occurs between the end user interface 400 or in the case of administrative transactions, the administration interface 500 , and the control unit 200 or the implementation management system 600 . Administrative transactions between the administration interface 500 and the control unit 200 or implementation management system 600 are managed by control unit administration transaction 150 and implementation management system administration transaction 140 respectively. Some transactions will utilize the implementation data capsule 800 to package together implementation data accessible to the control unit 200 and the implementation management system 600 . The implementation data capsule 800 can then be manipulated through various mechanisms by the end user. An example of this manipulation would be an end user identifying an implementation data capsule 800 located on the control unit 200 and wishing to transfer the implementation data capsule from the control unit to their end user interface 400 . This would be accomplished using a control unit transaction 120 initiated from end user interface 400 .
As shown in FIG. 2, one preferred embodiment of the control unit 200 includes central processor (CPU) 205 , RAM 210 , ROM 215 , clock 220 , Operating System 225 , network interface 230 , analysis processor 235 , implementation data capsule (IDC) processor 240 , billing processor 245 , pricing processor 250 , and data storage device 260 .
A conventional personal computer or computer workstation with sufficient memory and processing capability may be used as a control unit 200 . In the preferred embodiment it operates as a web server, both receiving and transmitting data inquires generated by end users. Control Unit 200 should generally be capable of high volume transaction processing, performing a significant number of mathematical calculations in processing communications and database searches. A Pentium processor such as the 400 MHz Pentium III, commonly manufactured by Intel Corp., may be used for CPU 205 . This processor employs a 32-bit architecture. Equivalent processors from such companies as Motorola Corp. and Sun Microsystems Inc. can be substituted.
Referring again to FIG. 2, analysis processor 235 , IDC processor 240 , billing processor 245 , and pricing processor 250 comprise software subsystems that provide specialized functions for control unit 200 . These subsystems are invoked appropriately as determined by the transactions requested from control unit 200 .
Analysis processor 235 provides the capability to search for and analyze information in data storage device 260 and return the information to the end user. End user requests involving queries can also be handled. Such requests are useful in determining if trends and patterns exist in the information stored in data storage device 260 . The results of these requests are then reported to the end user or administrator. Functions executed by analysis processor 235 may be supported by commercially available software, such as the Dimension Series Suite from Neo Vista Software, Inc. The Dimension Series Suite consists of data mining engines that organize the relationships between the information stored in data storage device 260 . An end user request, such as “Tell me all implementations that utilize Visual Basic in Microsoft Windows NT Environments”, would be interpreted and passed to the data mining engines which would in turn search the databases for relevant information. The results of the operation would be returned to the end user. Subsequent requests are re-submitted if the results returned did not match the users needs.
Implementation data processor 240 provides the capability to create implementation data capsules 800 and extract objects contained within the capsules. Implementation data processor 240 interacts with data storage device 260 and the databases contained within it. For example, an end user locates the implementation data they want to include in an implementation data capsule after utilizing analysis processor 235 . The end user requests implementation data processor 240 to create an implementation data capsule including the selected objects. Implementation data processor 240 extracts the objects from implementation objects database 275 and meta-information from the implementation database 280 and creates an implementation data capsule 800 . Implementation data capsule 800 is then compressed to save space and aid in efficient transporting between nodes.
Implementation data processor 240 also performs the reverse operation as described above. In this case, the objects contained in implementation data capsule 800 are examined by uncompressing and opening implementation data capsule. Implementation data processor 240 extracts the objects from implementation data capsule 800 whereby they are either updated or added to implementation objects database 275 and implementation database 280 .
When an end user requests to create implementation data capsule 800 , implementation management system 600 uses the results from the analysis processor 235 to extract the correct implementation objects from implementation objects database 275 and implementation database 280 . The implementation management system 600 collects the objects associated with the implementation key and the end user criteria and adds them to implementation data capsule 800 . Based on the objects selected, control files 825 are created and added to implementation data capsule 800 . Control files 825 contain information which indexes the contents of implementation data capsule 800 and is used when control unit 200 and implementation management system 600 open implementation data capsule 800 . If they exist and the user selects to include them in implementation data capsule 800 , implementation deliverables associated with the implementation objects, are stored in implementation deliverables storage 830 . The compression algorithm employed to reduce the size of implementation data capsule 800 may be supported by commercially available software such as Dynazip-AX manufactured by Inner Media, Inc.
The transfer and exchange of payments, charges, or debits, attendant to the method of the apparatus are supported by the billing processor 245 . Processing of credit card transactions by this processor may be supported with commercially available software such as Open Market Transact manufactured by Open Market, Inc. The billing processor 245 provides commerce functions that may include online account statements, order-taking and credit card payment authorization, credit card settlement, automated sales tax calculations, digital receipt generation, account-based purchase tracking, and payment aggregation for low priced services.
Pricing processor 250 calculates the price for an implementation data capsule 800 . This price maybe determined by a number of factors which may include the implementation objects, stored in implementation objects database 275 , the end user wishes to include in the IDC. The end user does not have to accept the price for the IDC and can remove some of the implementation objects included in the IDC. Pricing processor 250 will then re-calculate the price for the IDC based on the new configuration of the IDC. In another embodiment pricing may be determined or influenced based upon a “fixed price” or a “subscription” arrangement with the end user.
Data storage device 260 may include hard disk magnetic or optical storage units, as well as CD-ROM drives or flash memory. Data storage device 260 contains databases used in the processing of transactions in the present invention, including admin database 265 , end user database 270 , implementation objects database 275 , implementation database 280 , billing database 285 , audit database 290 , and IDC storage 295 . In a preferred embodiment database software such as SQL Server, manufactured by Microsoft Corporation, is used to create and manage these databases.
Admin database 265 maintains information on the administrators which may include name, company, address, phone number, ID number, passwords, active role in the projects, email addresses, voice mail addresses, and security access levels. Security access levels comprise the amount of control the administrator has over examining and updating information contained in the databases on the data storage device 260 .
End user database 270 maintains data on end userswhich may include name, company, address, phone number, ID number, passwords, email address, active role in the projects, billing preferences, past system usage, etc. End users can determine the amount of information they want to share with other users. End users are able to contact other users based on the information provided.
Implementation objects database 275 maintains an inventory of implementation objects. End users collect implementation data with respect to the technology systems they are implementing. The implementation data is input into the database and organized into logical groupings based on the method of the apparatus. Some examples of the implementation objects are names of stakeholders and implementation team members, characteristics describing technology system being implemented, organizational areas where the technology system is to be used, and various sub-projects associated with the implementation.
Implementation database 280 maintains an index of all implementations represented in control unit 200 . This database is indexed by the implementation key which is unique across all implementations.
Billing database 285 tracks commercial transactions, as well as billing preferences. This database is valuable in the event of complaints by end users regarding billing and payment discrepancies.
Audit database 290 records transactional information about all requests initiated between each node which can be retrieved for later analysis. This database may also log transaction traffic rates, login/logout attempts, and success/failure status of transactions.
Implementation data capsule (IDC) storage 295 acts as a storage area for implementation data capsules 800 . In one embodiment IDC storage 295 represents a hierarchical file system on control unit 200 .
Network interface 230 is the gateway to communicate with end users and administrators through respective end user interface 400 and administration interface 500 . Conventional internal or external modems or wireless network connection devices may serve as network interface 230 . Network interface 230 supports a various range of baud rates from 1200 upward, but may also be combined into such inputs as a T 1 or T 3 line if more bandwidth is required. In a preferred embodiment, network interface 230 is connected with the Internet to allow for the largest audience of end users to have access to the control unit 200 . Along similar lines, network interface 230 may also be connected to a private Intranet or other network to allow end users within a particular organization to access the control unit 200 .
While the above embodiment describes a single computer acting as the control unit, those skilled in the art will realize that the functionality can be distributed over a plurality of computers. In another embodiment, control unit 200 may be configured in a distributed architecture, as shown in FIG. 3, wherein the databases and processors are housed in separate units or locations. Control unit(s) 200 perform the primary processing functions and contain at a minimum RAM, ROM, and a general processor. Each of these control units is attached to WAN hub 300 which acts as the primary communications link with the other processors. WAN hub 300 itself may contain minimal processing capability with its primary function of acting as a passive device facilitating communications and routing. Although only three control units are shown in this embodiment, those skilled in the art will appreciate that an almost unlimited number of control units may be supported. In such a configuration, each control unit is in communication with its processors as well as other control units. Analysis processor 235 , IDC processor 240 , billing processor 245 , and pricing processor 250 all communicate through WAN hub 300 with control units 200 . Data storage device 260 is available to each control unit and processor through WAN hub 300 . This arrangement makes for a highly flexible and dynamic system, less prone to catastrophic hardware failures and bottlenecks. Those skilled in the art will also realize that the processors may also be combined and/or distributed over a plurality of computers. In addition those skilled in the art will recognize that the database entities contained in the data storage device 260 may also be distributed and/or implemented as entities of one database or multiple databases.
FIGS. 4 and 5 describe end user interface 400 and administrator interface 500 respectively. In an exemplary embodiment they are both conventional personal computers having an input device, such as a keyboard and mouse, or conventional voice recognition software package; a display device, such as a video monitor; a processing device such as a CPU; and a network interface such as a modem or high speed network connection.
Referring now to FIG. 4, there is described a preferred embodiment of an end user interface 400 which includes central processor (CPU) 405 , RAM 410 , ROM 415 , clock 420 , video driver 425 , video monitor 430 , input device 435 , network interface 440 , and data storage device 450 .
A Pentium processor such as the 400 MHz Pentium III described above may be used for the CPU 405 . Clock 420 is a standard chip-based clock which can serve to timestamp control unit transactions 120 and implementation management system transactions 130 . Network interface 440 is the gateway between end user interface 400 and a network such as the Internet. In a preferred embodiment, users interact with control unit 200 using end user interface 400 and administrator interface 500 through a Web Browser such as Internet Explorer manufactured by Microsoft Corporation or Netscape Communicator manufactured by Netscape Corporation.
Data storage device 450 is a conventional magnetic based hard disk storage unit. Information storage 460 may be used to store implementation data capsules 800 and other information while audit database 470 may be used for recording communications with the control unit 200 and implementation management system 600 as well as payment records. In one embodiment information storage 460 represents a hierarchical file system on end user interface 400 .
Referring now to FIG. 5, there is described a preferred embodiment of the administrator interface 500 which includes central processor (CPU) 505 , RAM 510 , ROM 515 , clock 520 , video driver 525 , video monitor 530 , input device 535 , network interface 540 , and data storage device 550 . Clock 520 is a standard chip-based clock which can serve to timestamp control unit administration transactions 150 and implementation management system administration transactions 140 .All of these components including data storage device 550 , information storage 560 , and audit database 570 may be identical to those described in FIG. 4 .
End user interface 400 and administrator interface 500 interact with implementation management system 600 using custom built applications programs appropriate to the respective operating system of the interface. Those skilled in the art will appreciate that any number of commercially available programming environments, plug-ins, executables, DLL's, applets or objects can be employed to design and build the applications programs. In addition those skilled in the art will appreciate that the end user interface 400 and the administrator interface 500 can utilize any number of commercially available operating systems such as Unix, Linux, Windows and Windows NT, Macintosh, Windows CE or Palm OS.
Referring to FIG. 6, the implementation management system 600 is described as comprising a central processor (CPU) 605 , RAM 610 , ROM 615 , clock 620 , Operating System 625 , network interface 630 , analysis processor 235 , implementation data capsule (IDC) processor 240 , implementation deliverable processor 640 , implementation planning processor 645 , and data storage device 660 .
A conventional personal computer, computer workstation or hand held, wireless personal digital assistant (PDA) with sufficient memory and processing capability may be used as implementation management system 600 . End users and administrators use their respective applications program to access implementation management system 600 . The implementation management system serves a different purpose than control unit 200 in the apparatus and method of the invention. It is a system used to collect and manage implementation data. It has the capability to share that implementation data with control unit 200 . Control unit 200 also has the capability to share information with implementation management system 600 . Those skilled in the art will appreciate that the implementation management system 600 may employ either the same or separate physical hardware as control unit 200 and that software components of the implementation management system 600 may either share code with or be entirely separate from the software components of control unit 200 . In addition those skilled in the art will appreciate that the databases and processors associated utilized by the implementation management system 600 and the control unit 200 may overlap or be consolidated in another embodiment of the invention.
Referring again to FIG. 6, analysis processor 235 , IDC processor 240 , implementation deliverable processor 640 , and implementation planning processor 645 comprise software subsystems that provide specialized functions for implementation management system 600 . These subsystems are invoked appropriately as determined by the transactions requested from implementation management system 600 .
Analysis processor 235 performs in the same way and includes the same capabilities as described above for control unit 200 .
Implementation management system 600 utilizes IDC processor 240 in the same manner as control unit 200 .
Implementation deliverable processor 640 is used to create various documents and output files based on the information stored in data storage device 660 . This processor may be supported by commercially available software such as Office 2000 and Microsoft Project 98 manufactured by Microsoft Corporation. In one embodiment, implementation management system 600 utilizes the instantiated objects in Office 2000 and Microsoft Project 98 to create Microsoft Word documents and Microsoft Project schedules. The data used to generate these documents is taken from implementation objects database 675 and implementation database 680 .
Implementation planning processor 645 creates an implementation plan using a proprietary and unique implementation planning method and process. The method and process first divides the implementation project into incremental sub-projects based upon the features and functions of the technology system that will be implemented and the locations and environments where the technology system will be implemented. The method and process then generates ratings for sub-projects depending upon numerical or other measures of the technical complexities, risk, priority, visibility, cultural complexities and resource complexities of each sub-project. Ratings may be provided by the end user or may be calculated automatically by the implementation planning processor 645 . Those skilled in the art will recognize that a large number of techniques may be used to automatically generate ratings, such as generating ratings using a weighted average of all characteristics of a sub-project or generating ratings using a weighting of some subset of all characteristics of a sub-project. Based upon the ratings associated with each sub-project the implementation planning processor creates an implementation plan that provides a preferred ordering and strategy for completing the sub-projects. As new relevant data is provided to the implementation management system 600 (such as additional features and functions of the technology system, environmental data or updates to ratings) the implementation processor automatically re-creates a revised implementation plan.
Data storage device 660 may include hard disk magnetic or optical storage units, as well as CD-ROM drives or flash memory. Data storage device 660 contains databases used in the processing of transactions in the present invention, including admin database 665 , end user database 670 , implementation objects database 675 , implementation database 680 , implementation deliverable storage 685 , audit database 690 , and IDC storage 695 . In a preferred embodiment database software such as Microsoft Access or SQL Server, both manufactured by Microsoft Corporation, is used to create and manage these databases.
Admin database 665 maintains information on the administrators which may include name, company, address, phone number, ID number, passwords, active role in the projects, email addresses, voice mail addresses, and security access levels. Security access levels comprise the amount of control the administrator has over examining and updating information contained in the databases on the data storage device 660 .
End user database 670 maintains data on end users, which may include name, company, address, phone number, ID number, passwords, email address, active role in the projects, billing preferences, past system usage, etc.
Implementation objects database 675 maintains an inventory of implementation objects. End users collect implementation data with respect to the technology systems they are implementing. The implementation data input into the database are organized into logical groupings based on the method of the apparatus. Some examples of the implementation objects are names of stakeholders and implementation team members, characteristics describing the technology system being implemented, organizational areas where the technology system is to be used, and various sub-projects associated with the implementation.
Implementation database 680 maintains an index of all implementations represented in implementation management system 600 . This database is indexed by the implementation key which is unique across all implementations.
Implementation delivery storage 685 stores output generated by the implementation deliverable processor 640 . In one embodiment implementation delivery storage represents a hierarchical file system on implementation management system 600 .
Audit database 690 stores transactional information about past communications which can be retrieved for later analysis. This database may also logs transaction traffic rates, login/logout attempts, and success/failure status of transactions.
Implementation data capsule (IDC) storage 695 acts as a storage area for implementation data capsules 800 . In one embodiment IDC storage 695 represents a hierarchical file system on implementation management system 600 .
Network interface 230 is utilized in the same way as described above with reference to FIG. 2 .
While the above embodiment describes a single computer acting as the implementation management system, those skilled in the art will realize that the functionality can be distributed over a plurality of computers. In another embodiment, implementation management system 600 may be configured in a distributed architecture, as shown in FIG. 7, wherein the databases and processors are housed in separate units or locations. Implementation management systems 600 perform the primary processing functions and contain at a minimum RAM, ROM, and a general processor. Each of these implementation management systems is attached to WAN hub 700 which acts as the primary communications link with the other processors. WAN hub 700 itself may contain minimal processing capability with its primary function of acting as a passive device facilitating communications and routing. Although only three implementation management systems are shown in this embodiment, those skilled in the art will appreciate that an almost unlimited number of implementation management systems may be supported. In such a configuration, each implementation management system is in communication with its processors as well as other implementation management systems. Analysis processor 235 , IDC processor 240 , implementation deliverable processor 640 , and implementation planning processor 645 all communicate through WAN hub 700 with implementation management systems 600 . Data storage device 660 is available to each implementation management system and processor through WAN hub 700 . This arrangement makes for a highly flexible and dynamic system, less prone to catastrophic hardware failures and bottlenecks. . Those skilled in the art will also realize that the processors may also be combined and/or distributed over a plurality of computers. In addition those skilled in the art will recognize that the database entities contained in the data storage device 660 may also be distributed and/or implemented as entities of one database or multiple databases.
Referring to FIG. 8, there is described a preferred embodiment of implementation data capsule 800 , which includes digital package 810 , implementation objects database 815 , implementation database 820 , control files 825 , and implementation deliverables storage 830 . Implementation objects database 815 , implementation database 820 , and implementation deliverables storage 830 represent a subset of all implementation objects and implementation data available in control unit 200 and implementation management system 600 . Control files 825 act as an index and inventory of the implementation objects and data contained in digital package 810 . IDC processor 240 utilizes control files 825 to update implementation objects database 275 and 675 and implementation database 280 and 680 and implementation deliverables storage 695 .
Digital package 810 acts as a container for the implementation objects and databases. Those skilled in the art will realize that digital package 810 can be gathered together with other digital packages and each reside in a single implementation data capsule 800 . In this embodiment, implementation data capsule 800 is used to transport multiple digital packages using a single control unit transaction 120 or implementation management system transaction 130 .
Two exemplary embodiments describe the versatility in using implementation data capsule 800 . In one embodiment, an end user wishes to take a “snapshot” of a technology system implementation which includes all implementation data, tools and strategies that have been entered to date. The end user then wishes to transfer the snapshot to their technology system vendor for review and expert advice. This is accomplished by requesting IDC processor 240 to create an implementation data capsule 800 and transfer it to control unit 200 . The vendor then submits a control unit transaction 120 to access and transfer the end users implementation data capsule for review.
In another embodiment, an end user is beginning the process of implementing a technology system. The end user has identified a set of implementation objects that can be used as a template and staring point for their implementation. The end user creates an implementation data capsule 800 which contains the implementation objects and transfers the implementation data capsule from control unit 200 to implementation management system 600 The end user utilizes IDC processor 240 in implementation management system 600 to create their working implementation environment using implementation data capsule 800 as a template.
Transaction Overview
The End User initiates a series of IMS transactions 150 to the Implementation Management System 600 and Control Unit transactions 120 to the Control Unit 200 . IMS transactions 150 will initiate transactions such as creating a new implementation, managing the implementation workflow, managing the implementation planning process and creating an Implementation Data Capsule 800 . Control Unit transactions 120 will initiate transactions such as searching for and locating an IDC 800 to be used as an implementation template, creating a custom IDC, providing implementation analysis and handling commerce items.
With reference to FIG. 9, there is described a process by which the end user initiates and completes a control unit transaction 120 . The end user creates a transaction request at step 900 . A transaction request may contain a specific request and any necessary parameters and criteria. For example an end user may initiate a control unit request to create a new IDC which contains specific implementation objects. Multiple requests may be bundled into a single transaction. The transaction is submitted to the control unit 200 at step 910 . At step 920 the control unit 200 then evaluates the request to determine the transaction type based upon the request, the parameters and criteria. An unlimited number of transaction types may be processed by the control unit and multiple transactions can be initiated and processed together. Common transaction types include analysis, IDC transfer, IDC creation, billing and payment. At step 930 the request is processed accordingly by the control unit 200 depending on the type of transaction requested. At step 940 the results of the control unit transaction 120 are returned to the end user completing the transaction.
With reference to FIG. 10, there is described a process by which the end user initiates and completes an IMS transaction 150 . The end user creates a transaction request at step 1000 . A transaction request may contain a specific request and any necessary parameters and criteria. For example an end user may initiate an IMS request to create a new implementation deliverable such as a project plan or schedule. Multiple requests may be bundled into a single transaction. The transaction is submitted to the IMS 600 at step 1010 . At step 1020 the IMS 600 then evaluates the request to determine the transaction type based upon the request, the parameters and criteria. An unlimited number of transaction types may be processed by the IMS and multiple transactions can be initiated and processed together. Common transaction types include implementation data input, implementation planning, deliverable creation, IDC creation, implementation setup and implementation data management. At step 1030 the request is processed accordingly by the IMS 600 depending on the type of transaction requested. At step 1040 the results of the IMS transaction 150 are returned to the end user completing the transaction.
The administrator initiates a series of IMS administration transactions 140 to the Implementation Management System 600 and Control Unit administration transactions 150 to the Control Unit 200 . IMS administration transactions 140 will initiate transactions such as creating a new implementation, managing the implementation workflow, managing the implementation planning process and creating an Implementation Data Capsule 800 . Control Unit administration transactions 150 will initiate transactions such as searching for and locating an IDC 800 to be used as an implementation template, creating a custom IDC, providing implementation analysis and handling commerce items.
With reference to FIG. 11, there a described the process by which the administrator initiates and completes a control unit administration transaction 150 . The administrator creates an administration transaction request at step 1100 . A transaction request may contain a specific request and any necessary parameters and criteria. For example an administrator may initiate a control unit administration request to release an IDC to the end user community. Multiple requests may be bundled into a single transaction. The transaction is submitted to the Control Unit 200 at step 1110 . At step 1120 the Control Unit 200 then evaluates the request to determine the transaction type based upon the request, the parameters and criteria. An unlimited number of transaction types may be processed by the Control Unit and multiple transactions can be initiated and processed together. Common transaction types include reviewing and releasing an IDC to an end user and general maintenance of the control unit environment. At step 1130 the request is processed accordingly by the control unit 200 depending on the type of transaction requested. At step 1140 the results of the control unit administration transaction 150 are returned to the administrator completing the transaction.
With reference to FIG. 12, there is described a process by which the administrator initiates and completes an IMS administration transaction 140 . The administrator creates a transaction request at step 1200 . A transaction request may contain a specific request and any necessary parameters and criteria. For example an administrator may initiate an IMS administration request add a new authorized user to the IMS. Multiple requests may be bundled into a single transaction. The transaction is submitted to the IMS 600 at step 1210 . At step 1220 the IMS 600 then evaluates the request to determine the transaction type based upon the request, the parameters and criteria. An unlimited number of transaction types may be processed by the IMS and multiple transactions can be initiated and processed together. Common transaction types would include setup of the IMS environment and maintenance of the IMS environment. At step 1230 the request is processed accordingly by the IMS 600 depending on the type of transaction requested. At step 1240 the results of the IMS transaction 140 are returned to the administrator completing the transaction.
Implementation Management Embodiment
In one embodiment the present invention is used by the end user to facilitate, manage and support the implementation of a technology system through a series of transactions with the IMS 600 and control unit 200 .
1. The end user creates one or more Implementation Data Capsules which will act as “implementation templates” through a combination of IMS transactions 130 and control unit transactions 120 (FIG. 13 ).
2. The end user then initiates an IMS transaction 130 for starting a new implementation (based upon the appropriate implementation template) and registers the implementation with the control unit 200 . (FIG. 14)
3. The end user then initiates a series of IMS transactions 130 for inputting implementation data into the IMS 600 . (FIG. 15)
4. The end user then initiates a series of IMS transactions 130 to the implementation planning facility with the goal of creating an implementation plan and strategy. (FIG. 16)
5. The end user then initiates an IMS transaction 130 to create an IDC 800 that contains implementation data and planning information. (FIG. 17)
6. The end user then initiates control unit transactions 120 that transfer the IDC 800 to the control unit 200 . (FIG. 18)
7. The end user then initiates control unit transactions 120 that will analyze the IDC 800 for issues or problems that will impact the end user's implementation. (FIG. 19)
8. The end user then initiates a series of IMS transactions 130 for creating implementation deliverables such as implementation schedules, reports and project plans. (FIG. 20)
9. The end user then continues with the implementation process and continues to initiate IMS transactions 130 to update and manage the data and information associated with the implementation. (FIG. 15)
10. When the implementation process is complete the end user initiates an IMS transaction 130 to create an updated IDC 800 . (FIG. 17)
11. The end user then initiates a control unit transaction 120 to transfer the IDC 800 to the control unit 200 . (FIG. 18)
12. The administrator then initiates a combination of IMS administration transactions 140 and control unit administration transactions 150 to release and make available the IDC and the contents of the IDC to other end users. (FIG. 13)
FIG. 13 describes the process of creating an IDC that can be used as an “implementation template” by the IMS. At step 1300 the administrator initiates a request to create a new IDC. At step 1305 the administrator enters specific criteria which will be used to locate implementation objects that will be used as the basis for the new IDC. For example the administrator may specify criteria surrounding the implementation of Microsoft Excel in the Apple Macintosh environment. At step 1310 the IDC processor returns a list of implementation objects matching the criteria based upon data within the implementation objects database The administrator selects specific objects from this list at step 1320 to be included in the new IDC and the IDC processor builds the new IDC at step 1325 and adds to the IDC to the IDC storage area within the Control Unit. In another embodiment the process of selecting specific implementation objects is bypassed and the IDC processor automatically builds the IDC based upon the criteria provided at step 1305 without specific criteria selected. Optionally various commercially available compression and encryption algorithms 1330 may be employed during the building of the IDC. At step 1335 the new IDC is reviewed and tuned by the administrator using the IMS. At step 1340 the administrator releases the new IDC so that it can be accessed and utilized by end users.
FIG. 14 describes the process of an end user creating a new implementation within the IMS based upon an “implementation template” IDC and registering the implementation with the control unit. At step 1400 the end user initiates a request to create a new implementation. An implementation refers to the project of implementing a particular technology in a specific area within the end user's organization. At step 1405 the end user provides selection criteria to the IDC to locate a list of IDC's that could be used as a template for the new implementation. At step 1410 a list of IDC which match the criteria specified is provided and at step 1415 the end user selects the IDC which will be used as template for the new implementation. At step 1420 the IDC processor analyzes the IDC selected and computes any fees or charges that will need to be paid to utilize the IDC as a template. If a fee is required the control unit handles and processes the payment at step 1425 . At step 1430 the IDC is transferred to the IMS and a new implementation is created within the IMS at step 1435 . In another embodiment the end user creates a new implementation without utilizing an IDC as a template. At step 1440 the end user registers the new implementation with the control unit completing the process.
FIG. 15 describes the process of an end user inputting and updating implementation information into the IMS. At step 1500 a data input request is initiated by the end user. At step 1505 the end user selects which implementation object type the implementation information will be associated with. For example the end user may be entering information about “stakeholders” in the IMS. In this case the end user would select the Stakeholder implementation object type. At step 1510 the end user determines whether a new implementation object will be added or an existing implementation object will be updated. At step 1515 an existing implementation object is updated while at step 1520 a new implementation object is added. At step 1525 all implementation information added or updated is recorded in the IMS.
FIG. 16 describes the process of an end user using the IMS implementation planning facility to create an implementation plan and strategy. At step 1600 an implementation planning request is initiated by the end user. At step 1605 the end user enters or updates planning information and criteria. At step 1610 the IMS implementation planning processor analyzes the criteria and implementation data from the IMS. At step 1615 an implementation plan and framework is automatically created by the implementation planning processor.
FIG. 17 describes the process of completing a transaction related to the creation of an IDC. At step 1700 an IDC creation request is initiated by the end user. At step 1705 the process of creating an IDC commences by creating a control file. The control file contains information about the implementation and the IDC that will be utilized by the Control Unit. For example the control file could contain an index and keywords of all the items in the IDC. At step 1710 the IDC processor determines the inventory of all objects and information that will be included in the IDC. In one embodiment the end user may include all implementation objects and information in the IDC while in another embodiment the user may select which implementation objects will be included through selection parameters 1715 . In step 1720 the IDC digital archive 810 is created which includes all selected implementation information and objects. In one embodiment the IDC can optionally be encrypted and compressed 1725 using commercially available compression and encryption utilities. At step 1730 the IDC is saved to the IMS storage device 697 . Once this transaction is complete the IDC can be transferred to the control unit or other end users.
FIG. 18 describes the process of completing a transaction related to the transfer of an IDC to the control unit. At step 1800 an IDC transfer is initiated by the end user. At step 1805 the transfer request is created which includes the specific IDC to be transferred and information related to the transfer such as end users name and contact information. At step 1810 the IDC transfer request is transferred to the control unit. At step 1815 the control unit verifies that the implementation associated with the IDC is registered with the control unit. The control unit at step 1820 then processes the IDC transfer request with implementation information added and updated to the implementation and end user databases. At step 1825 the implementation object database is updated. At step 1830 the IDC is moved to the IDC storage area in the control unit. At step 1835 the transaction is recorded in the audit database and the end user is notified that the transaction was successful 1840 .
FIG. 19 describes the process of the control unit analyzing an IDC for issues or problems related to the implementation. For example an end user may want to know if the implementation plan and strategy that has been created is realistic based upon other similar implementations. In another embodiment the end user may want the implementation to be audited to ensure that the implementation data entered is accurate. At step 1900 a request to analyze an IDC is made to the control unit. At step 1905 the end user selects the IDC(s) that will be analyzed and in step 1910 specified the type of analysis that will be done. Based upon the type of analysis selected specific analysis criteria may be provided by the end user. At step 1915 the analysis is done using the analysis processor within the control unit. At step 1920 the results of the analysis are returned to the end user by the control unit.
FIG. 20 describes the process of completing a transaction relating to the creation of implementation deliverables from the IMS. At step 2000 a request to create implementation deliverables such as a project schedule, plan or report is initiated by the end user. At step 2005 the end user optionally selects which implementation objects are to be included in the deliverable. For example the end user may decide only to include information about the implementation team in a report. At step 2010 the end user selects the deliverables to be created. Based upon this selection the implementation deliverables processor generates the requested deliverables in step 2015 .
Implementation Data Exchange Embodiment
In one embodiment the present invention is used by the end user to facilitate the exchange of implementation data with another end user through a series of transactions with the IMS 600 and control unit 200 . The purpose of this exchange is to enable other end users (such as a vendor, consultant or industry expert) to review and possibly update the end user's implementation data. When the review is complete the implementation data will be returned the end user.
1. The end user initiates an IMS transaction 150 to create an IDC 800 that contains implementation data (FIG. 17 ).
2. The end user then initiates control unit transactions 120 that transfers the IDC 800 to the control unit 200 . Included in the transaction request is the identification(s) of the other end user(s) where the IDC should be routed. (FIG. 18)
3. The control unit 200 then routes the IDC 800 to the IMS 600 and notifies the appropriate end users.
4. The receiving end user initiates a series of IMS transactions 150 to review (and possibly update) the implementation data.
5. When the review is complete the receiving end user initiates an IMS transaction 150 to create an IDC 800 that contains implementation data (FIG. 17 ).
6. The receiving end user initiates control unit transactions 120 that transfers the IDC 800 to the control unit 200 . (FIG. 18)
7. The control unit 200 then routes the IDC 800 to the IMS 600 and notifies the sending end user that the transaction is complete.
Billing Embodiment
FIG. 21 describes an exemplary billing system of the present invention. End users may be billed and make payments for executing various control unit transactions 120 and IMS transactions 130 such as implementation analysis and review. In addition end users may be billed and make payments for the license and use of various IDC's 800 that are used as templates with the IMS 600 . End user invoicing and payments are described using conventional credit card electronic charges, checks, Electronic Funds Transfer (“EFT”), or digital cash. These payment methods are meant to be merely illustrative, as there are many equivalent payment methods commonly known in the art which may be used.
The billing process is initiated at step 2100 when the end user initiates a control unit transaction 120 or IMS transaction 170 which is deemed to be billable. Once the billing process is started the price and tracking number of the control unit transaction 120 or the IMS transaction 170 is processed and sent to the billing database 290 at step 2105 . At step 2110 there are a number of billing protocols that can be used. For example, one protocal, cash on delivery (“COD”), requires that the end user pay before completing a control unit transaction 120 or an IMS transaction 170 . Another protocol is a credit system in which the end user pays at the end of the billing period.
At step 2115 the end users preferred billing method is retrieved from the control unit 120 . In the COD protocol the billing processor 245 generates a bill prior to completing the control unit transaction 120 or the IMS transaction 170 . In a credit protocol the billing processor 245 searches the billing database 290 at the end of each billing period and totals the amount owed by each end user. At step 2120 the appropriate billing module (credit card, EFT, check, electronic cash) is initiated.
Implementation Data Capsule Pricing Embodiment
FIG. 22 describes an exemplary IDC pricing system of the present invention. End users may be billed and make payments for the license and use of various IDC's 800 . The price of an IDC may be determined based upon the objects that are included in the IDC from the implementation object database 275 and the IDC's stored in IDC storage 297 . The pricing method described is meant to be merely illustrative, as there are other many pricing methods which may be employed.
The IDC pricing process is initiated at step 2200 when the end user initiates a request to create an IDC. At step 2205 the end user enters criteria in order to identify potential implementation objects to be included in the IDC. At step 2210 the IDC processor 240 identifies a list of implementation objects which match the criteria provided in step 2205 . At step 2215 the end user selects implementation objects to be included in the new IDC 800 . As the user selects specific implementation objects the pricing processor 250 automatically calculates the price of the implementation object using data from the implementation object database 275 (see step 2220 ). A total price of all implementation objects selected is maintained throughout the selection process. The pricing processor 250 automatically calculates discounts and other pricing incentives as objects from the implementation object database 275 are selected.
At step 2225 the IDC processor builds the IDC based upon the implementation objects selected. At step 2230 the billing database is updated with the price of the IDC 800 and the billing process (as described in FIG. 21) is initiated at step 2235 .
Implementation Marketplace and Community Embodiment
Another embodiment of the present invention revolves around the creation of an implementation marketplace and community. In one embodiment an end user develops an IDC 800 that could contain valuable implementation data, tools and strategies for a specific type of technology system implementation. The end user can transfer the IDC 800 to the control unit 200 and request that the IDC 800 may be made available to be sold or licensed to other end users. A number of pricing strategies could be selected by the end user such as a fixed price or a bid approach. Other end users could then access, review and purchase the IDC by initiating a series of control unit transactions 120 with the control unit 200 .
In another embodiment end users could procure the services of an implementation expert or consultant of a specific type of technology system implementation using the present invention. Through a control unit transaction 120 end users can contact and establish a dialog with one or more experts for a specific technology system. Implementation Data Capsules 800 can be exchanged between the end user and the expert as described in the Implementation Data Exchange Embodiment.
In another embodiment an end user can establish dialogs with other end users that are involved in similar technology system implementations. Implementation Data Capsules 800 can be exchanged between the end users as described in the Implementation Data Exchange Embodiment. | 4y
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1. RELATED CASES
[0001] This is a continuation of co-pending application Ser. No. 10/609,076, filed Jun. 27, 2003, which is in turn a continuation-in-part of co-pending Ser. No. 10/131,430, filed Apr. 24, 2002, entitled “Trash Can Assembly”, the entire disclosures of which are incorporated by this reference as though set forth fully herein.
BACKGROUND OF THE INVENTION
[0002] 2. Field of the Invention
[0003] The present invention relates to household items, and in particular, to a trash can assembly that incorporates a number of improvements and enhancements.
[0004] 3. Description of the Prior Art
[0005] A major concern for both the home and the workplace is containing and holding wastes, refuse, and trash until permanent disposal. Trash cans act as containers for holding trash and other wastes that are produced in any typical home or office. Trash and garbage cans often employ lids and covers to contain the trash and its associated odor, to hide the trash from view, and to prevent the trash from contaminating areas beyond the lid.
[0006] Conventional trash cans have been improved over the years to make them more user-friendly, sanitary, and hygienic. For example, many trash cans are now provided with a foot pedal positioned adjacent the base of the trash can so that a user can step on the foot pedal to open the lid of the trash can, thereby freeing up the user's hands to deposit trash, or to change the plastic liner or bag that is used to line the trash can. Other trash cans have even provided an interior metal or plastic liner that fits inside the trash can, and which can be removed to be washed. However, these conventional trash cans still suffer from a number of drawbacks.
[0007] For example, the foot pedals on some of the conventional trash cans are noisy to use. In particular, stepping on a foot pedal of a conventional trash can often results in a loud banging noise as the lid is opened, and releasing the step on the foot pedal will also result in another loud banging noise as the lid slams shut under the force of gravity. These banging actions also result in wear and tear to the contacting parts.
[0008] Other problems are associated with the internal liner. In conventional trash cans that use an internal liner, the user typically needs to remove the internal liner from the trash can to dispose of the contents therein. To do so, the user typically lifts the internal liner from the trash can, and this may result in the user gripping portions of the surfaces of the internal liner (or a trash bag that lines the internal liner), so that the user's fingers may come into contact with dirt, germs or trash items. In many of the conventional trash cans, there are no good ways to grip and hold the internal liner without the user's fingers actually contacting the surface of the trash bag that lines the internal liner, or the surface of the internal liner itself.
[0009] Thus, there remains a need for a trash can that overcomes the drawbacks identified above.
SUMMARY OF THE DISCLOSURE
[0010] It is an object of the present invention to provide a trash can assembly that reduces noise and wear when the step pedal is actuated to open and close the lid.
[0011] It is another object of the present invention to provide a trash can assembly that allows the user to remove an internal liner in a sanitary manner.
[0012] It is yet another object of the present invention to reduce the metal-to-metal grinding of moving parts in a trash can assembly so as to improve the durability and performance of the trash can assembly.
[0013] It is yet a further object of the present invention to provide a trash can assembly which has a plurality of separate inner liners.
[0014] In order to accomplish the objects of the present invention, there is provided a trash can assembly that has a shell having an enclosing wall. The assembly has a lid fitted over the top end of the shell, a pedal positioned adjacent the bottom end of the shell, a link assembly coupling the pedal and the lid, and a motion damper coupled to the link assembly for slowing the closing motion of the lid.
[0015] In accordance with another embodiment of the present invention, the assembly can also include an inner liner that is retained inside the shell, the inner liner having a peripheral lip, and a support frame secured to the top end of the shell, the support frame having a ridge on which the lip of the inner liner rests, and with the support frame further including a groove adjacent the inner liner.
[0016] In accordance with another embodiment of the present invention, two or more inner liners can be provided inside the shell.
[0017] In accordance with another embodiment of the present invention, the lid is pivotably connected to the upper edge of the outer shell by a connector which has a sleeve that is coupled to the upper edge of the outer shell, a non-metal tube that is positioned inside the sleeve, and a shaft received inside the bore of the tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a front perspective view of a trash can assembly according to one embodiment of the present invention.
[0019] FIG. 2 is a cross-sectional side view of the trash can assembly of FIG. 1 .
[0020] FIG. 3 is a side plan view of the trash can assembly of FIG. 1 shown without the outer shell.
[0021] FIG. 4 is a rear view of the trash can assembly of FIG. 1 shown without the outer shell.
[0022] FIG. 5 is an enlarged cross-sectional side view of the base of the trash can assembly of FIG. 1 .
[0023] FIG. 6 is a bottom plan view of the trash can assembly of FIG. 1 shown without the outer shell.
[0024] FIG. 7 is an enlarged top perspective view of the upper part of the trash can assembly of FIG. 1 .
[0025] FIG. 8 is an enlarged view of the area labeled X in FIG. 7 .
[0026] FIG. 9 is an isolated perspective view of a motion damper that can be used with the assembly of FIG. 1 .
[0027] FIG. 10 is an enlarged top perspective view of the upper part of the trash can assembly of FIG. 1 illustrating a modification made thereto.
[0028] FIG. 11 is an exploded isolated perspective view of one lid portion and tube of the trash can assembly of FIG. 10 .
[0029] FIG. 12 is an enlarged isolated view of a portion of the tube and shaft piece of the trash can assembly of FIG. 10 .
[0030] FIG. 13 is an enlarged isolated view of one top corner of the trash can assembly of FIG. 10 .
[0031] FIG. 14 is a cross-sectional view of the tube and a lid portion of the trash can assembly in FIG. 10 .
[0032] FIG. 15 illustrates the provision of a washer between the bracket and the upper hooked end of the lifting rod.
[0033] FIG. 16 is a perspective view of the trash can assembly of FIG. 1 showing the provision of two separate inner liners.
[0034] FIG. 17 is a top plan view of the trash can assembly of FIG. 1 showing the provision of two separate inner liners.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims. In certain instances, detailed descriptions of well-known devices and mechanisms are omitted so as to not obscure the description of the present invention with unnecessary detail.
[0036] FIGS. 1-9 illustrate one embodiment of a trash can assembly 20 according to the present invention. The assembly 20 has an outer shell 22 and an inner liner 24 that is adapted to be retained inside the outer shell 22 .
[0037] The outer shell 22 is a four-sided shell that has four side walls, including a front wall 42 . It is also possible to provide the outer shell 22 in a generally cylindrical, oval or egg shape. The inner liner 24 can have the same, or different, shape as the outer shell 22 . The lid is made up of two separate lid portions 26 and 28 that are split at about the center of the outer shell 22 , each of which is hingedly connected to an upper support frame 130 (see FIG. 7 ) along a top side edge of the outer shell 22 in a manner such that the lid portions 26 , 28 pivot away from each other (see arrows AA in FIG. 4 ) when they are opened. The outer shell 22 and its lid portions 26 and 28 can be made of a solid and stable material, such as a metal. The upper support frame 130 can be secured to the opened top of the outer shell 22 , and can be provided in a separate material (e.g., plastic) from the outer shell 22 . Each lid portion 26 , 28 has a side edge 30 that has a sleeve 32 extending along the side edge 30 . A shaft (not shown) is retained inside the sleeve 32 and has opposing ends that are secured to one side edge of the upper support frame 130 , so that the lid portion 26 , 28 can pivot about an axis defined by the shaft and its corresponding sleeve 32 . An L-shaped bracket 34 is secured at the rear end of each lid portion 26 , 28 . One leg of the bracket 34 is secured to the underside of the lid portion 26 , 28 , and the other leg of the bracket 34 has an opening 40 that is adapted to receive an upper hooked end 36 of a corresponding lifting rod 38 .
[0038] In addition, a toe-kick recess 44 can be provided on the outer shell 22 adjacent the base 46 of the outer shell 22 , and is adapted to receive a foot pedal 48 that is pivotably secured to a pedal bar 60 in the base 46 . The toe-kick recess 44 can be formed as part of the base 46 , and the outer shell 22 would define a curved cut-out to receive the recess 44 . The curved cut-out in the shell 22 can be made by first cutting out a properly sized and configured hole in the body of the outer shell 22 , and then inserting a plastic curved panel that defines the actual recess 44 . The recess 44 extends into the interior confines of the outer shell 22 (as defined by the periphery of the outer shell 22 ). The recess 44 also extends upwardly for a short distance from the base 46 . The pedal bar 60 is made of a material (e.g., metal) that carries some weight, and extends from the foot pedal 48 along the base 46 and is then pivotably coupled to the lifting rods 38 that extend upwardly along the rear of the outer shell 22 to connect the lid portions 26 , 28 . The pedal bar 60 and the lifting rods 38 operate to translate an up-down pivot motion of the pedal 48 to an up-down pivot motion for the lid portions 26 , 28 . Each of these components will be described in greater detail hereinbelow.
[0039] Referring now to FIGS. 3-6 , the base 46 of the outer shell 22 has a raised or domed base panel 52 and a skirt or flange portion 50 that extends from the base panel 52 . In one embodiment of the present invention, the base panel 52 , the skirt 50 and the recess 44 can be formed in one plastic piece. The pedal bar 60 is retained under the base panel 52 and inside the skirt 50 . The pedal bar 60 has two short side walls 64 . The front of the pedal bar 60 is attached to the pedal 48 , and the rear of the pedal bar 60 has two opposite holes 62 . One of the holes 62 is provided on each of the two opposing side walls 64 , and each hole 62 receives a lower hooked end 66 of a corresponding lifting rod 38 . A fulcrum rod 68 extends through the two side walls 64 of the pedal bar 60 at a location that is closer to the front of the pedal bar 60 than the rear of the pedal bar 60 . Thus, the pedal bar 60 can be pivoted about a pivot axis defined by the fulcrum rod 68 . In particular, the pedal bar 60 can be pivoted between two positions, a first rest position as shown in FIG. 2 where the pedal 48 is at a vertically higher position than the rear of the pedal bar 60 , and a second open position (where the lid portions 26 , 28 are opened) as shown in FIG. 5 where the pedal 48 is pressed to a vertically lower position than the rear of the pedal bar 60 .
[0040] Thus, the fulcrum rod 68 is positioned at a location that is closer to the front of the pedal bar 60 than the rear of the pedal bar 60 so that the portion of the pedal bar 60 that is rearward of the fulcrum rod 68 would be greater (and therefore heavier) than the portion of the pedal bar 60 that is forward of the pedal bar 60 , thereby causing the rear of the pedal bar 60 to be at a vertically lower position than the pedal 48 when in the rest position of FIG. 2 .
[0041] As shown in FIG. 5 , the base panel 52 defines a recessed region 70 with a soft material 72 (e.g., a foam sponge) secured below the recessed region 70 . The recessed region 70 acts as a stop member in that it prevents the rear of the pedal bar 60 from being raised to a vertical level that exceeds the vertical position of the recessed region 70 , as shown in FIG. 5 . The soft material 72 therefore functions as a noise and contact absorber so that there will be minimal noise and wear on the pedal bar 60 when it contacts the recessed region 70 .
[0042] In many applications, given the dimensions of the base 46 , it will be difficult to first position the pedal bar 60 inside the base 46 and then attempt to fit a lengthy fulcrum rod inside the base 46 and insert the fulcrum rod through the pedal bar 60 . Therefore, the present invention provides a novel method for securing the fulcrum rod 68 in its desired position with respect to the base 46 and the pedal bar 60 . First, referring to FIG. 6 , the base panel 52 is provided with a column 74 that extends vertically downwardly from the base panel 52 , and the column 74 has a horizontal bore (not shown) that opens towards the center of the base 46 . Next, the fulcrum rod 68 is extended through opposing and aligned openings in the two side walls 64 so that the two opposing ends 76 , 78 of the fulcrum rod 68 extend beyond the side walls 64 . In the next step, the pedal bar 60 and the fulcrum rod 68 are positioned inside the base panel 52 , with one end 76 of the fulcrum rod 68 positioned inside the bore of the column 74 . The other end 78 of the fulcrum rod 68 has a flat configuration with a hole (not shown), so that a screw 80 can be threaded through the hole in the end 78 to secure the fulcrum rod 68 to the base panel 52 .
[0043] A pair of springs 84 and 86 are provided to normally bias the lid portions 26 , 28 to the closed position shown in FIG. 2 . Referring to FIGS. 2-4 , each spring 84 , 86 has a first end 90 that is secured to the base panel 52 , and a second end 92 that is secured to a bent portion 94 of one of the lifting rods 38 . Thus, when the assembly 20 is not experiencing any external forces (i.e., it is in the closed position), the springs 84 , 86 will normally bias the lifting rods 38 in the downward vertical direction, thereby causing the lid portions 26 , 28 to be closed. The springs 84 , 86 also prevent the lower hooked ends 66 from becoming disengaged from the rear of the pedal bar 60 , and takes out any slack in the linkage involving the lifting rods 38 .
[0044] The assembly 20 provides a motion damper 96 that functions to dampen the closing motion of the lid portions 26 , 28 so that the lid portions 26 , 28 can close slowly and not experience a hard slamming motion. The motion damper 96 is illustrated in greater detail in FIG. 9 , and can be embodied in the form of the “Rotary Motion Damper” sold by ITW Delpro of Frankfort, Ill., although other known and conventional motion dampers can be utilized without departing from the scope of the present invention. The motion damper 96 has a toothed bar 98 with a row of teeth 100 positioned along a side thereof. One end of the toothed bar 98 has a pair of aligned openings 102 . A platform 104 has a pair of guides 106 that receive the toothed bar 98 . A toothed damping wheel 108 is carried on the platform 104 and is adapted to engage the teeth 100 on the toothed bar 98 as the platform 104 experiences relative movement in both directions (see arrows A and B) along the toothed bar 98 . Assuming that the damping wheel 108 remains stationary, when the toothed bar 98 moves in the direction B, the damping wheel 108 does not offer any resistance so the toothed bar 98 can move smoothly and quickly in the direction B. However, when the toothed bar 98 moves in the direction A, the damping wheel 108 does offer resistance so the toothed bar 98 can only move very slowly in the direction A. The motion damper 96 is positioned in the interior of the outer shell 22 , and is secured to both the base panel 52 and the pedal bar 60 . In particular, the platform 104 has a connecting element 110 that is secured to a bracket (not shown) in the base panel 52 . The bracket can be secured to the base panel 52 by a screw 116 as shown in FIG. 2 . In addition, the end of the toothed bar 98 with the aligned openings 102 extends through an opening in the base panel 52 , and a damping rod 112 secured to the pedal bar 60 extends through the openings 102 (see FIGS. 5 and 6 ) to couple the toothed bar 98 to the pedal bar 60 . Thus, the platform 104 of the motion damper 96 is essentially fixed at a stationary position with respect to the base panel 52 , and the toothed bar 98 can be moved up or down (i.e., in the directions B or A) as the rear end of the pedal bar 60 is pivoted up or down by the pedal 48 .
[0045] The operation of the trash can assembly 20 will now be described. When the assembly 20 is not in use, the lid portions 26 , 28 are normally closed as shown in FIG. 2 . At this position, the springs 84 and 86 are relaxed and do not exert any bias. To open the lid portions 26 , 28 , the user steps on the pedal 48 , which pivots the pedal bar 60 about the fulcrum rod 68 with the pedal 48 moving vertically downward, and the rear end of the pedal bar 60 being pivoted vertically upwardly. The soft material 72 provides a buffer or absorber to minimize any noise that may be caused by the pedal bar 60 contacting the recessed region 70 . As shown in FIGS. 3-5 and 7 - 8 , the rear end of the pedal bar 60 pushes the lifting rods 38 upwardly, so that the lifting rods 38 will push the lid portions 26 , 28 open about the pivoting of the shafts in the sleeves 32 . The lid portions 26 , 28 will pivot away from each other to expose the top of the of the outer shell 22 . Simultaneously, the damping rod 112 will push the toothed bar 98 upwardly (i.e., in the direction B in FIG. 9 ). As described above, the damping wheel 108 will not offer any resistance to the movement of the toothed bar 98 , so the entire lifting motion of the rear of the pedal bar 60 and the lifting rods 38 will be smooth and relatively quick. At this opened position, the springs 84 and 86 are stretched and therefore biased. As long as the user maintains his or her step on the pedal 48 , the bias of the springs 84 , 86 is overcome, the rear of the pedal bar 60 will remain in the position shown in FIG. 5 , and the lid portions 26 , 28 will remain opened.
[0046] When the user releases the pedal 48 , the combined weight of the pedal bar 60 (i.e., a pulling force) and the lid portions 26 , 28 (i.e., pushing forces), as well as gravity and the natural bias of the springs 84 , 86 , will cause the lid portions 26 , 28 will pivot downwardly to their closed positions. In other words, the lifting rods 38 , the toothed bar 98 and the pedal bar 60 will all experience a downward motion. In this regard, the fact that the fulcrum rod 68 is positioned closer to the pedal 48 (i.e., the front of the pedal bar 60 ) means that the rear of the pedal bar 60 is actually heavier, and will exert a force to aid in pulling the lifting rods 38 down in a vertical direction. However, the damping wheel 108 will resist the downward vertical movement (i.e., in the direction of arrow A in FIG. 9 ) of the toothed bar 98 , so the entire downward motion of the rear of the pedal bar 60 and the lifting rods 38 will be slowed. By slowing this downward motion of the pedal bar 60 and the lifting rods 38 , the lid portions 26 , 28 will close slowly, and the pedal bar 60 will be lowered slowly, all to avoid any annoying loud slamming actions or noises.
[0047] Referring now to FIGS. 2 and 7 , the upper support frame 130 has a border shoulder 132 that extends along its inner periphery which is adapted to receive the upper lip 140 of the inner liner 24 so that the inner liner 24 can be suspended on the shoulder 132 inside the outer shell 22 during use. The support frame 130 has opposing ends 134 and 136 , with a scalloped groove 138 formed in each end 134 , 136 . The scalloped grooves 138 allow the user to insert his or her fingers into the grooves 138 under the upper lip of the inner liner 24 to lift the inner liner 24 from the interior of the outer shell 24 when the lid portions 26 , 28 are opened. This provides a convenient way for the user to remove the inner liner 24 from the outer shell 22 , without requiring the user to grab or grip unnecessarily large portions of the inner liner 24 . The hinged connection of the lid portions 26 , 28 to the upper support frame 130 shown in FIG. 7 can be modified as shown in FIGS. 10-14 . In FIG. 7 , each lid portion 26 , 28 has a metal shaft that is retained in a sleeve 32 and has opposing ends that are secured to the upper support frame 130 in a manner such that the corresponding lid portion 26 or 28 can pivot about an axis defined by the shaft and the sleeve 32 . The sleeve 32 can be formed by curling part of the edge of the metal lid portion 26 , 28 in a manner that leaves a longitudinal opening along the length of the sleeve 32 between the outermost edge of the sleeve 32 and the lid portion 26 , 28 . This curling is best illustrated in FIG. 14 in connection with the sleeve 32 a. The metal shaft can be retained inside this sleeve 32 . Unfortunately, the metal-on-metal contact between the shaft and the sleeve 32 causes wear and tear, and result in the generation of squeaky noises when the shaft pivots inside the sleeve 32 . In addition, after extended use, food, dust and other waste matter may enter the interior of the sleeve 32 via the longitudinal opening, which may impede the pivoting motion of the shaft inside the sleeve 32 .
[0048] The present invention provides a modified connection in FIGS. 10-14 that overcomes these drawbacks. The same numeral designations will be used to designate the same elements in FIGS. 7 and 10 - 14 , except that an “a” will be added to the designations in FIGS. 10-14 . In the embodiment shown in FIGS. 10-14 , the metal shaft 200 is retained inside a non-metal (e.g., plastic) tube 202 , which is in turn retained inside the sleeve 32 a, as best shown in FIG. 14 . The tube 202 has a generally cylindrical configuration with a protruding edge 204 extending along the length of the tube 202 . The protruding edge 204 is configured as a somewhat rectangular block that is adapted to fit snugly into the longitudinal opening of the sleeve 32 a, thereby blocking the longitudinal opening and preventing dust and particles from entering the interior of the sleeve 32 a. As best shown in FIG. 14 , the tube 202 does not completely fill up the interior space of the sleeve 32 a.
[0049] The tube 202 has an interior bore 206 through which two separate shaft pieces 208 can be inserted. Both shaft pieces 208 can be identical in construction, with one provided at each of the opposing ends of the tube 202 . The shaft pieces 208 can be made from metal. As best shown in FIG. 12 , each shaft piece 208 has a smaller-diameter inner section 210 and a larger-diameter outer section 212 . The inner section 210 is inserted into the bore 206 at one end of the tube 202 , and the outer section 212 has a larger diameter to ensure that part of the shaft piece 208 remains outside the bore 206 .
[0050] To assemble the lid portion 26 , 28 , the user or manufacturer first inserts the tube 202 into the sleeve 32 a in a manner such that the protruding edge 204 is snugly fitted into the longitudinal opening of the sleeve 32 a. The sleeve 32 a and its tube 202 are then placed into the appropriate location on the side edge of the upper support frame 130 as shown in FIG. 10 . Then, as shown in FIG. 13 , the inner section 210 of each shaft piece 208 is inserted through bores 218 in the upper support frame 130 that are aligned with the bore 206 of the tube 202 when the sleeve 32 a and its tube 202 are positioned in the upper support frame 130 . The inner section 210 will extend through the bore 218 in the upper support frame 130 and then into the bore 206 of the tube 202 . A portion of the outer sections 212 of the shaft pieces 212 will be exposed to the outside of the bore 218 , but most of the outer sections 212 will be positioned inside the bore 218 . With one shaft piece 208 provided at each opposing end of the tube 202 and sleeve 32 a, the lid portions 26 , 28 can pivot about the axis defined by these shaft pieces 208 .
[0051] A small opening 220 is provided on the protruding edge 204 adjacent each end of the tube 202 . The free end of the inner section 210 of each shaft piece 208 is positioned adjacent this opening 220 . As a result, a user can remove the lid portions 26 , 28 by inserting a sharp-tip object (e.g., screw-driver) through the openings 220 (see FIG. 10 ) and pushing the inner section 210 of each shaft piece 208 out of the bores 206 and 218 .
[0052] Thus, the provision of the non-metal tube 202 provides two immediate benefits. First, the protruding edge 204 prevents dust and particles from entering the interior of the sleeve 32 a. Second, the non-metal material of the tube 202 eliminates the metal-on-metal contact or grinding of a pivoting metal shaft within a metal sleeve.
[0053] FIGS. 10 and 15 also illustrate another modification, where a non-metal (e.g., plastic) washer 230 can be provided to prevent the undesirable metal-to-metal grinding between the bracket 34 and the upper hooked end 36 of the lifting rod 38 . Specifically, a plastic washer 230 can be positioned in the opening 40 in the bracket 34 . The washer 230 can have a sleeved configuration with a flange 232 so that the upper hooked end 36 can extend through the washer 230 . As a result, the washer 230 acts as a separating layer between the metal upper hooked end 36 and the metal bracket 34 .
[0054] FIGS. 1-9 illustrate the use of one inner liner 24 , but it is also possible to provide two or more inner liners. For example, FIGS. 16 and 17 illustrate two inner liners 24 a and 24 b that can be configured to fit snugly, and in side-by-side fashion, inside the outer shell 22 . The provision of two inner liners 24 allows the user to sort the trash, for example, to separate recycleable waste matter from other waste matter.
[0055] The above detailed description is for the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of the invention. The scope of the invention is best defined by the appended claims. In certain instances, detailed descriptions of well-known devices, components, mechanisms and methods are omitted so as to not obscure the present description with unnecessary detail. | 4y
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The present application is a continuation in part of application entitled SHOWER BOW Ser. No. 572,423 filed on Aug. 27, 1990 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Bathtubs and stall showers that use a shower curtain loosely hanging from a shower curtain bar are all of poor design. When the shower water raises the air temperature in the showering area it creates an air flow movement up and out of the showering area. It is replaced with cool air from outside the showering area. This causes the shower curtain to come into the showering area. This invention will correct this poor design of the shower curtain. In all forms of my invention the rigid high impact rod is put in the brackets the rod will bow and form a horizontal self supporting rigid arch this then will prevent the shower curtain from coming into the showering area. This present invention can be used in any stall or tub shower or anywhere else a shower curtain is used.
I show three different shower configurations. One being the conventional tub shower installation consisting of three vertical walls and a horizontal bar mounted by end supports and a loosely hung shower curtain directly above the leading edge of the tub. Two being a two vertical wall shower unit with a shower curtain rod mounted by end supports directly above the leading edge of the shower drain base. Three being a one vertical wall shower unit with a shower curtain rod mounted by end supports directly above leading edge of the drain base.
In some showering area the present invention will enlarge the shower area to provide a greater stall space for body movement.
2. Description of the Prior Art
U.S. Pat. No. 4,754,504 this invention enlarges the shower area but fails to correct the poor design of shower curtain.
U.S. Pat. No. 4,361,914 this device does prevent the movement of a flexible shower curtain but this patent does not show a one-piece self supporting horizontal arch that can be used in one or two wall shower unit or anywhere a shower curtain is used.
U.S. Pat. No. 4,229,842 Gilmore teaches a device he refers to as a shower curtain adapter for expanding the showering space within a shower enclosure. Referring to FIG. 1, a flexible adapter rod 3 is pressure mounted between the right and left hand vertical walls by rubber tips 9 to provide friction causing the adapter rod to bow outward. This rod 3 is vertically supported by a ball chain 4 to prevent downward gravity movement and a hollow vertical tube 2 to prevent upward movement. This patent does not show a one piece self supporting horizontal arch that can be used any where a shower curtain is used. Without the ball chain and hollow vertical tube this device will not efficiently support and maintain a shower curtain.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a view of a one wall shower unit with a shower curtain hanging from a horizontal bar mounted by end supports directly above the leading edge of the drain base and illustrating the present invention.
FIG. 2 is a view of a two wall shower unit with a shower curtain hanging from a horizontal bar mounted by end supports directly above the leading edge of the drain base and illustrating the present invention.
FIG. 3 is a view of a conventional tub shower installation consisting of three walls and a shower curtain hanging from a horizontal bar mounted by end supports directly above the leading edge of the tub and illustrating the present invention.
FIG. 4 is a fragmented view of FIG. 2 illustrating a shower bow hanging from the shower curtain bar in storage position showing one type of hanger.
FIG. 5 is a fragmented view of FIG. 2 illustrating a shower bow with the same type of hanger as FIG. 4 in its functional configuration.
FIG. 6 is a dissected view of the shower bow with the same type of hanging device as FIG. 4 and FIG. 5.
FIG. 7 is a fragmented view of FIG. 2 illustrating a shower bow hanging from the shower curtain bar in storage position showing another type of hanger.
FIG. 8 is a fragmented view of FIG. 2 illustrating a shower bow with the same type of hanger as FIG. 7 in it functional configuration.
FIG. 9 is a dissected view of the shower bow with the same type of hanger device as FIG. 7 and FIG. 8.
FIG. 10 is a fragmented view of FIG. 2 illustrating a shower bow hanging from the storage slot in the bracket showing still another type of hanger.
FIG. 11 is a fragmented view of FIG. 2 illustrating a shower bow with the same type of hanger as FIG. 10 in it functional configuration.
FIG. 12 is a dissected view of the shower bow with the same type of hanging device as FIG. 10 and FIG. 11
FIGS. 13a & 13b are enlarged views of brackets the same type as in FIG. 1 thru FIG. 9
FIGS. 14a & 14b are enlarge views of brackets the same type as in FIG. 10 thru FIG. 12
FIG. 15 is an enlarged fragmented view of vertical shower wall with molded one piece shower wall liner or sometimes called a module unit showing a built in or molded in brackets and storage slot that can be used in FIG. 1 thru FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in more detail to the drawings, FIG. 1 shows the invention in its operative position as applied to a one wall stall shower. Drain base 16 is connected to vertical wall 15 and a standard shower head 14 mounted on wall 15 and a standard shower curtain bar 12 mounted by end supports about 66 inches directly above the leading edge of the drain base 16 with shower curtain 13 surrounding the drain base 16 to prevent water from escaping from the showering area. The high impact rigid rod 2 is mounted in brackets 1 and 3 that are mounted on wall 15, 30 inches below bar 12 this will prevent the shower curtain from coming in on the showering area.
FIG. 2 shows the invention in its operative position as applied to a two wall stall shower. Drain base 19 is connected to vertical walls 17 and 18, and standard shower head 14, mounted on the walls 17 and 18 is a standard shower bar 12 mounted by end supports about 66 inches directly above the leading edge of the drain base 19 with shower curtain 13 hanging from bar 12. The high impact rigid rod 2 is put in to the brackets 1 and 3 that are mounted on walls 17 and 18 30 inches below bar 12, this will prevent the shower curtain from coming into the showering area.
FIG. 3 shows the invention in its operative position as applied to a standard over the tub shower installation. Tub 23 is connected by three vertical walls 20, 21 and 22 and a standard shower bar 12 mounted by end supports between walls 20 and 22 about 66 inches directly above the leading edge of tub 23. With shower curtain 13 hanging from bar 12, the high impact rigid rod 2 is mounted in brackets 1 and 3 that are mounted on walls 20 and 22, 30 inches below bar 12, this will prevent the shower curtain from coming into the showering area.
FIG. 4, a fragmented view of FIG. 2, shows the invention in one of its storage positions hanging from bar 12 by shower curtain ring 11 supporting hanger 7 that is connected by a single bolt 8 and washer 9 to the high impact rigid rod 2 this device only supports the rod 2 in storage position.
FIG. 5, a fragmented view of FIG. 2, illustrating a shower bow with the same type of storage hanger as FIG. 4 in its functional configuration by turning the rod 2, and putting it in the brackets 1 and 3. In the open position it will form a horizontal self supporting arch.
FIG. 6 is a dissected view of the shower bow with the same type of storage hanging device as FIG. 4 and FIG. 5. Brackets 1 and 3 are of the type illustrated in FIG. 13. A high impact rigid rod 2 the diameter of which can be of any configuration. Washers 9 allow 7 and 2 to swivel. A bolt 8 connects 7, 9 and 2 at pivot point. A nut 10 that connects to 8, the hanger 7 is 1/8 by 3/4 inch. by 30 inches. It can be of flexible or rigid material. The ring 11 may be one of the shower curtain rings already present and serve the function of supporting the shower curtain as well as the hanger 7 or additional ring supporting only the hanger.
FIG. 7, a fragmented view of FIG. 2, illustrating a shower bow hanging from the shower curtain bar 12 in another storage position. The hook type of hanger 4 is connected to the high impact rigid rod 2 at 2 inches from one end.
FIG. 8, a fragmented view of FIG. 2, illustrating a shower bow with the same type of hanger as FIG. 7 in its functional configuration. By lifting the rod 2 up and off bar 12 and putting it in the brackets 1 and 3 it will form a horizontal self supporting rigid arch.
FIG. 9 is a dissected view of the shower bow with the same type of hanger device as FIG. 7 and FIG. 8 1 and 3 are brackets of the type illustrated in FIG. 13.
FIG. 10, a fragmented view of FIG. 2, illustrating a shower bow hanging from the storage slot in the bracket showing still another type of hanger. The bracket 5 is the same type illustrated in FIG. 14. It has a storage slot and it is mounted 30 inches below bar 12, rod 2 is put in the slot for storage.
FIG. 11, a fragmented view of FIG. 2, illustrating a shower bow with the same type of hanger as FIG. 10 in its functional configuration. Rod 2 is removed from the storage slot in bracket 5 or 6 and put into brackets 5 and 6. In the open position it will form a horizontal self supporting rigid arch.
FIG. 12 is a dissected view of the shower bow with the same type of storage hanging device as FIG. 10 and FIG. 11. Brackets 5 and 6 are of the same type illustrated in FIG. 14.
FIGS. 13a and 13b are enlarged views of brackets the same type as in FIG. 1 thru FIG. 9 The opening 24 in 3 and 1 are the same diameter configuration as rod 2 illustrated in FIG. 1 thru FIG. 9. Opening 24 goes in 1 inch at a 30% angle and down at a 10% angle.
FIGS. 14a and 14b are enlarged views of brackets the same type as in FIG. 10 thru FIG. 12 The opening 24 in 6 and 7 are the same diameter configuration as rod 2 illustrated in FIG. 10 thru FIG. 12 Opening 24 goes in 1 inch at a 30% angle and down at a 10% angle. 26 is a storage slot of the same configuration as rod 2 and is vertical.
FIG. 15 is an enlarged fragmented view of vertical wall 27 illustrating a one piece molded shower wall liner 29 showing a built in or molded in brackets 28 and storage slot 30. | 4y
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BACKGROUND OF THE INVENTION
The invention relates to razor cartridges having blades retained by metal clips.
In one type of movable-blade razor cartridge design, as shown for example in U.S. Pat. No. 4,378,634, blades can move up and down in slots in a cartridge housing against resilient arms during shaving. Metal clips on the housing retain the blades in the slots and determine the positions of the cutting edges of the blades in the at-rest position. In manufacture, the blades are first loaded into the housing; then a U-shaped clip is positioned over the housing and blades, and the legs of the clip are bent around the bottom of the housing.
SUMMARY OF THE INVENTION
In one aspect, the invention features, in general, a razor cartridge including a housing, blades mounted on the housing, and a metallic retaining clip that wraps around the housing and retains the blades on the housing. The housing has a fulcrum portion that extends outward beyond adjacent surface portions of the housing on two sides of the fulcrum portion, and the retaining clip is bent over the fulcrum portion beyond the elastic limit of the clip.
Certain implementations of the invention include one or more of the following features. In certain implementations there is a fulcrum portion for each of the two ends of the clip. The fulcrum portion tapers and has a blunt upper surface. The fulcrum portion is deformed and reduced in height by pressure applied to the fulcrum portion during bending of the clip over the fulcrum portion. The clip has a notch that is aligned with a notch post on the housing, and the clip bends at the fulcrum at a narrowed portion of the clip adjacent to the notch. The housing has a raised edge adjacent to an edge of the clip that positions the clip on the housing. The blades are movably mounted in slots in the housing. The blades are mounted on a top portion of the housing, and the ends of the clip are located at a bottom portion of the housing. The housing is recessed adjacent to the ends of the clip to receive the end portions of the clip during bending.
In another aspect, the invention features, in general a razor cartridge including a housing, blades mounted on the housing and a retaining clip. The housing has a wedge portion that extends outward beyond an adjacent portion and makes an interference fit with an end of the clip so as to facilitate retaining the clip on the housing.
In certain implementations, the housing has a raised edge adjacent to an edge of the clip that positions the clip on the housing, and the wedge portion extends sideways from the raised edge. The wedge portion has an angled surface at the interference fit, and the end portion of the clip has a mating angled surface. A portion of the wedge portion overlies a portion of the clip at the interference fit.
In other aspects the invention features housings as already described for use in razor cartridges and methods of assembling razor cartridges using the housings and clips as already described.
Embodiments of the invention may have one or more of the following advantages. The use of fulcrum portions and wedge portions permits longer clips to be used and thicker clip material to be used without having the end portions of the clips spring back to too large an extent after forming. The longer and thicker clips facilitate use on cartridge housings that have been made wider in order to accommodate a third blade.
Other advantages and features of the invention will be apparent from the following description of the preferred embodiment thereof and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a razor according to the invention.
FIG. 2 is an exploded perspective view of a blade unit of the FIG. 1 razor.
FIG. 3 is a partial bottom view of the FIG. 2 blade unit.
FIG. 4 is a vertical sectional view, taken at 4--4 of FIG. 3, of a housing of the FIG. 2 blade unit.
FIG. 5 is a vertical sectional view, taken at A--A of FIG. 3, of the FIG. 4 cartridge housing.
FIG. 6 is a partial vertical sectional view showing a forming die used to bend retaining clips around the FIG. 4 cartridge housing.
FIGS. 7, 8, and 9 are vertical sectional views, taken at A--A of FIG. 3, showing the FIG. 4 housing and a retaining clip at three different stages during the assembly of the clip on the housing.
FIG. 10 is a vertical sectional view, taken at A--A of FIG. 3, of the assembled FIG. 2 blade unit with the ends of the retaining clip in a desired final position.
FIG. 11 is a partial vertical sectional view, taken at 11--11 of FIG. 10, showing the interference fit and overlying contact of a wedge portion of the housing and the retaining clip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, shaving razor 10 includes handle 12 and replaceable shaving cartridge 14. Cartridge 14 includes molded plastic housing 16, which carries three blades 18, guard 20 and cap 22. Cartridge 14 also includes plastic interconnect member 24 on which housing 16 is pivotally mounted. Interconnect member 24 removably and fixedly attaches to handle 12 and has two arms 26 that pivotally support housing 16 at its two sides. Cartridge 14 is shown in its spring-biased, upward position in FIG. 1.
Referring to FIG. 2, housing 16 of cartridge 14 has inwardly facing slots 28 in side walls 30 for receiving the ends of base portions 32 of blades 18. Housing 16 also has respective pairs of resilient arms 36 on which each blade 18 is resiliently supported. Blades 18 are located in a substantially unobstructed region 38 between side walls 30 to provide for ease of rinsing of the cartridge during use.
Cap 22 provides a lubricous shaving aid and is received in slot 40 at the rear of housing 16. Cap 22 may be made of a material comprising a mixture of a hydrophobic material and a water leachable hydrophilic polymer material, as is known in the art and is described, e.g., in U.S. Pat. Nos. 5,113,585 and 5,454,164, which are hereby incorporated by reference. Guard 20 includes a finned elastomeric unit molded on the front of housing 16 to engage and stretch the user's skin; other skin engaging protrusions, e.g., as described in U.S. Pat. No. 5,191,712, which is hereby incorporated by reference, can be used.
Metal clips 42 are secured at the respective sides of housing 16 inside of raised edges 44 of side walls 30 in order to retain blades 18 within housing 16 and to locate the cutting edges of spring-biased blades 18 at a desired exposure when in the at-rest position. Clips 42 also wrap around the bottom of housing 16 and prevent the removal of the ends of arms 26 of interconnect member 24. Clips 42 are made of 0.018"thick aluminum material, which is thicker than the material used in the clips of the blade unit of the commercial embodiment of the type of design described in the above-mentioned U.S. Pat. No. 4,378,634. In addition, the arms of the clips that are bent around the bottom of housing 16 are both longer than those employed in the commercial embodiment of the type of design described in the above-mentioned patent, because there are three blades (instead of two) and the housing thus is wider. The thicker material and the longer arms to be bent cause the arms to tend to elastically return to a larger extent after forces bending the clips around the housing have been released. Housing 16 includes certain features (described below) to maintain the thicker, longer clips in a desired final position.
Referring to FIG. 3, it is seen that the end portions 50 of clips 42 have notches 52 that are aligned with notch posts 54 (see also FIG. 4) of housing 14. It is also seen that housing 16 has wedge portions 56 that extend in from raised edges 44 and have angled surfaces 58 that contact angled surfaces 60 of end portions 50 of clips 42. Wedge portions 56 (see also FIG. 4) and the contacting surfaces 60 of clips 42 make an interference fit in order to help retain the ends of clips 42 on housing 16.
Referring to FIGS. 4 and 5, it is seen that housing 16 has fulcrums 62 that extend outward beyond the adjacent surface portions of housing 16 on both sides of fulcrums 62. As shown in FIG. 5, fulcrums 62 have a semicircular cross-section and therefore are tapered and have a blunt upper surface.
In manufacture, blades 18 are located on housing 16 by inserting the ends of base portions 32 in slots 28 and depressing the blades downward against resilient arms 36. Prior to assembly, retaining clips 42 are U-shaped, and the portion of the U that joins the two legs has the same contour as the upper portion of housing 16 within raised edges 44. The upper portions of the preassembled clips 42 thus have the same shape of the upper portions of clips 42 as shown in FIG. 2. Prior to assembly, the two legs of the U-shaped clip (which legs correspond to portions 66, 68 in FIG. 2) are directed straight downward and parallel to each other, and leg 66 is shorter than leg 68.
The clip/housing/blade assembly (with the upper portion of clips 42 seated on housing 16 inside of raised edges 44) is directed downward against forming die 100 shown in FIG. 6. Surfaces 102, 104 of die 100 deflect legs 66 and 68 inward as the housing/blade/clip assembly is brought closer to die 100. This causes the legs 66, 68 of clip 42 to initially bend around the bottom of housing 16 to the position shown in FIG. 7. At this stage in the forming process, the end portions 50 of legs 66, 68 have just made initial contact with fulcrums 62. (In FIGS. 7-10, the base portions 32 of blades 18 and the ends of arms 26 are not shown on housing 16, though they are present during these stages of the manufacturing process and in the final assembly.)
Referring to FIG. 8, with further advancement of the housing/blade/clip assembly toward die 100, the end portions 50 of the clips 42 tend to bend around fulcrums 62 at regions nearby notches 52 where clips 42 are thinner. Simultaneously with bending of clips 42 around fulcrums 62, fulcrums 62 begin to be crushed from the resulting forces, and the crushed material of fulcrums 62 is directed toward recess 72. At the same time, angled surfaces 60 of clips 42 move past angled surfaces 58 of wedge portions 56 (FIG. 3), and notches 52 begin to pass over notch posts 54 (FIGS. 3, 4).
Referring to FIG. 9, further advancement of the housing/blade/clip assembly toward the forming die causes the ends 70 of the clips to contact the bottom of recess 72 of housing 16 in the position of their most deflected travel. At this point, fulcrums 62 have been crushed flat, with displaced material in recess 72, and ends 50 have been permanently bent beyond the elastic limit of the clip material at the regions of the clips overlying fulcrums 62. At the same time, angled surfaces 60 of clips 42 travel further over angled surfaces 58 of wedge portions 56 (FIG. 3), and the tops of wedge portions 56 are deformed (i.e., swaged) by projection 106 of forming die 100, causing displaced wedge material to slightly overly the ends of clips 42 and to create an interference fit that exerts a normal spring force against wedge portions 56.
When the housing/blade/clip assembly is removed from forming die 100, the ends 50 tend to elastically return slightly to the position shown in FIGS. 10 and 11, though such movement is inhibited by the swaged plastic of wedges 56.
The interference fit between angled clip surfaces 60 and angled wedge surfaces 58 and the overlying swaged material (as shown in FIG. 11) tend to hold the ends of the clips 42 in place and to inhibit them from moving outward from housing 16. Also, notches 52 of clips 42 receive notch posts 54, causing end portions 50 of clips 42 to be captured between projections 42 and wedge portion surfaces 58 and to inhibit clip 42 from opening up during use, e.g., when the cartridge is subjected to excessive forces as might arise when the cartridge is dropped.
Other embodiments of the invention are within the scope of the appended claims. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR COMPUTER PROGRAM LISTING
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] (1) Field of the Invention
[0005] This application is directed to field of temporary water containment dams and more particular a portable system that can be assembled into a temporary water containment dam.
[0006] (2) Description of Related Art
[0007] Temporary dams or dikes are often needed to hold back water, whether for emergency flood control, water diversion, repairs to structures normally surround or covered by water such as bridges or banks, construction projects, etc. Conventionally, sandbags and earthen berms or dams are used in these situations to form dikes to contain the water, however, these methods are time consuming and very labor intensive.
[0008] U.S. Pat. No. 6,676,333 by Wiseman et al is an attempt to provide a temporary type of structure, but it lacks practicality due to the frequent support structures, and the membrane used to contain the water is poorly supported.
[0009] U.S. Pat. No. 6,450,733 by Krill et al is a design requiring significant foundational support. As a practical matter, it is not very portable or mobile.
[0010] U.S. Pat. No. 6,132,140 by Kullberg is another attempt to provide a temporary type of structure, but it also lacks practicality and economy due to the excessive weight/design of the membrane support face, which is very heavy. Also, the design lacks consideration to ensure that a multi-curve path can be followed.
[0011] U.S. Pat. No. 6,079,904 by Trisl is a solid wall containment system. The design is very heavy, complicated, and the pipe/rod system requires field bending. Field installation is labor intensive; requiring training and special tools.
[0012] U.S. Pat. No. 6,012,872 by Perry et al describes a water filled modular system. The design is complicated and it is questionable that the design would be stable under actual hydrostatic pressure conditions.
[0013] U.S. Pat. No. 5,470,177 by Hughes is a solid wall containment system. The design is very complicated, heavy, and needs soil for weight to stabilize the base. The system is difficult and unappealing to utilize in the event of a natural disaster where it needs to be installed by a flood. Also, no consideration is given except for a straight system design.
[0014] U.S. Pat. No. 3,213,628 by Serota is a water filled plastic design structure, stayed by a wire anchor system.
[0015] The design is overly complicated for a temporary dam system requiring an excessive amount of work to fill the various structures with water in place.
[0016] Sandbags are a method to build a temporary containment wall or dike, and it is a very labor intensive method. Because the sand bags are stacked on top of each other to form the wall, and the wall often wall needs to be relatively high, it is often the case that the base needs to be wider than the top. Additionally, not only is it time consuming to fill and place the sandbags, it takes a lot of labor to deconstruct sandbag walls after they are no longer needed. In emergency situations, it is often hard to prioritize the labor to deconstruct the sandbag wall after a crisis is over.
[0017] In the case of a simple earthen dam, large machinery is often needed to construct it and deconstruct it, and this can be troublesome or even dangerous in the circumstances.
[0018] Additionally, earthen dams and sandbags can involve a relatively high environmental impact. In the case of sandbags, sand left behind from the sandbags can have an environmental impact. In the case of earthen dams, often the dirt for the dam is taken from the site causing an impact on the surrounding environment and often the earthen dam cannot be completely leveled when it is no longer needed, leaving traces of the dam behind.
[0019] A number of portable dam devices and systems have been developed for creating temporary water containment dikes because of the time and labor requirements needed to create a temporary containment wall of sandbags or an earthen dam. These devices have been developed to be relatively transportable and quick to set up with less labor required than needed for sandbags or earthen dams. They typically consist of a framework that can be assembled at a site to create the temporary dam.
[0020] These systems also have to be sufficiently strong to withstand the hydrostatic pressure that can be exerted as a result of having to hold back a body of water. Additionally, because they will have to be quickly set up on whatever ground surface is present at the site of the body of water, they have to be relatively compact to be transportable, and relatively quick to set up.
[0021] It is highly desirable to design a system that uses unskilled labor to assemble, such as can be constructed on site during an impending disaster, with confidence that it's simplicity is reasonably foolproof in design.
[0022] Further, it is desirable to design a system using a minimum amount of supports per length of dam, so that a system could be erected as quickly as possible when a flood on a river, lake, or similar body of water, will soon occur due to an unpredictable event. It is also desirable to utilize a support system that is light weight and can be readily transported by manual labor, so that trucks can deliver the containment system parts to a central location, and then the actual erection and construction is handled by human labor when the parts have to be carried by hand over moderate to long distances. In particular, it is desirable that no piece is too large or heavy for one or two individuals to carry. A weight of approximately 50 lbs or less would therefore be desirable for a single individual to carry, or 100 lbs or less for two people.
[0023] It is additionally desirable to provide a design that is easily adaptable to ground terrain conditions, so that a long portable water containment system could follow a multi-curved path based on a lake front, waterfront, beach line, river bank, tree line, property line, path, roadway, etc. For example, an entire lake may need to be surrounded by a temporary water containment system.
[0024] These requirements have resulted in previously designed systems being relatively complicated, consisting of numerous heavy braces, overly rigid connection points, fixed designs, and complicated support members. Especially in the case of lateral support, the previous systems often require quite complex ways of linking the temporary structure to provide lateral support, which often involves numerous braces and lateral support members.
[0025] In particular, previous attempts have difficulties with providing light weight designs and simplified adaptability to changes in following a multi-curved path.
[0026] Accordingly, there is a need for a portable and temporary dam system that is sufficiently strong to contain a body of water, yet relatively simple, transportable and easy to set up.
BRIEF SUMMARY OF THE INVENTION
[0027] It is an object of the present invention to provide a system and method that overcomes problems in the prior art.
[0028] An embodiment of the present invention is a supporting structure, a membrane support plate, and a water membrane which contacts the water and contains it. The supporting structure is light weight in design, and alternates in three primary parts: an end support frame and a middle supporting frame. A top supporting frame is also included in many embodiments, but not in all. The design features simplified field erection, light weight transportation, and an efficient design for following a field directed path without the use of surveyors.
[0029] An important embodiment of the present invention includes additional structures which allow convenient methods to turn the support structure and membrane support plate in a way that allows the water containment system to follow a curved path rather than only follow a straight line. Convenient features provide a method to create a path that follows a lake front, shoreline, river bed, etc.
[0030] The water containment system is constructed by connecting the support structures, along with the membrane support plates, together to form a lengthwise continuous length so that the membrane support plates form a long continuous supporting wall. A water membrane, i.e. a flexible liquid-impervious membrane, is placed over the water membrane plates extending down to the ground and over the entire front surface of the temporary dam. The water membrane stops the water, and the membrane support plate is held in place by the support structures. The weight of the water on the membrane naturally provides a sealing effect. Thus, the body of water will be readily contained.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0031] FIG. 1 shows other art for portable flood control.
[0032] FIGS. 2A-2B show other art sandbag method of portable flood control.
[0033] FIGS. 3A-3H shows partial assembly and detail views of an improved design support structure.
[0034] FIG. 4 is a side view of an alternate embodiment of an improved design support structure.
[0035] FIG. 5 shows multiple supports connected in a side by side manner to provide a portable water containment system.
[0036] FIG. 6 is a view showing back support details of how interconnecting plates are utilized that allow flexibility in a curved design rather than a straight design.
[0037] FIG. 7 is another view showing back support details of how interconnecting plates are utilized that allow flexibility in a curved design rather than a straight design.
[0038] FIG. 8 shows a cross section of the design when used to contain water.
[0039] FIG. 9 shows a top view where the water containment system is not in a straight line by using a special plate.
DETAILED DESCRIPTION OF THE INVENTION
[0040] This application incorporates by reference the entirety of Canadian Application No. CA 2628067 , filed on Apr. 2, 2008.
[0041] FIG. 1 illustrates another art design where an inflated water dam is used to retain low water levels of a lake or dam spillover. A pump 101 is used to fill an elastomer tube 102 which is nearly filled with water 105 to hold back a water level 103 on a lake or river bed surface 104 . This device has some advantages in rapid deployment, but is offset by disadvantages in sliding on the lake bed due to hydrostatic pressure when the water level is high, and seepage underneath the elastomer tube.
[0042] FIG. 2A-2B illustrate a common method of stacking sandbags for a portable dam where the sandbags are stacked in an alternate manner, both in height and depth so that the top sandbag row has a large supporting base. Other stacking arrangements are common and the top row may have a larger or more narrow base, depending upon the local conditions. FIG. 2A is a cross section and FIG. 2B is a frontal view. Sandbags often allow seepage, depending on various factors, and are a common method for low level water containment heights where the hydrostatic pressure against the sandbag wall is lower.
[0043] FIGS. 3A-3B show a support for an embodiment of the present invention as viewed from the rear.
[0044] An end support frame comprising a horizontal member 301 A, a back support member 301 B, and a plate support member 301 C are joined together to create the entire end support. The back support member connects to the plate support member substantially at the middle of the plate support member. The supports are joined by welding, bolts, machining, clips, mechanical fasteners, and the like. Alternately, the end support frame is manufactured or machined out of one piece. The end support frame is made from materials such as metal or reinforced plastics, such as fiberglass. In one embodiment, the end support frame is made from a material that is corrosion resistant, such as a galvanized steel or aluminum. In another embodiment, it is made primarily from aluminum or steel tube. In another embodiment, it is coated with a corrosion resistant material, such as paint.
[0045] A middle support frame comprising a middle horizontal member 304 a vertical member 303 and a bottom horizontal member 302 are joined together to create the entire middle support frame. Similar to the end support frame, the middle support frame is made from materials such as metal or reinforced plastics, such as fiberglass. In one embodiment, the middle support frame is made from a material that is corrosion resistant, such as a galvanized steel or aluminum. In another embodiment, it is made primarily from aluminum or steel tube. In another embodiment, it is coated with a corrosion resistant material, such as paint.
[0046] The middle support frame is connected to an end support frame by mechanical clips 309 C,D,E,F on each side, as will be illustrated later. The clips are tabs with bolt holes that allow mechanical fasteners, such as bolts, nuts, or screws, to be used which connect the end support frame to the middle support frame and then another end support frame together as illustrated in FIG. 3A . In this manner, an entire supporting structure is built up by alternating end support frames and middle support frames, all connected together in the field.
[0047] FIG. 3B also illustrates a top support frame, comprising a top horizontal member and two end clips 309 A,B. Similar to the end support frame, the top horizontal member is made from materials such as metal or reinforced plastics, such as fiberglass. In one embodiment, the middle support frame is made from a material that is corrosion resistant, such as a galvanized steel or aluminum. In another embodiment, it is made primarily from aluminum or steel tube. In another embodiment, it is coated with a corrosion resistant material, such as paint.
[0048] Use of a top support frame, as conceived in the present invention is one embodiment, and not a requirement. Depending upon the supporting structure rigidity and design, the need for the additional top support is dependent upon the overall requirements. Similar to the middle support frame, the top support frame is connected to an end support frame by the mechanical clips 309 A,B on each side. The clips are tabs with bolt holes that allow mechanical fasteners, such as bolts, nuts, or screws, to be used which connect the end support frame to the top support frame and then another end support frame together as illustrated in FIG. 3A . In this manner, an entire supporting structure is built up by alternating end support frames, then middle and top support frames, all connected together in the field.
[0049] FIG. 3A also illustrates a partial assembly of the final structure. Bolts 307 A,C,E are used to join the supports together. A hole 308 in the end support is useful for field stabilization of the support frame and also for connecting to additional support to the earth, such as a spike, rod, telescoping leg, or a foot pad. It is also useful for storage purposes. Alternately, the end support incorporates a telescoping leg and the hole 308 is utilized to adjust the leg length.
[0050] Holes 310 on the end support frame are used for a stabilization plate that will be illustrated later. A membrane supporting plate 306 faces the body of water. If a sufficiently rigid membrane supporting plate 306 is used, a top support frame is not required. The spacing of the holes 310 between end support frames is a predetermined design criterion based on the height of water to be contained, materials used for the various components, and overall optimization for weight.
[0051] FIG. 3C additionally illustrates the end support structure and highlights the angle of the membrane support structure from horizontal 319 remains substantially 45 degrees in the initially assembled state. This provides for a supporting structure of an economic design with a primary weight load toward the lower front of the membrane supporting plate 306 . This will cause the end support frame to thrust into the soil closest to the membrane supporting plate. In the field under actual load conditions, this angle will vary in practice.
[0052] FIG. 3D shows a front isometric view of the partial assembly shown in FIG. 3A .
[0053] FIG. 3E shows a bracing plate 311 with connecting holes 312 inside an overall length 313 . The length 313 is designed based on substantially matching the width of the membrane support plate, the length of the top support frame, and the length of the middle support frame to within the tolerances needed to fit the section together. In a preferred embodiment, the bracing plate and the membrane support plates will overlap slightly when assembled to avoid the need for another set of bolt holes. The length of the bracing plate will be close to, but slightly longer than the top support frame and the middle support frame.
[0054] Along with the bracing plate 311 , a bracing connecting plate 314 with slotted turning holes 316 and turning connecting holes 315 are used to attach the bracing connecting plate to an end support frame.
[0055] FIG. 3F shows a membrane support plate 317 at a designed spacing width 313 . Attaching/connecting holes are spaced on the surface of the membrane support plate. FIG. 3G shows various cross sections of the membrane support plate 306 , and is not meant to be restrictive but illustrative of embodiments. To go along with the bracing plate, a membrane turning plate 318 A with a bending line 321 along with a membrane turning connecting plate 320 with slotted turning holes 322 and membrane turning plate connecting holes 323 are used to attach the membrane turning plate to an end support frame.
[0056] For the sake of simplicity in erection, it is achievable to design the bracing plate, end support, middle support, top support, and the membrane support plate so that each one is 100 lbs or less. With attention to design parameters, and by making the support spacing more frequent, it is also attainable to design each plate/support so each one is 50 lbs or less in weight. These weights are generally recognized as reasonable values for two healthy individuals or a single healthy individual to lift and carry. Thus every component of the water containment system is transportable by two individuals or a single individual.
[0057] FIG. 4 shows an embodiment where some flexibility in design for an end support frame is needed. An end support frame comprising a horizontal member 401 , a back support member 404 , and a plate support member 405 are joined together to create the entire end support. The back support member connects to the plate support member substantially at the middle of the plate support member by a pivoting joint 406 . The horizontal support member is attached to the back support member by a sliding shuttle 402 A and a bolt 403 A. Similarly, the horizontal support member is joined to the plate support member 405 by a sliding shuttle 402 B and a bolt 403 B. Both shuttles are incrementally locked in place by choosing a through hole in the back support member and plate support member. The horizontal support member 401 can be chosen in length to achieve a particular back support angle. This allows the overall structure to adapt to a particular ground elevation and allow the membrane support plate to remain substantially at a 45 degree angle.
[0058] Similarly to the fixed design already discussed, the end support frame members are each machined or manufactured out of one piece. The end support frame is made from materials such as metal or reinforced plastics, such as fiberglass. In one embodiment, the end support frame is made from a material that is corrosion resistant, such as galvanized steel or aluminum. In another embodiment, it is made primarily from aluminum or steel tube. In another embodiment, it is coated with a corrosion resistant material, such as paint.
[0059] FIG. 5 illustrates multiple supports connected in a side by side manner to provide a portable water containment system. In this figure, only a straight line system is shown.
[0060] FIG. 6 illustrates the method of turning the membrane plate wall at an angle. The membrane turning plate 318 B along with the membrane turning connecting plate 320 are attached to two side by side end supports so that the angle changes, based on the designed curve of the membrane turning plate 318 B. The isosceles trapezoid rectangle along with the fold lines define the angular change. Because the membrane turning connecting plate 320 makes a slight spacing change for the bracing plate 311 between the end supports, the bracing connecting plates 314 are used as illustrated. The slotted holes in the membrane turning connecting plate 320 and in the bracing connecting plates 314 will take care of minor issues in alignment.
[0061] FIG. 7 similarly illustrates the method of turning the membrane plate wall at an angle. In this case, the membrane turning plate 318 A turns the angle in a different direction, but the general assembly remains the same, as is illustrated.
[0062] In one featured embodiment, the membrane turning plates 318 A,B turn the membrane plate wall angles 45 degrees. In other embodiments, other angles are used.
[0063] FIG. 8 shows a cross section of the assembly when the water membrane 802 is holding back water 801 . The system is designed to contain water for a wide variety of depths up to near the very top of the support frame. The water membrane is pieced together by a zipper, strapping, snaps, hook and loop, and the like. The water membrane is preferably made by a flexible water resistant material, such as a PVC, 18-28 ounce/square yard reinforced fabric that is tear resistant.
[0064] FIG. 9 shows a top view of two examples of membrane plates in a connected water containment system where membrane turning plates alter the angular orientation. Angles 901 and 902 , as illustrated, are 45 and 30 degrees respectively, but as this figure clearly illustrates, other angles could easily be designed into membrane turning plates.
[0065] The system is capable of being erected in deep flowing water and can withstand substantial wave action. Also, as a result of its low angle design, the system will perform well in icy conditions by breaking up the ice on its sloping face, thus acting like an inverted ice-breaker. In addition to its capability of dealing with significant ice flow, the system will deflect floating debris.
[0066] An extended seepage path results in a very low flow rate under the dam and can be easily managed by a sump pump. Overtopping will not result in a breach of the structure.
[0067] The dam is readily disassembled by disconnecting the dam sections, and the system is generally connected together by mechanical fasteners such as bolts and nuts. It is also connectable by convenience fasteners, such as pins with enhanced hardware features that readily ensure their retention inside a hole.
[0068] While various embodiments of the present invention have been described, the invention may be modified and adapted to various operational methods to those skilled in the art. Therefore, this invention is not limited to the description and figures shown herein, and includes all such embodiments, changes, and modifications that are encompassed by the scope of the claims. | 4y
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REFERENCE TO COPENDING APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 179,726, filed Apr. 11, 1988, now U.S. Pat. No. 4,827,046, incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to integrated reactor and extraction systems and operating techniques for converting crude methanol or the like to lower methyl tertiary-alkyl ethers, such as MTBE. In particular, this invention relates to a system for converting crude methanol to valuable products by etherifying lower branched olefins, such as C 4 -C 7 normally liquid iso-olefins.
It is known that isobutylene and other isoalkenes produced by hydrocarbon cracking may be reacted with methanol over an acidic catalyst to provide methyl tertiary butyl ether (MTBE) and isoamylenes may be reacted with methanol over an acidic catalyst to produce tertiary-amyl methyl ether (TAME). Those ethers having the formula CH 3 --O--R, where R is a tertiary alkyl radical, are particularly useful as octane improvers for liquid fuels, especially gasoline.
MTBE and TAME are known to be high octane ethers. The article by J. D. Chase, et al., Oil and Gas Journal, Apr. 9, 1979, discusses the advantages one can achieve by using these materials to enhance gasoline octane. The octane blending number of MTBE when 10% is added to a base fuel (R+O=91) is about 120. For a fuel with a low motor rating (M+O=83) octane, the blending value of MTBE at the 10% level is about 103. On the other hand, for an (R+O) of 95 octane fuel, the blending value of 10% MTBE is about 114.
Increasing demand for high octane gasolines blended with lower aliphatic alkyl ethers as octane boosters and supplementary fuels has created a significant demand for isoalkylethers, especially the C 5 to C 7 methyl alkyl ethers, such as methyl tertiary butyl ether (MTBE) and tertiary amyl methyl ether (TAME). Methanol may be readily obtained from coal by gasification to synthesis gas and conversion of the synthesis gas to methanol by well-established industrial processes. As an alternative, the methanol may be obtained from natural gas by other conventional processes, such as steam reforming or partial oxidation to make the intermediate syngas. Crude methanol from such processes usually contains a significant amount of water, usually in the range of 4 to 20 wt %; however, the present invention is useful for removing water in lesser amounts or greater.
It is main object of the present invention to provide a novel and economic technique for removing excess water from crude methanol feedstocks, including novel reactor systems and equipment for treating oxygenate feedstocks prior to etherification and disposing of raffinate containing methanol. It has been discovered that aqueous methanol streams, such as etherification feedstock extraction byproduct can be economically upgraded by catalytic conversion concurrently with hydrocarbons.
SUMMARY OF THE INVENTION
A continuous technique has been found for converting crude alcohol to lower alkyl t-alkyl ethers. In a preferred embodiment, a continuous feedstock separation and etherification reactor system is provided for converting crude methanol feedstock to methyl t-alkyl ether. This system includes: extractor means for contacting crude feedstock liquid containing a minor amount of water with a liquid olefinic hydrocarbon extraction stream under extraction conditions favorable to selective extraction of methanol, thereby providing an extract liquid stream rich in methanol and an aqueous raffinate stream lean in methanol; first catalytic reactor means operatively connected for contacting the extract stream in a catalytic reaction zone with acid etherification catalyst in an etherification reaction zone under process conditions to convert a major portion of methanol to ether; effluent separation means for recovering ether product from unconverted olefinic hydrocarbon and methanol; and second catalytic reactor means operatively connected for contacting said raffinate stream with conversion catalyst in the presence of said unconverted olefinic hydrocarbon and methanol to produce normally liquid hydrocarbon product.
These and other objects and features of the invention will be understood from the following description and in the drawing.
DRAWING
FIG. 1 of the drawing is a schematic etherification system flowsheet depicting the present invention; and
FIG. 2 is a typical fluidized bed reactor system useful for upgrading hydrocarbons and co-converting raffinate.
DETAILED DESCRIPTION
Typical feedstock materials for etherification reactions include olefinic streams, such as FCC light naphtha and butenes rich in isoolefins. These aliphatic streams are produced in petroleum refineries by catalytic cracking of gas oil or the like. The crude methanol commercially available from syngas processes may contain, for instance 4 to 17 wt % water, which must be removed, preferrably to a methanol purity of about 99.8 wt %. It has been found that more than 75% of crude feedstock methanol can be recovered by liquid extraction with light olefinic liquid extractant, such as butenes and C 5 + light olefinic naphtha. The typical feed ratio range is about 5 to 20 parts hydrocarbon extractant per part by volume of methanol.
Typical equipment according to the present invention includes a continuous feedstock separation and etherification reactor system for converting crude methanol oxygenate feedstock and isoolefin to methyl t-alkyl ether, wherein the unit operation apparatus includes: extractor means for contacting crude feedstock liquid containing a minor amount of water with a liquid hydrocarbon extraction stream under extraction conditions favorable to selective extraction of methanol, thereby providing an extract liquid stream rich in methanol and an aqueous raffinate stream lean in methanol; first catalytic reactor means operatively connected for contacting the extract stream in a catalytic reaction zone with acid etherification catalyst in an etherification reaction zone under process conditions to convert a major portion of methanol to ether; second catalytic reactor means for contacting said raffinate stream with methanol conversion catalyst in the presence of hydrocarbon to produce a liquid hydrocarbon stream; and means for charging at least a portion of said liquid hydrocarbon stream from said second reactor means to said extractor means as said extraction stream.
Referring to the drawing, a continuous stream of crude methanol (MeOH) feedstock is introduced via conduit 10 with a stream of C 4 + olefinic hydrocarbon liquid extractant introduced via conduit 12 to a top inlet of extraction separation unit 14, operated at about 35°-40° C. These streams are contacted under liquid extraction conditions to provide an aqueous raffinate phase. An aqueous stream containing a major amount of the water present in the crude feedstock is withdrawn via conduit 16. The lighter organic extract phase containing hydrocarbon extraction solvent and the major amount of feedstock methanol is recovered from extraction unit 14 via conduit 18, and introduced under temperature and process conditions suitable for conversion of methanol in contact with etherification catalyst in reactor system 30. From reactor 30, the effluent product stream passes via line 32 to a debutanizer or, optionally, depentanizer fractionation tower 40.
In separation unit 40 the C5+ methyl tert-alkyl ether product is recovered as a liquid product, along with unreacted C5-C6 hydrocarbons in the extractant. Tower overhead comprising unreacted C 4 + hydrocarbons and methanol are passed via condenser means 44, 46 to liquid accumulator 48. The debutanizer overhead vapor stream is sent to catalytic conversion unit 50, where it is contacted concurrently with aqueous raffinate from line 16, and optionally lower olefins rich in C2-C5 light hydrocarbons.
The aqueous raffinate stream 16 consists essentially of water, partitioned methanol (50-80 wt %) and a trace of hydrocarbon. This stream is reactive at elevated temperature in the presence of an acid zeolite catalyst, such as medium pore shape selective zeolite, such as , ZSM-5, etc., in a fluidized bed reaction zone. For example, the aqueous methanol raffinate stream may be coreacted with olefinic light gas and/or other reactive hydrocarbon feedstreams in an oligomerization reaction section, as described by Owen et al in U.S. Pat. No. 4,788,365, incorporated herein by reference. The aqueous methanol may be introduced as a liquid directly to the reaction zone (bottom or middle section), as herein described with regard to FIG. 2, or vaporized and mixed with hydrocarbon feed. Optionally, FCC fuel gas containing ethene may be injected at the bottom of the fluidized bed reaction zone and converted along with the raffinate stream as herein described.
EXTRACTION UNIT OPERATION
The typical preferred crude feedstock material is methanol containing about 4 to 17% by weight water. The extraction contact unit may be a stirred multi-stage vertical extraction column adapted for continuous operation at elevated pressure. Any suitable extraction equipment may be employed, including cocurrent, cross-current or single contactors, wherein the liquid methanol feedstock is intimately contacted with a substantially immiscible liquid hydrocarbon solvent, which may be a mixture of C 4 + aliphatic components including lower alkanes, n-alkenes or relatively pure isoalkenes, such as isobutylene, etc. This unit operation is described in Kirk-Othmer Encyclopedia of Chemical Technology (Third Ed.), 1980, pp. 672-721. Other equipment for extraction is disclosed in U.S. Pat. Nos. 4,349,415 (DeFilipi et al), 4,626,415 (Tabak), and 4,665,237 (Arakawa et al). Unit operation details are also disclosed by Harandi et al in copending U.S. patent application Ser. No. 043729, filed Apr. 29, 1987, now U.S. Pat. No. 4,831,195 incorporated herein by reference. The methanol extraction step can be performed advantageously in a countercurrent multistage design, such as a simple packed column, rotating disk column, agitated column with baffles or mesh, or a series of single stage mixers and settlers.
As an example of typical methanol extraction with FCC light naphtha in a liquid-liquid contact and separation unit for extracting crude methanol containing 4 wt % water at about 38° C. (100° F.). The extractor unit and water wash unit are operated at about 35°-65° C. (100°-150° F.) and 0-2000 kPa. The stream composition for each feed, light extract phase and heavy raffinate phase is given in Table I.
TABLE 1______________________________________Extraction Operation Raffinate FCC Light Crude Light HeavyComponent Naphtha Methanol Liquid Phase Liquid Phase______________________________________Methanol 149.87 113.96 35.91(lbmol/hr)Water 11.11 0.40 10.71C.sub.4 51.13 50.98 0.15C.sub.5 330.10 329.23 0.87C.sub.6 163.38 163.02 0.36Total 544.61 160.98 657.59 48.00Methanol Recovered (wt %) 76.0Water Entrained in Methanol 0.2*______________________________________ (*based on dry hydrocarbon feed)
Etherification Operation
The reaction of methanol with isobutylene and isoamylenes at moderate conditions with a resin catalyst is known technology, as provided by R. W. Reynolds, et al., The Oil and Gas Journal, June 16, 1975, and S. Pecci and T. Floris, Hydrocarbon Processing, December 1977. An article entitled "MTBE and TAME--A Good Octane Boosting Combo", by J. D. Chase, et al., The Oil and Gas Journal, Apr. 9, 1979, pages 149-152, discusses the technology. A preferred catalyst is a polyfunctional ion exchange resin which etherifies and isomerizes the reactants. A typical acid catalyst is Amberlyst 15 sulfonic acid resin.
Processes for producing and recovering MTBE and other methyl tert-alkyl ethers for C 4 -C 7 isoolefins are known to those skilled in the art, such as disclosed in U.S. Pat. Nos. 4,544,776 (Osterburg et al) and 4,603,225 (Colaianne et al). Various suitable extraction and distillation techniques are known for recovering ether and hydrocarbon streams from etherication effluent.
CONVERSION OF METHANOL AND HYDROCARBONS TO LIQUID HYDROCARBONS
Zeolite catalysis technology for upgrading lower aliphatic hydrocarbons and oxygenates to liquid hydrocarbon products are well known. Commerial Methanol-to-Gasoline (MTG), methanol-to olefins (MTO), aromatization (M2-Forming) and Mobil Olefin to Gasoline/Distillate (MOG/D) processes employ shape selective medium pore zeolite catalysts for these processes. It is understood that the present zeolite conversion unit operation can have the characteristics of these catalysts and processes to produce a variety of hydrocarbon products, especially liquid aliphatic and aromatics in the C5-C9 gasoline range.
Description of Zeolite Catalysts
Recent developments in zeolite technology have provided a group of medium pore siliceous materials having similar pore geometry. Most prominent among these intermediate pore size zeolites is ZSM-5, which is usually synthesized with Bronsted acid active sites by incorporating a tetrahedrally coordinated metal, such as Al, Ga, Fe or mixtures thereof, within the zeolitic framework. These medium pore zeolites are favored for acid catalysis; however, the advantages of ZSM-5 structures may be utilized by employing highly siliceous materials or cystalline metallosilicate having one or more tetrahedral species having varying degrees of acidity. ZSM-5 crystalline structure is readily recognized by its X-ray diffraction pattern, which is described in U.S. Pat. No. 3,702,866 (Argauer, et al.), incorporated by reference.
Zeolite hydrocarbon upgrading catalysts preferred for use herein include the medium pore (i.e., about 5-7A) shape-selective crystalline aluminosilicate zeolites having a silica-to-alumina ratio of at least 12, a constraint index of about 1 to 12 and acid cracking activity (alpha value) of about 1-250, preferably about 3 to 80 based on total catalyst weight. In the fluidized bed reactor the coked catalyst may have an apparent activity (alpha value) of about 10 to 80 under the process conditions to achieve the required degree of reaction severity. Representative of the ZSM-5 type medium pore shape selective zeolites are ZSM-5, ZSM-11, ZSM-12, ZSM-22, ZSM-23, ZSM-35, and ZSM-48. Aluminosilicate ZSM-5 is disclosed in U.S. Pat. No. 3,702,886 and U.S. Pat. No. Re. 29,948. Other suitable zeolites are disclosed in U.S. Pat. Nos. 3,709,979; 3,832,449; 4,076,979; 3,832,449; 4,076,842; 4,016,245; 4,414,423; 4,417,086; 4,517,396 and 4,542,251. The disclosures of these patents are incorporated herein by reference. While suitable zeolites having a coordinated metal oxide to silica molar ratio of 20:1 to 200:1 or higher may be used , it is advantageous to employ a standard ZSM-5 having a silica alumina molar ratio of about 25:1 to 70:1, suitably modified if desired to adjust acidity and oligomerization/aromatization characteristics. A typical zeolite catalyst component having Bronsted acid sites may consist essentially of aluminosilicate ZSM-5 zeolite with 5 to 95 wt. % silica and/or alumina binder.
These siliceous zeolites may be employed in their acid forms, ion exchanged or impregnated with one or more suitable metals, such as Ga, Pd, Zn, Ni, Co and/or other metals of Periodic Groups III to VIII. The zeolite may include a hydrogenation-dehydrogenation component (sometimes referred to as a hydrogenation component) which is generally one or more metals of group IB, IIB, IIIB, VA, VIA or VIIIA of the Periodic Table (IUPAC), especially aromatization metals, such as Ga, Pd, etc. Useful hydrogenation components include the noble metals of Group VIIIA, especially platinum, but other noble metals, such as palladium, gold, silver, rhenium or rhodium, may also be used. Base metal hydrogenation components may also be used, especially nickel, cobalt, molybdenum, tungsten, copper or zinc. The catalyst materials may include two or more catalytic components, such as a metallic oligomerization component (eg, ionic Ni +2 , and a shape-selective medium pore acidic oligomerization catalyst, such as ZSM-5 zeolite) which components may be present in admixture or combined in a unitary bifunctional solid particle. It is possible to utilize an ethene dimerization metal or oligomerization agent to effectively convert feedstock ethene in a continuous reaction zone.
Certain of the ZSM-5 type medium pore shape selective catalysts are sometimes known as pentasils. In addition to the preferred aluminosilicates, the gallosilicate, and ferrosilicate materials may be employed. ZSM-5 type pentasil zeolites are particularly useful in the process because of their regenerability, long life and stability under the extreme conditions of operation. Usually the zeolite crystals have a crystal size from about 0.01 to 2 microns or more. In order to obtain the desired particle size for fluidization in the turbulent regime, the zeolite catalyst crystals are bound with a suitable inorganic oxide, such as silica, alumina, etc. to provide a zeolite concentration of about 5 to 95 wt. %. It is advantageous to employ a standard ZSM-5 having a silica:alumina molar ratio of 25:1 or greater in a once-through fluidized bed unit to convert 60 to 100 percent, preferably at least 75 wt %, of the monoalkenes and methanol in a single pass. In the preferred embodiment 25% H-ZSM-5 catalyst calcined with 75% silica-alumina matrix binder is employed unless otherwise stated.
Particle size distribution can be a significant factor in achieving overall homogeneity in turbulent regime fluidization. It is desired to operate the process with particles that will mix well throughout the bed. Large particles having a particle size greater than 250 microns should be avoided, and it is advantageous to employ a particle size range consisting essentially of 1 to 150 microns. Average particle size is usually about 20 to 100 microns, preferably 40 to 80 microns. Particle distribution may be enhanced by having a mixture of larger and smaller particles within the operative range, and it is particularly desirable to have a significant amount of fines. Close control of distribution can be maintained to keep about 10 to 25 wt % of the total catalyst in the reaction zone in the size range less than 32 microns. Accordingly, the fluidization regime is controlled to assure operation between the transition velocity and transport velocity.
Fluidized Bed Reactor Operation
Suitable olefinic feedstreams to the olefin upgrading unit comprise C 2 -C 5 alkenes, including unreacted butylenes and amylenes from the etherification operation. Non-deleterious components, such as C 1 -C 2 lower paraffins and inert gases, may be present. The reaction severity conditions can be controlled to optimize yield of olefinic gasoline or C 6 -C 8 BTX hydrocarbons, according to product demand. It is understood that aromatic hydrocarbon and light paraffin production is promoted by those zeolite catalysts having a high concentration of Bronsted acid reaction sites. Accordingly, an important criterion is selecting and maintaining catalyst inventory to provide either fresh or regenerated catalyst having the desired properties. Reaction temperatures and contact time are also significant factors in the reaction severity, and the process parameters are followed to give a substantially steady state condition wherein the reaction severity is maintained within the limits which yield a desired weight ratio of propane to propene in the reaction effluent.
In a turbulent fluidized catalyst bed the conversion reactions are conducted in a vertical reactor column by passing hot reactant vapor or lift gas upwardly through the reaction zone at a velocity greater than dense bed transition velocity and less than transport velocity for the average catalyst particle. A continuous process is operated by withdrawing a portion of coked catalyst from the reaction zone, oxidatively regenerating the withdrawn catalyst and returning regenerated catalyst to the reaction zone at a rate to control catalyst activity and reaction severity to effect feedstock conversion.
Upgrading of olefins by such hydrogen contributors in co-conversion reactors is taught by Owen et al in U.S. Pat. No. 4,788,365 and 4,090,949. In a typical process, the methanol and olefinic feedstream is converted in a catalytic reactor under oligomerization conditions and moderate pressure (ie-100 to 2500 kPa) to produce a predominantly liquid product consisting essentially of C 5 + hydrocarbons rich in gasoline-range mono-olefins and aromatics. The use of fluidized bed catalysis permits the conversion system to be operated at low pressure drop, which in an economically practical operation can provide a maximum operating pressure only 50 to 200 kPa above atmospheric pressure. Another important advantage is the close temperature control that is made possible by turbulent regime operation, wherein the uniformity of conversion temperature can be maintained within close tolerances, often less than 5° C. Except for a small zone adjacent the bottom gas inlet, the midpoint measurement is representative of the entire bed, due to the thorough mixing achieved.
Referring now to FIG. 2, liquid methanol-containing raffinate 16 from the extractor is passed under pressure via feed conduit 116 for injection into vertical reactor vessel 110 above a feed distributor grid 112, which provides for distribution of hot vapor from etherification separation overhead passing via conduit 114 through the small diameter holes in the grid 112. Fluidization is effected in the bottom portion of the bed by upwardly flowing gas introduced via conduit 114, which may be supplemented with additional reactive gas 114A, such as FCC ethylenic fuel gas or the like. Although depicted without baffles, the vertical reaction zone can contain open end tubes above the grid for maintaining hydraulic constraints, as disclosed in U.S. Pat. No. 4,251,484 (Daviduk and Haddad). Optionally, a variety of horizontal baffles may be added to limit axial mixing in the reactor. Thermodynamic conditions in the reaction vessel can be controlled by adjusting liquid injection rate, vapor feed temperature, catalyst temperature and rate, or by heat exchange means 115.
Provision is made for withdrawing catalyst from above grid 112 by conduit means 117 provided with flow control valve means to control passage via air lift line 118 to the catalyst regeneration system in vessel 120 where coked catalyst particles are oxidatively regenerated in contact with air or other regeneration gas at high temperature. In order to add sufficient heat to the catalytic reaction zone 110, energy may be added by combustion of flue gas or other fuel stream in the regenerator. Regenerated catalyst is returned to the reactor fluid bed 110 through conduit means 122 provided with flow control valve means. The hot regenerated catalyst is charged to the catalyst bed sufficiently below the upper interface to achieve good mixing in the fluid bed. The rate of flow for regenerated catalyst may be adjusted to provide the degree of thermal input required for effecting endothermic conversion, and the rate will depend upon the amount and composition of the alkane components.
Initial fluidization is achieved by forcing a lift gas upwardly through the catalyst. A light gas, with or without diluent or recycle, may be charged at a bottom portion of the reactor beneath grid 112. Pressurized liquid feedstock is introduced above reactant distributor grid 112, and pumped to one or more spray nozzles. The liquid is dispersed into the bed of catalyst thereabove at a velocity sufficient to form a generally upwardly flowing suspension of atomized liquid reactant with the catalyst particles and lift gas. Advantageously, the liquid methanol-containing reactant feed is injected into the catalyst bed by atomizing the pressurized liquid feedstream to form readily dispersible liquid particles having an average size of 300 microns or less. This contributes to rapid vaporization of the liquid at process pressure. Exothermic conversion provides sufficient heat to vaporize the liquid quickly.
Cyclone catalyst particle separator means may be positioned in an upper portion of the reactor vessel. The product effluent separated from catalyst particles in the cyclone separating system then passes to effluent separation system 130. The product effluent is cooled and separated to recover C5+ liquid gasoline range hydrocarbons or offgas, along with any byproduct water or catalyst fines carried over. A portion of the light gas effluent fraction may be recycled by compressing to form a motive gas for the liquid feed or recycle for use as lift gas. The recovered hydrocarbon product comprising C 5 + olefins and/or aromatics, paraffins and naphthenes is thereafter processed to obtain the desired aromatic and/or aliphatic products.
Optimized process conditions the turbulent bed has a superficial vapor velocity of about 0.2 to 2 meters per second (m/sec). At higher velocities entrainment of fine particles may become excessive and beyond 10 m/sec the entire bed may be transported out of the reaction zone. At lower velocities, the formation of large bubbles or gas voids can be detrimental to conversion. Even fine particles cannot be maintained effectively in a turbulent bed below about 0.1 m/sec.
A convenient measure of turbulent fluidization is the bed density. A typical turbulent bed has an operating density of about 100 to 500 kg/m 3 , preferrably about 300 to 500, measured at the bottom of the reaction zone, becoming less dense toward the top of the reaction zone due to pressure drop and particle size differentiation. This density is generally between the catalyst concentration employed in dense beds and the dispersed transport systems. Pressure differential between two vertically spaced points in the reactor column can be measured to obtain the average bed density at such portion of the reaction zone. For instance, in a fluidized bed system employing ZSM-5 particles having a clean apparent density of 1.06 gm/cc and packed density of 0.85, an average fluidized bed density of about 300 to 500 kg/m 3 is satisfactory.
By virtue of the turbulence experienced in the turbulent regime, gas-solid contact in the catalytic reactor is improved, providing substantially complete conversion, enhanced selectivity and temperature uniformity. One main advantage of this technique is the inherent control of bubble size and characteristic bubble lifetime. Bubbles of the gaseous reaction mixture are small, random and short-lived, thus resulting in good contact between the gaseous reactants and the solid catalyst particles.
A significant advantage of the present invention is that operation in the turbulent fluidization regime is optimized to produce high octane C 5 + liquid in good yield. The weight hourly space velocity and uniform contact provides a close control of contact time between vapor and solid phases, typically about 3 to 25 seconds. Another advantage of operating in such a mode is the control of bubble size and life span, thus avoiding large scale gas by-passing in the reactor. The process of the present invention does not rely on internal baffles in the reactor for the purpose of bubble size control such as the baffles which are employed in the prior art dense bed processes discussed above.
As the superficial gas velocity is increased in the dense bed, eventually slugging conditions occur and with a further increase in the superficial gas velocity the slug flow breaks down into a turbulent regime. The transition velocity at which this turbulent regime occurs appears to decrease with particle size. The turbulent regime extends from the transition velocity to the so-called transport velocity, as described by Avidan et al in U.S. Pat. No. 4,547,616 and by Tabak et al. in U.S. Pat. No. 4,579,999, incorporated herein by reference.
A typical single pass reactor unit employs a temperature controlled catalyst zone with indirect heat exchange and/or adjustable gas quench, whereby heat can be removed or added, depending on the exothermicity or endothermicity of the reaction which in turn depends on the relative concentrations of olefin and paraffins in the feed. The reaction temperature can be carefully controlled in the usual operating range of about 250° C. to 650° C., preferably at average reactor temperature of 350° C. to 580° C. Energy conservation in the system may utilize at least a portion of the reactor exotherm heat value by exchanging hot reactor effluent with feedstock and/or recycle streams. Optional heat exchangers may recover heat from the effluent stream prior to fractionation. For highly endothermic reactions (high alkane concentration in the feed) additional heat can be supplied to the reactor from the regenerator. Various fuels can be burned in the regenerator to raise the temperature of the catalyst. It is preferred to operate the olefin conversion reactors at moderate pressure of about 100 to 3000 kPa (atmospheric to about 400 psig). The weight hourly space velocity (WHSV, based on total olefins in the fresh feedstock) usually is about 0.1-5 WHSV.
The present invention is particularly advantageous in the economic dewatering of crude methanol, thus avoiding expensive and energy-intensive prefractionation by distillation. By extracting methanol from the crude feedstock with olefinic hydrocarbon reactant liquid, substantial utilities and equipment savings are realized. Various modifications can be made to the system, especially in the choice of equipment and non-critical processing steps. | 4y
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This is a continuation of application Ser. No. 07/581,771 filed on Sep. 13, 1990, now abandoned, which is a continuation-in-part of application Ser. No. 07/433,931, filed Nov. 9, 1989 now abandoned.
BACKGROUND
1. Field of the Invention
The present invention relates to a media transport mechanism in a printer and in particular to a high accuracy vacuum belt used in conjunction with pinch roller assemblies for precise media handling.
2. Description of the Prior Art
The prior art devices will be discussed in terms of printers, although the concepts may be equally applicable to other devices having vacuum belts in conjunction with pinch roller assemblies.
There has been a continuing need for precise media handling in a printer, and especially at the region of the media where the printing takes place. The prior art devices adopted one of many ways of transporting media through the printing area; however, each of them suffer from some inherent drawbacks which reduce the accuracy of the printing.
In one type of prior art device which uses a flat stationary platen, friction drive rollers alone are used. Typically, two sets of friction drive rollers are provided on two separate drive shafts. However, the use of friction drive rollers introduces printing inaccuracies due to some deficiencies. First, it is difficult to synchronize two drive shafts. A usual technique to overcome this problem is to slightly over-drive the exit rollers to ensure that the media is tensioned adequately. However, during the entrance and exit of the media, there are times when the media is held down by only one set of rollers. Inaccuracies may be introduced during the transition from one set of rollers to the other set. Second, inaccuracies may occur because the rollers may become deformed. Third, the leading and trailing edges of the media are not well controlled by the two sets of drive rollers.
In a second type of prior art device, a rotary platen is used to advance media through the printing area. However, since the printing surface is curved, the resulting print gap will vary, which will cause inconsistencies in printing.
In a third type of prior art device, a tractor feed device is used to transport continuous sheets of media across a printing area. However, the paper positioning accuracy is severely affected by the accuracy of the holes in the media. Furthermore, tractor feed is inappropriate for transporting individual cut sheets.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a media transport mechanism which allows continuous and cut sheets of media to be transported through the printing area of a printer more precisely so as to reduce inaccuracies in printing.
It is another object of this invention to provide a media transport mechanism which accurately controls media linear velocity and displacement.
It is another object of this invention to provide a media transport mechanism which presents a flat printing surface adjacent the print head to maintain a constant print gap.
It is another object of this invention to provide a media transport mechanism which prevents the print head from contacting the media.
It is another object of this invention to provide a media transport mechanism which maintains control of the leading and trailing edges of the media at all times.
It is another object of this invention to provide a media transport mechanism which prevents media skew.
A media transport mechanism according to this invention comprises a vacuum belt supportably wrapped around two sprocket assemblies and plenum having a rigid platen with vacuum slots provided thereon. The vacuum belt is disposed in facing relation to a print head, the vacuum belt having two pinch roller assemblies disposed in spaced-apart relation across the front surface of the vacuum belt, with each pinch roller assembly including two pinch rollers which, in conjunction with the vacuum belt, grip and advance a sheet of media across the front surface of the vacuum belt during printing, with the plenum providing a vacuum hold-down force through the vacuum slots in the plenum for holding the media flat against the front surface of the vacuum belt.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in connection with one embodiment thereof with reference to the accompanying drawings:
FIG. 1 is a perspective view of the vacuum belt and pinch roller assembly;
FIG. 2 is an exploded perspective view of the vacuum belt and pinch roller assembly;
FIG. 3 is a right side view of the right side of the vacuum belt and pinch roller assembly, with a portion broken away;
FIG. 4 is a view of a portion of the vacuum belt; and
FIG. 5 is a perspective view of the plenum of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the vacuum belt and pinch roller assembly will be described with reference to FIGS. 1-5.
FIGS. 1 and 2 show the vacuum belt and pinch roller assembly to be used in a printer, which may be, for example, an ink jet or impact printer. A vacuum belt 2 is wrapped around two sets of sprockets, a pair of upper sprockets comprising an upper left sprocket 20 and an upper right sprocket 22, and a pair of lower sprockets comprising a lower left sprocket 24 and a lower right sprocket 26.
The vacuum belt 2 is guided and driven by the upper sprockets. The upper left sprocket 20 and the upper right sprocket 22 are mounted on opposite ends of an upper idler shaft 34. The right end of the upper idler shaft 34 is fitted into a slot in a right end cap 42, while the left end of the upper idler shaft 34 extends through a left end cap 41 to mount the axle of a pulley 16, which operates to drive the upper idler shaft 34 and thus, the vacuum belt 2. Both the upper left sprocket 20 and the upper right sprocket 22 have sprocket pins 28 that ar adapted to be fitted into sprocket holes 30 on opposite edges of the vacuum belt 2 for driving the vacuum belt 2. The left end of a hollow elongated upper idler support roller 36 is attached to the inside of the upper left sprocket 20, and the right end of the hollow elongated upper idler support roller 36 is attached to the inside of the upper right sprocket 22. The upper idler support roller 36 encloses the upper idler shaft 34 and provides support to hold the vacuum belt 2 flat and to prevent the vacuum belt 2 from collapsing in the middle portion.
Unlike the upper sprockets, the lower left sprocket 24 and the lower right sprocket 26 do not have sprocket pins. Thus, the lower sprockets only guide but do not drive the vacuum belt 2. The lower left sprocket 24 and the lower right sprocket 26 are also mounted on opposite ends of a corresponding lower idler shaft 38. Unlike the upper idler shaft 34, the lower idler shaft 38 is not connected to a pulley and is not driven. The left end of the lower idler shaft shaft 38 is fitted into a slot in the left end cap 41, while the right end of the lower idler shaft shaft 38 is fitted into a slot in the right end cap 42. There is also a hollow lower idler support rollers 40 having its left end attached to the lower left sprocket 24 and its right end attached to the lower right sprocket 26. The lower idler support roller 40 encloses the lower idler shaft 38 and performs the same function as the upper idler support roller 36, that is, to provide support to hold the vacuum belt 2 flat and to prevent the vacuum belt 2 from collapsing in the middle portion.
As shown in FIGS. 1, 2 and 4, the vacuum belt 2 is formed with a plurality of perforated vacuum holes 32 spaced one-eighth of an inch apart from each other. The vacuum holes 32 should be substantially small (e.g., 0.032 inches in diameter in the illustrated embodiment) to provide enough impedance to the air flow when a sheet of media 14 is not covering the holes 32. The sheet of media 14 may be any type of printable sheet medium, such as paper or transparency. The vacuum holes 32 should also be in close proximity to each other so that the whole surface of the vacuum belt 2 beneath the media 14 forms a vacuum. As shown in FIG. 1, the vacuum holes 32 extend over a width of the vacuum belt 2 which is greater than the width of the sheet of media 14. The vacuum belt 2 is also formed of a plurality of sprocket holes 30 which are aligned along both edges of the vacuum belt 2 and have a diameter which is wider than that of the vacuum holes 32. The sprocket holes aligned along the left edge of the vacuum belt 2 are adapted to receive the sprocket pins 28 of the upper left sprocket 20 while the sprocket holes aligned along the right edge of the vacuum belt 2 are adapted to receive the sprocket pins 28 of the upper right sprocket 22. The vacuum belt 2 is made from a flexible material, such as polyester, so that the inaccuracy due to belt-stretching is minimal.
Referring to FIGS. 1 and 2, the vacuum belt and pinch roller assembly further comprises two sets of pinch rollers, an upper set and a lower set. The upper set comprises a pair of upper pinch rollers 8 which are carried so as to engage the outside surface of the upper portion of the vacuum belt 2. The upper pinch rollers 8 are mounted on an upper roller shaft 4, which has its left end fitted into a slot in an upper left arm 52 and its right end fitted into a slot in an upper right arm 50. The upper roller shaft 4 is an idler shaft and is not driven at all. The upper right arm 50 is part of and extends from the frame of the right end cap 42 while the upper left arm 52 is part of and extends from the frame of the left end cap 41. Springs 66 are fitted along the external surface of the arms 50 and 52 to connect the opposite ends of the shaft 4 to the respective arms 50 and 52. The shaft 4 is spring-loaded by the springs 66 which bias the shaft 4 and the upper pinch rollers 8 against the vacuum belt. The rollers 8 rotate only in response to the motion of the vacuum belt 2 or the print media when present.
The lower set of pinch rollers is identical to the upper set. The lower set comprises a pair of lower pinch rollers 10 carried so as to engage the outside surface of the lower portion of the vacuum belt 2, and mounted on a lower roller shaft 6 supportably fitted at opposite ends in slots of a lower right arm 54 and a lower left arm 56. The lower right arm 54 and the lower left arm 56 extend from the frames of the right end cap 42 and the left end cap 41, respectively. Springs 68 are fitted along the external surface of the arms 54 and 56 to connect the opposite ends of the shaft 6 to the respective arms 54 and 56. The shaft 6 is spring-loaded by the springs 68 which bias the shaft 6 and the lower pinch rollers 10 against the vacuum belt.
A vacuum chamber or plenum 47 is provided as shown in FIGS. 2 and 5. The plenum 47 has a rigid platen 43 on its front face. The plenum 47 is essentially enclosed but has an opening 49 on its right side for receiving the generated vacuum pressure. As shown in FIGS. 1-3 and 5, the right end cap 42 has an opening 44 which receives the opening 49 on the right side of the plenum 47. The opening 44 in the right end cap 42 is connected to a vacuum blower 48 by a tube or duct 46. The vacuum blower 48 is capable of generating a vacuum at 0.2-0.4 inches of water at the flow rate of 10-100 cfm.
Referring to FIG. 2, the platen 43 is disposed on the inside surface of the vacuum belt 2 opposite from the print head 12, and provides support to the cross-sectional printing area of the vacuum belt 2 between the two sprocket assemblies. Further, as shown in FIGS. 2 and 5, the platen 43 is formed with a plurality of vacuum slots 45 so that the generated vacuum can be effectively felt by the print media 14 through the plurality of vacuum holes 32 while the vacuum belt 2 and the print media 14 are being collectively advanced. The rear surface and the left side of the plenum 47 are also enclosed so that the plenum 47 is air-tight. This prevents the vacuum force from escaping except through the vacuum slots 45.
The pulley 16 is belt-driven by a belt 18. A stepper motor 17 drives the pulley 16 so as to rotate the upper idler shaft 34, the upper left sprocket 20 and the upper right sprocket 22 in the clockwise direction (see FIGS. 2 and 3). The rotation of the upper sprockets cause the sprocket pins 28 fitted in the sprocket holes 30 on the vacuum belt 2 to rotatably advance the vacuum belt 2.
The operation of the vacuum belt and pinch roller assembly will now be described with reference to FIGS. 1 and 3. A sheet of media 14 is initially picked from a media source, such as a tray or cassette, and the media's leading edge delivered to the lower portion of the front surface of the vacuum belt 2. The leading edge of the media 14 is gripped by the lower pinch rollers 10 and the vacuum belt 2. As the vacuum belt 2 advances, the lower pinch rollers 10 also rotate and help to advance the media 14 along the front surface of the vacuum belt 2. A vacuum hold-down force is provided by the vacuum slots 45 in the plenum 47 located on the inside of the vacuum belt 2 to ensure that the media 14 is held flat against the front surface of the vacuum belt as the media is advanced through a printing area. The printing area is defined as the area of the vacuum belt 2 between the upper pinch rollers 8 and the lower pinch rollers 10. The arrows 58 in FIG. 3 indicate the direction in which the media 14 is pulled towards the vacuum belt 2 by the vacuum hold-down force.
As the media 14 is advanced through the printing area, a reciprocating print head 12 held out of contact with the media 14 prints the desired pattern or text onto the media 14 (see FIGS. 1 and 3). As the media 14 is advanced across the front surface of the vacuum belt 2, the upper pinch rollers 8 engage the leading edge of the media 14 and operate in unison with the vacuum belt 2 and the lower pinch rollers 10. As the trailing edge of the media 14 disengages the lower pinch rollers 10, the upper pinch rollers 8 assume control of the media 14 together with the vacuum belt 2 until the trailing edge of the media 14 is disengaged from the upper pinch rollers 8 and delivered to an output tray (not shown).
The vacuum belt and pinch roller assembly described above accurately controls the transportation of continuous and cut sheets of media 14 through the printing area and ensures accurate linear velocity and displacement of the media. The use of the pinch rollers in conjunction with the vacuum belt allows control of the leading and trailing edges of the media 14 at all times while the media 14 is within the printing area. The vacuum belt and pinch roller assembly also prevents the print head 12 from touching the media 14, and the effective vacuum hold-down force and the flat surface of the vacuum belt ensure that the gap between the media 14 and the print head 12 is contant so as to improve print quality.
While the invention has been shown and described with reference to a preferred embodiment thereof, it will be appreciated by those having skill in the art that variations in form and detail may be made therein without departing from the spirit and scope of the invention. | 4y
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[0001] The present application is a continuation-in-part of priority of pending U.S. patent application Ser. No. 13/066,630, filed on Apr. 21, 2011, entitled “Hydroponic Produce Display Apparatus, which claims priority of U.S. Provisional Patent Application Ser. No. 61/343,038, filed on Apr. 22, 2010, entitled “Hydroponic Produce Display Apparatus”.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to a hydroponic produce production and display apparatus and, more particularly, the invention relates to a hydroponic produce display apparatus allowing home, kitchen, in-store and market display and storage of unpicked, growing vegetables and herbs to consumers.
[0004] 2. Description of the Prior Art
[0005] Traditionally, agricultural produce displayed in supermarkets, farmer's markets, or other venues has previously been harvested and transported, and as such often suffers wilting and cosmetic blemishes, damage to body and structure, loss of nutrition, and the resulting negative effects on consumption. By presenting living, growing crop plants in the marketplace showing none of the negative characteristics of harvest and transport, many of these hurdles to consumption can be overcome, and storage life of the harvested product increased dramatically. Additionally, presenting crops in a way that allows consumers to choose and harvest plants themselves introduces a positive tactile experience to consumers that contributes to a pleasing customer experience. Additionally, crop plants that are not picked in the marketplace are kept alive and healthy and can be returned with the production containers to the producer to be harvested and introduced to the market in a more traditional manner. The shelf life of live plants in such a system dramatically exceeds the shelf life of harvested vegetables and herbs.
SUMMARY
[0006] The present invention is a method for in-store and market display of plants. The method comprises providing a basin for holding a volume of liquid, forming an opening in the basin, providing a hydroponic container having a first end and a second end, cooperating the first end of the hydroponic container with the opening in the basin, growing plants within the hydroponic containers, moving liquid from the basin to the second end of the hydroponic container, and exchanging the harvested hydroponic containers with unharvested hydroponic containers.
[0007] In addition, the present invention includes a method for in-store and market display of plants. The method comprises providing a basin having an open top, the basin holding a volume of liquid, positioning a cover on the open top of the basin, the cover being permeable to liquid, providing a display backing having a first end, a second end opposite the first end, a first side, and a second side opposite the first side, mounting the first end of the display backing over the open top of the basin, extending the display backing vertically from the basin, mounting the plants to the display backing, introducing liquid to the plants mounted to the display backing, moving liquid from the basin to the liquid introduction means, providing a plurality of vertical hydroponic towers, forming inset channels in the display backing allowing the plurality of vertical hydroponic towers to be inserted within the inset channels and stand flush with the face of the display backing, and moving excess liquid from the liquid introduction means not absorbed by the plants into the basin for transfer back to the liquid introduction means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a front elevational view illustrating a hydroponic produce display apparatus, constructed in accordance with the present invention, with the display skirt, drainage trough with grate cover, display backing, male brackets, overhead sprayers, and horizontal trough drip irrigation systems;
[0009] FIG. 2 is a front elevational view illustrating the plumbing and irrigation system of the hydroponic produce display apparatus of FIG. 1 , constructed in accordance with the present invention, including inflow and outflow valves with flood valve, pump, ultraviolet light sterilizer, diversion valves, overhead sprayer system, and horizontal trough drip irrigation systems;
[0010] FIG. 3 is a front elevational view illustrating the structural framework of the hydroponic produce display apparatus of FIG. 1 , constructed in accordance with the present invention;
[0011] FIG. 4 is a perspective view illustrating another embodiment of the hydroponic produce display apparatus, constructed in accordance with the present invention, with the base tank, the pump, the electrical cord, the irrigation tubing extending to the sprayer/dripper head, the bracket for securing the vertical tower to the support arm, the hole to receive the excess irrigation solution, and the maintenance port;
[0012] FIG. 5 is a front elevational view illustrating a bracket of the hydroponic produce display apparatus, constructed in accordance with the present invention;
[0013] FIG. 6 is a perspective view illustrating the bracket of the hydroponic produce display apparatus, constructed in accordance with the present invention;
[0014] FIG. 7 is a front view illustrating the hydroponic produce display apparatus, constructed in accordance with the present invention, with inset channels allowing vertical hydroponic towers to stand flush with a face of the display apparatus;
[0015] FIG. 8 is a front perspective view illustrating the hydroponic produce display apparatus, constructed in accordance with the present invention, with inset channels allowing vertical hydroponic towers to stand flush with the face of the display apparatus;
[0016] FIG. 9 is another front perspective view illustrating the hydroponic produce display apparatus, constructed in accordance with the present invention, with inset channels that allow vertical hydroponic towers to stand flush with a face of the display apparatus;
[0017] FIG. 10 is a rear perspective view illustrating the hydroponic produce display apparatus, constructed in accordance with the present invention, with inset channels that allow vertical hydroponic towers to stand flush with a face of the display apparatus;
[0018] FIG. 11 is a front view illustrating still another embodiment of the hydroponic produce display apparatus, constructed in accordance with the present invention; and
[0019] FIG. 12 is side perspective view illustrating the hydroponic produce display apparatus of FIG. 11 , constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] As illustrated in FIGS. 1-12 , the present invention is a hydroponic produce display apparatus, indicated generally at 10 , allowing in-store and market display of unpicked, growing vegetables and herbs to consumers. The hydroponic produce display apparatus 10 described herein sustains plant life and vitality by supporting the irrigation and display of discreet, modular hydroponic production containers 12 in various forms, including nutrient film technique troughs, drip technique troughs, aeroponic tubes, and vertical hydroponic towers.
[0021] Being lightweight and portable in design, the hydroponic produce display apparatus 10 of the present invention is easily transported from market to market as well as being permanently or semi-permanently plumbed and plugged into electrical outlets for long-term displays or in-home use. Since hydroponic containers 12 on display are exchanged on a regular basis to ensure proper plant growth- and as such, the hydroponic produce display apparatus 10 described herein is designed primarily to sustain plant appearance and vitality until on-site harvest at the market or store, not to provide plant nourishment or promote plant growth. However, by utilizing a nutrient solution the system, some embodiments of the present invention may be used for home and commercial hydroponic production.
[0022] In one embodiment of the hydroponic produce display apparatus 10 of the present invention, the hydroponic produce display apparatus 10 utilizes a rectangular basin 14 , rounded on the two narrow ends and varying in internal volume from fifteen (15 gal.) gallons to three (3 gal.) gallons. In addition, the basin 14 has a drain valve 16 with a hose fitting attached to its wall or base. The basin 14 is secured upon a steel framework 18 and enclosed in a decorative skirt 20 of wood, metal, or plastic varying in height from approximately six (6″) inches to approximately two (2′) feet, encircling the circumference of the basin 14 .
[0023] Flush with the top of the decorative skirt 20 runs a drainage trough circling the inner circumference of the decorative skirt 20 . The trough can be replaced with individual grates 22 in some embodiments. The trough or grate 22 has an internal return pipe at one end that transfers water from the trough down to the basin 14 resting in the middle of the display. The top of the trough is covered by the decorative grate 22 set in a plastic or metal drain that forms an inset approximately three (3″) inches to twelve (12″) inches in width. From the inner edge of the inset rises a display face constructed of wood, metal, or plastic flashing rising to the display top, either straight or tapering inward slightly as it rises, and rising to a height of approximately two (2′) feet to approximately eight (8′) feet. In some embodiments, the display face rises from the front of the grate 22 with inset channels 24 that hold vertical hydroponic towers 12 . In this embodiment, the grate 22 is mostly covered by the face of the display and the vertical towers 12 inset into the display rest on the grate 22 with their faces flush to the face of the display. The display face is fixed to a steel, wooden, or plastic framework. The top of the display can be open or covered by a plastic, wood, or metal decorative top.
[0024] The display face of the display can be configured in a number of ways meant to attach hydroponic towers or troughs 12 to the display. In one embodiment, the display face has the inset channels 24 that allow the vertical towers 12 to stand flush with the face of the display. In others, a series of brackets 26 of variable spacing, having flat, upward projecting hooks of metal for attaching vertical hydroponic towers 12 directly to the display. This hook corresponds with the complementary bracket on the backs of the vertical hydroponic towers. When attached, the vertical towers 12 stand upright, with the bottoms of the towers 12 resting on the grate 22 of the inset 24 , with one or more brackets 26 securing the tower 12 to the display. In this configuration, the plants growing in the towers face outward, away from the display. Towers 12 can be displayed on one side or both of the display or two displays can be place back to back to display completely encircling the display. Advertisement and information boards can also be attached to these brackets 26 offering information on the produce being marketed. When horizontal troughs are being secured to the display, a framework 30 is secured to the upper display brackets that support the horizontal troughs as a series of tapered shelves, with one end of all the troughs slightly elevated above the other to facilitate drainage. At the depressed end, a square or circular pipe stands vertically, with corresponding ports to receive the draining end of the troughs. The bottom of this drainpipe rests on the inset grate 22 and drains into the internal drainage trough. Depending on the type of display 10 , troughs will be displayed as above on both flat sides of the display 10 , with informational and advertisement boards displayed on the rounded ends of the display 10 . Irrigation of the displayed plants within the hydroponic produce display apparatus 10 of the present invention is accomplished using a tubing system 32 that rises either from the basin 14 in the display base, or from a three-way “Y” fitting having a valved hose fitting attached on one side, while on the other side interrupting the tubing system 32 above the basin. A pump rests in the basin 14 and pumps water from the basin 14 through a valve and through the “Y” fitting to an ultra violet sterilizer. Water flows through the sterilizer to the top of the display where a “tee” interrupts the irrigation tubing having a valve on both of the downstream ends allowing water to be diverted via valves to two different irrigation structures. The first irrigation structure is employed when vertical hydroponic towers are being displayed. It consists of a ring of irrigation tubing radiating from the center of the display to form a ring around the upper edge of the display backing. Misting, spraying or dripping nozzles are inserted into the irrigation tubing at appropriate intervals so that water is introduced to the tops of the hydroponic towers. The second irrigation option is employed when displaying horizontal hydroponic troughs and consists of a vertical drop-pipe that hangs over the exterior of the display back, on the end of the display that supports the raised ends of the hydroponic or aeroponic troughs. From this pipe feeder tubes emerge horizontally and are inserted into the raised ends of the hydroponic troughs. To the ends of these feeder tubes a variety of spraying, misting, and dripping nozzles can be attached, depending on display crop requirements.
[0025] In another embodiment of the hydroponic produce display apparatus of the present invention, as best illustrated in FIGS. 11 and 12 , hydroponic towers only are displayed, being held erect by a support arm 40 of metal attached to a plastic tank base 14 . Similarly to the above-described invention, the tower is irrigated from the top and drains into the basin/base 14 , which collects the irrigation solution to be pumped back to the top of the tower by a small submersible pump within the basin/base. This base 14 can rest upon a metal stand, rest directly on the floor, or have wheels to make transport easier. The cord for the pump emerges from the rear of the base tank. The base 14 may or may not have a cover for aesthetic appeal or to control algal growth within the base tank 14 . This particular embodiment is also well-suited to dual use for home hydroponic production as well as plant preservation and display.
[0026] The hydroponic produce display apparatus 10 of the present invention has the potential to dramatically increase both the shelf life and quality of produce at market as well as change consumer experiences at market. The apparatus 10 takes advantage of modularity in hydroponic production systems to introduce a new means of marketing produce to consumers, and to offer new methods incentives for wholesale and retail marketers to utilize locally-produced vegetables and herbs. Potential markets for the hydroponic produce display apparatus 10 include farmer's market retailers, commercial and restaurant kitchens, grocery stores and specialty crop stores as well as home produce consumers.
[0027] The hydroponic produce display apparatus 10 of the present invention is unique in form and function over traditional display technology has consisted of bins or containers with doors since the apparatus 10 is constructed to form a housing that incorporates unharvested plant propagation containers. It functions as a life-support system for hydroponic produce. The irrigation system 32 is essential to the function of the display allowing at-market displays that irrigate the roots of unharvested, living vegetables. The hydroponic produce display apparatus 10 is unique in application resulting in tangible benefits that offer a distinct advantage over the use of traditional bin and refrigerated displays, including elimination of spoilage (produce has an indeterminate shelf life), elimination of refrigeration costs (energy and equipment), allowing secondary use and distribution of uncut produce (eliminating another source of waste for producers), and elimination of most packaging and harvest-related labor costs for producers. The hydroponic produce display apparatus 10 provides either horizontal or vertical brackets or channels to retain horizontal or vertical plant production equipment and is essentially a storage device as much as a display device eliminating the need for refrigeration. Towers and troughs are exchanged by the producer on a regular basis with harvested containers being removed, and unharvested containers being installed in the hydroponic produce display apparatus 10 .
[0028] The foregoing exemplary descriptions and the illustrative preferred embodiments of the present invention have been explained in the drawings and described in detail, with varying modifications and alternative embodiments being taught. While the invention has been so shown, described and illustrated, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention, and that the scope of the present invention is to be limited only to the claims except as precluded by the prior art. Moreover, the invention as disclosed herein may be suitably practiced in the absence of the specific elements which are disclosed herein. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for the removal of hydrocarbons from soil, particularly in raising the temperature of soil containing hazardous, volatile hydrocarbons to facilitate the removal of these hydrocarbons through vapor extraction. This method is particularly well suited for the removal of hydrocarbons with relatively high boiling points and for the removal of hydrocarbons from soil containing clay or fine silt.
2. Brief Statement of the Prior Art
The improper disposal of hydrocarbons and the leakage of hydrocarbons from underground storage tanks has resulted in contamination of the ground and groundwater beneath every city and town in the developed countries of the world. Many techniques have been developed to remediate soil and groundwater contaminated with hydrocarbons. Some techniques are limited to the remediation of soil only; others remediate both the soil and the underlaying groundwater.
"Vapor extraction" is a common method of environmental remediation; this method draws vapors containing volatile hydrocarbons from the soil. As these vapors are withdrawn from the soil, the quantity of hydrocarbons remaining in the soil and the underlaying groundwater is gradually reduced. When vapor extraction is conducted long enough, the quantity of hydrocarbons remaining in the soil and groundwater are reduced to a point which is considered non-threatening to the public health. When the vapors are drawn from the soil and exhausted into the atmosphere, with or without treatment, the method is called "open-loop". When the vapors are drawn from the soil, treated, and pumped back down into the soil, the method is called "closed-loop".
Because the vapors drawn from the soil often contain hazardous hydrocarbons, local, state, or federal environmental regulations may require that the vapors be treated to prevent air pollution. When the treatment equipment generates heat, and this heat is used to heat the treated vapors prior to injecting them back into ground, the process is called "closed-loop, thermally-enhanced vapor extraction". The heated vapors slowly raise the temperature of the contaminated soil, thereby enhancing the vaporization of the remaining hydrocarbons in the soil.
"Pump and treat" is a common method of remediating contaminated groundwater only; it uses a well to extract contaminated groundwater from the ground. The extracted groundwater is treated to remove the dissolved and floating hydrocarbons before being discharged to a local sewer or surface water.
The prior art can be conveniently divided into four groups: closed-loop technologies, both thermally-enhanced (thermal) and non-thermally-enhanced (non-thermal); and open-loop technologies, both thermal and non-thermal. Techniques in these categories have been developed to simultaneously treat both soil and groundwater, groundwater only, soil only, and free (hydrocarbon) product only. They are summarized as follows:
Soil and Groundwater
Technologies which simultaneously treat both soil and groundwater include: a closed-loop, non-thermal process disclosed in U.S. Pat. No. 4,966,564 and entitled "Soil and Groundwater Remediation System" which issued Oct. 30, 1990 to Carberry; an open-loop, thermal process disclosed in U.S. Pat. No. 5,018,576 entitled "Process for In Situ Decontamination of Subsurface Soil and Groundwater" issued on May 28, 1991 to Udell et al.; and an open-loop, non-thermal process disclosed in U.S. Pat. No. 5,050,676 entitled "Process for Two Phase Vacuum Extraction of Soil Contaminants" issued on Sep. 24, 1991 to by Hess et al., in U.S. Pat. No. 4,945,988 entitled "Apparatus and Process for Removing Volatile Contaminants From Below Ground Level" issued on Sep. 24, 1991 to Payne et al., and in U.S. Pat. No. 4,832,122 entitled "In-Situ Remediation System and Method for Contaminated Groundwater" issued on May 23, 1989 to Corey et al.
Groundwater Only
Technologies which treat groundwater only include an open-loop, non-thermal process disclosed in U.S. Pat. No. 6,892,664, entitled "Decontamination of Sites Where Organic Compound Contaminants Endanger the Water Supply" issued on Jan. 9, 1990 to Miller.
Soil Only
Technologies which treat soil only include: a closed-loop, thermal process disclosed in U.S. Pat. No. 4,982,788, entitled "Apparatus and Method for Removing Volatile Contaminants from the Ground" issued on Jan. 8, 1991 to Donnely; two closed-loop, non-thermal processes disclosed in U.S. Pat. No. 4,890,673, entitled "Method for Removing Volatile Contaminants from Contaminated Earth Strata" issued on Jan. 2, 1990 to Payne, and that disclosed in U.S. Pat. No. 4,730,672, entitled "Method of Removing and Controlling Volatile Contaminants from the Vadose Layer of Contaminated Earth" issued on Mar. 15, 1988 to Payne; and an open-loop, non-thermal process disclosed in U.S. Pat. No. 4,886,119, entitled "Method of and Arrangement for Driving Volatile Impurities from the Ground" on Dec. 12, 1989 to Bernhardt et al; in U.S. Pat. No. 4,842,448, entitled "Method of Removing Contaminants from Contaminated Soil In Situ" on Jun. 27, 1989 to Koerner et al., and in U.S. Pat. No. 4,660,639, entitled "Removal of Volatile Contaminants from the Vadose Zone of Contaminated Ground" on Apr. 28, 1987 to Visser et al.; and in U.S. Pat. No. 4,593,760 , entitled "Removal of Volatile Contaminants from the Vadose Zone of Contaminated Ground" on Jun. 10, 1986 to Visser et al.
Free Product Only
Technologies which treat free product only include the open-loop, non-thermal process disclosed in U.S. Pat. No. 4,183,407, entitled "Exhaust system and Process for Removing Underground Contaminant Vapors" on Jan. 15, 1980 to Knopik.
Some of the above technologies use concepts found in processes developed to remove crude oil and other fuel hydrocarbons from the ground. These processes are summarized as follows:
Hydrocarbon Removal
Technologies which remove hydrocarbons from the ground include: closed-loop, thermal processes disclosed in U.S. Pat. No. 3,881,551, entitled "Method of Extracting Immobile Hydrocarbons" issued on May 6, 1975 to Terry et al. and disclosed in U.S. Pat. No. 4,303,127, entitled "Multistage Clean-Up of Product Gas from Underground Coal Gasification" issued on Dec. 1, 1981 to Freel et al.; and an open-loop, thermal process disclosed in U.S. Pat. No. 4,474,237, entitled "Method for Initiating an Oxygen Driven In-Situ Combustion Process" issued on Oct. 2, 1984 to Shu; and an open-loop, non-thermal process disclosed in U.S. Pat. No. 4,369,839, entitled "Casing Vacuum System" issued on Jan. 25, 1983 to Freeman et al. and disclosed in U.S. Pat. No. 4,345,647, entitled "Apparatus to Increase Oil Well Flow" issued on Aug. 24, 1982 to Carmichael.
Of the technologies cited above, six are closed-loop processes, of which three are thermal. Two of the three thermal technologies are used exclusively to recover hydrocarbon fuels; only one is used for environmental remediations. In the thermal process cited above is by Terry et al., it is not used for the environmental remediation of either soil or groundwater. Rather, it is used to extract a hydrocarbon fuel from deep beneath the earth. The process recirculates a heated fluid through a formation containing a solid hydrocarbon fuel. As the heated fluid passes through the formation, the solid fuel melts and flows through the formation to a well where it is pumped to the surface. The heat transfer medium is a liquid, not a gas.
In addition, there are fourteen open-loop processes, of which only two are thermal. Of the two thermal processes, one is used to recover hydrocarbon fuels, and one is used for environmental remediations.
Only two of the above processes, whether open or closed loop, are used for environmental remediation and employ heat. Donnelly employs a combination of heat from a heat pump and an independent electric coil to heat air drawn from contaminated soil before it is reinjected into the ground. Udell et al. simply injects live steam into the ground.
The technologies cited above which are used to recover hydrocarbon fuels employ heat by either circulating a heated fluid through the geological formation containing the fuel or by igniting the formation itself. Terry et al. circulates a heated fluid; Freel et. al. and Shu ignite the formation. Both are inefficient and are not effective for soil remediation.
In general, the above references fall short of the goals of performing adequate remediation for several reasons. For example, the non-thermal processes for remediating contaminated soil developed by Carberry, Morrow, Hess et al., Payne et al., Corey et al., Payne, Bernhardt et al., Koerner et al., and Visser et al. are generally limited to more volatile hydrocarbons such as those found in gasoline.
Although the processes developed by Udell et al. and Donnelly do heat the soil, they are substantially complex and quite expensive to operate. In the case of Udell et al., steam is injected into the ground where it condenses. The condensing steam heats the soil and volatilizes high-boiling hydrocarbons, but as the condensed steam migrates vertically through the soil, it leeches hydrocarbons out of the soil. When the condensed steam reaches the underlaying water table, it contaminates the groundwater. Special ground-water extraction wells are needed to extract and treat the contaminated groundwater from the ground. The cost of operating the steam boilers and extracting and treating the contaminated groundwater is very substantial. Further, none of the energy contained in the hydrocarbons removed from the soil is used to operate the process.
The process developed by Donnelly is also expensive to operate, and, again, none of the energy contained in the hydrocarbons removed from the soil is used to operate the process. The Donnelly process has the additional limitation of using a refrigerated coil to remove hydrocarbons from vapors drawn from the soil before these vapors are heated and reinjected back into the soil. Unless the refrigerated coil is operated in the cryogenic temperature range which would capture all of the hydrocarbons, which is unlikely due to the prohibitive cost, the vapors reinjected into the ground will contain significant amounts of hydrocarbons. Consequently, the Donnelly process actually recirculates hydrocarbons through the soil. This scheme limits the extent of remediation which can be achieved.
In a typical soil remediation, the soil is often a mixture of sand, silts, and clays which may be present in discrete layers, called lenses. When this soil is remediated using non-thermal vapor extraction, as demonstrated by the patents cited above, the hydrocarbons held by the silts and clays are very difficult to remove. Due to their high surface areas, clays and silts have a strong affinity for hydrocarbons and retard their volatilization.
SUMMARY OF THE INVENTION
The invention is a closed-loop, thermal process for remediating soil contaminated with volatile hydrocarbon chemicals. It is particularly well suited for the remediation of soils containing hydrocarbons with relatively high boiling points and for soils which contain clays or silts. The process uses a combination of at least one extraction well which is used to withdraw vapors from contaminated soil and at least one injection well, called a "fire" well which is used to burn all of the hydrocarbons present in the recovered vapors and then inject the combustion gases into areas in and about the contaminated soil. The heat in the combustion gases is used to raise the temperature of the contaminated soil and volatilize hydrocarbons in the soil.
In practice, fuel gas and air are introduced into the top of a burner located on top of a fire well where they are mixed and ignited to produce a flame; the flame projects downward from the burner into the fire well. A vacuum pump is used to draw hydrocarbon-bearing vapors from contaminated soil. These vapors are introduced into the flame section of the fire well beneath the burner, where they are ignited, producing additional heat. The ignited gases continue downward and exit at the bottom of the fire well through perforations provided for this purpose.
The combustion gases are pumped into the soil surrounding the fire well under positive pressure. The extraction wells surrounding the fire well are under negative pressure and help to draw the combustion gases through the soil. The combustion gases raise the temperature of the soil and cause the hydrocarbons contained in the soil to vaporize and flow toward the extraction wells.
In addition to providing a method for remediating soil containing hydrocarbons with relatively high boiling points, as described above, the present invention presented here provides a method for removing hydrocarbons which are adsorbed onto soils containing clays and silts. Dielectric heating can be used to supplement the heating performed by the combustion gases. In practice, the positive terminal of a direct-current power supply is attached to the metallic fire well. The negative terminal is attached to several conducting rods which are driven into the soil surrounding the fire well. As electrical current flows through the soil from the conducting rods to the fire well, the soil through which the current passes heats up.
Heating the soil permits remediating soil containing hydrocarbons with relatively high boiling points. The present invention is able to remediate soil containing hydrocarbons with much higher boiling points such as those found in diesel fuel.
By placing the openings of the fire well either in or below the clayey soil, the heat from the combustion gases exiting the fire well will spread laterally and vertically throughout the clayey soil. This effect is particularly noticeable when the hot combustion gases from the fire well are released into sandy soil below a clay lens. The hot combustion gases spread laterally through the sandy soil below the clay lens and heat a wide portion of the clay lens. As the clay is heated, volatile hydrocarbons held by the clay are slowly released.
The effect of dielectric heating is also more pronounced when remediating clay lenses. In a typical soil remediation, clay lenses will be separated by sandy soil. Due to their respective differences in surface area, the clay lenses often contain a higher concentration of hydrocarbons than the surrounding sand. Placing the conducting rods in the clay lenses, which hold more water than the surrounding sand, provides a preferential path through which the electrical current will flow. In this manner, the clay lenses are heated to a much greater extent than the sand for the surrounding sand. This is precisely the effect that is desired. The soil containing the higher concentration of hydrocarbons receives the most heat.
BRIEF DESCRIPTION OF THE DRAWING
The benefits and advantages of the present invention will be best shown with reference to the drawing of which Figure is a schematic diagram of the process shown with respect to a side sectional view of the ground layers in which remediation is to be performed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the present invention employs two separate types of wells to remediate soil which is contaminated with hazardous volatile hydrocarbons. The structures will be first described for identification before a description of the operation. Beginning at the left side of the Figure, the above ground level is demarcated by a grade 11 line. Above grade 11, a propane gas storage tank 13 is supported. Tank 13, as well as other vessels and equipment of FIG. 1 may be truck mounted or skid mounted and may therefore have a common means of support to provide greater ease of operation an mobility.
The tank 13 is shown with grade 11 level mounting legs 15. Extending from the tank 13 is a propane gas supply line 17 connected to a valve 19. Valve 17 has a pressure tap leading to a pressure indicator 21. As is shown, pressure indicator 21 can be used to regulate valve 17. Valve 19 is connected to a valve 25. Valve 25 is connected to a valve 29. Valve 25 has a pressure tap leading to a pressure indicator 27. As is shown, pressure indicator 27 can be used to regulate valve 25. Valve 25 is connected to a motorized valve 29. Motorized valve 29 is controllably connected to pressure limit switch actuators 31 and 33. Pressure limit switch actuators 31 and 33 have a pressure tap connection to the other side of valve 29.
A valve 35 is also connected to valve 29. Valve 35 is connected to a flow indicator 37, which may be a visual flow indicator, either analog or digital. Valve 35 and flow indicator 37 are connected to a flow control valve 39. Flow control valve 39 is connected to a shutoff valve 41. The other side of shutoff valve 41 is in communication with the internal portion of a fire well 45.
Fire well 45 extends both above and below grade 11. Looking below the grade 11, and along the extent of fire well 45, it can be seen that fire well 45 is shown extending through a first sandy soil layer 47, a clay bearing soil layer 49 and into a second sandy soil layer 51. Fire well 45 is a continuous casing and may be made of metal in direct contact with the soil layers 47, 49, and 51. It is understood that multiple layers may be present, and that the fire well may extend through several layers of differing depth and several alternating layers of different types of material. At the lower extent of fire well 45, as it extends into layer 51, the fire well is fitted with a series of exit perforations 53. In the Figure, the exit perforations occur at the layer 51, and beneath the clay bearing layer 49.
Referring to the right side of the Figure, an air filter 55 is connected to the suction side of an air blower 57. The outlet of the blower is connected to a pressure indicator 59, flow control valve 61, check valve 63 and flow indicator 65. The check valve 63 is also connected to a flow control valve 67. The actuator of flow control valve 67 may be linked to the actuator of flow control valve 39 such that flow control valves 67 and 39 may be actuated in concert with each other. Flow control valve 67 is connected to one end of another flow control valve 69. The other end of flow control valve 69 is connected to the end of the fire well 45.
Fire well 45 also has a tap 71 leading to a flame (burner) sensing switch 73 which is used to control valve 29, along with inputs from pressure limit switch actuators 31 and 33. Fire well 45 also has a recirculation inlet 75, shown slightly above grade 11. Fire well 45 is also shown with a broken line along its length to illustrate the fact that it may be of any length. A series of arrows are shown at the lowermost portion of fire well 45, and adjacent the exit perforations 53, to indicate the flow of hot combustion products from the fire well 45.
To the right of the fire well 45 is a vapor-extraction well 77. Vapor-extraction well 77 similarly has a series of perforations, however these are inlet perforations 81. Typically, but not always, vapor-extraction well 77 may be shorter than fire well 45. The inlet perforations 81 are shown as being in a sandy soil layer 47, which is above the clay bearing layer 49. The vapor-extraction well 77 extends above grade 11 and communicates through a withdrawal port, shown in the Figure as being its upper end, with a pressure indicator 83, a temperature indicator 85, and a knockout pot 87.
Knockout pot 87 has a level gauge 89 and a drainage valve 91. An overhead line 93 connects the knockout pot 87 with the suction side of a vacuum pump 95. The outlet of vacuum pump 95 communicates with the recirculation inlet 75 of the fire well 45 through a series combination of a flow control valve 97, a check valve 99, and a flow indicator 101. Along this line of fluid communication there is a pressure indicator 103 located nearer the outlet of the vacuum pump 95 and a sample port 105 located nearer the recirculation inlet 75 of the fire well 45.
Also extending below grade 11 is one or more conducting rods 111. Conducting rod 111 may have any portion of their length exposed or insulated. For example, conducting rod 111 may have its lower length exposed and its upper length insulated. Conducting rod 111 is powered by either a direct-current or alternating-current power supply 113. The power supply 113 may also be connected, as is shown in the Figure, to the fire well 45. Alternatively, the power supply 113 may be connected to another conducting rod 111, to produce a voltage difference between several conducting rods 111 and the fire well 45, or to produce a voltage difference between one or more conducting rods 111 and another set of one or more conducting rods 111. In the configuration of the Figure, the conducting rod 111 is installed to pass current through the clay bearing soil layer 49, between the conducting rod 111 and the fire well 45.
The temperatures at various points in the configuration of the Figure may be measured to monitor the progress of the remediation activity. A first temperature probe rod 121 is inserted below grade and shown to the left of the conducting rod 111. The temperature probe rod 121 can have a temperature indicating device, such as a thermocouple or multiple thermocouples at any point or points along its length. For example, the temperature indicating elements could be arranged to allow measurements to be taken at each of the first sandy soil layer 47, clay bearing soil layer 49 and second sandy soil layer 51. The temperature probe rod 121 is configured to measure the temperature surrounding the fire well 45.
Another temperature probe rod 123 is configured to measure the temperature in the first sandy soil layer 47, between the fire well 45 and the vapor-extraction well 77. Other temperature probe rods similar to the temperature probe rods 121 and 123 may be employed. Temperature probe rod 121 is connected to temperature-sensing element 125 while temperature probe rod 123 is connected to temperature-sensing element 127. Another temperature-sensing element 129 is connected, as shown partially in dashed line format, to a temperature element (not shown) at some length within the fire well 45. The temperature-sensing elements 127, 125 and 129 are connected to temperature recorder 131, so that the process operating temperatures of the remediation process may be measured. In addition, a pressure indicator 135 is also attached to the upper end of fire well 45 to indicate the back pressure within the fire well 45.
The operation of the remediation device and process of the present invention is as follows. The process removes hydrocarbons from contaminated soil by injecting hot combustion gases directly from a gas burner (the details of which are not shown, but which will be referred to as burner 137), forming the upper section of the fire well 45, into soil located below grade 11. The burner 137 forms the upper section of the fire well 45, and the combustion gases exit at the base of the well through the exit perforations slots provided for this purpose. As the soil adjacent to the well, and particularly the second sandy soil layer 51 is heated, hydrocarbons, eventually within all of the first sandy soil layer 47, clay bearing soil layer 49, and second sandy soil layer 51 are volatilized and withdrawn from the soil through the vapor-extraction well 77. From the vapor-extraction well 77, the vapors pass through the knock out pot 87 where entrained water in these vapors is removed, and which may be periodically drained through drainage valve 91. The vacuum pump 95, which may be a blower similar to air blower 57, feeds these hydrocarbons into the recirculation inlet 75 where they are ignited, producing additional heat. The heat produced by burning these hydrocarbons accelerates the removal of more hydrocarbons from the soil, which in turn produces even more heat. The flow of hydrocarbon-bearing vapors directed into the fire well are measured with a flow indicator 101. The area adjacent the recirculation inlet 75 is kept hot enough to combust these hydrocarbons as they enter the fire well 45.
The air blower 57 is in communication with the air-inlet port of the burner 137, and the flow of air is measured with a flow indicator 65. The flow of propane and air is controlled with standard flow control valves 39 and 67 designed for this purpose. The propane and air are mixed inside the burner 137 and ignited to produce a flame; the flame projects downward from the burner 137 into the fire well 45. The ignited gases continue downward and exit at the bottom of the fire well 45 through exit perforations 53 provided for this purpose.
The hot combustion gases urged into the first sandy soil layer 51 spread out beneath the contaminated clay bearing soil layer 49, raising the temperature of the contaminated clay bearing soil layer 49. As the temperature of the contaminated clay bearing soil layer 49 is raised, hydrocarbons contained within this soil are volatilized and drawn toward the inlet perforations 81 of the vapor-extraction well 77.
In addition to using a hot gas to apply heat to the soil, the soil may be heated dielectrically. This is accomplished by passing a current through the soil from conducting rod 111 placed in the soil, below grade 11, and downwardly through the clay bearing soil layer 49, and to the casing of the metallic fire well. The amount of heat applied to the soil is proportional to the amount of current flowing through the soil.
The power supply 113 is shown connected to both the fire well 45 and conducting rod 111 such that the a weak electrical current is established between the conducting rod 111 and the fire well 45. When a direct-current (DC) power supply is used, the conducting rod 111 functions as the negative pole (cathode) of a DC circuit, and the fire well 45 functions as the positive pole (anode) of the circuit.
Heating the soil, including the first sandy soil layer 47, clay bearing soil layer 49, and second sandy soil layer 51, accomplishes at least two goals. First, relatively non-volatile hydrocarbons such as those found in diesel fuel are vaporized and removed from the soil. Conventional, non-thermal vapor extraction is generally limited to relatively volatile hydrocarbons such as those found in gasoline. Secondly, as the soil is heated, and the vapor pressure of the volatile hydrocarbons in the soil is increased, the time required to remediate the soil is reduced.
Temperatures are monitored using temperature-sensing elements: temperature element 125 is used to monitor the temperature of the first sandy soil layer 51 in proximity to the discharge of the fire well 45; temperature element 127 is used to monitor the temperature of the second sandy soil layer 57 in proximity to the inlet of the vapor-extraction well 77; and temperature element 129 is used to monitor the temperature in a flame section 141 of the fire well 45 which is generally shown as extending between recirculation inlet 75 and tap 71. These temperatures may be recorded continuously on the temperature recorder 131.
Pressures are monitored using pressure-sensing elements: pressure indicator 135 is used to measure the pressure at the top of the fire well 45; pressure indicator 83 is used to measure the vacuum at the top of the vapor-extraction well 77; pressure indicator 21 is used to measure the pressure in the propane storage tank 13; and pressure indicator 27 is used to measure the pressure of the propane supplied to the burner.
Progress in remediating the soil, including first sandy soil layer 47, clay bearing soil layer 49 and second sandy soil layer 51 may be monitored by periodically analyzing samples of the vapors drawn from below grade 11 through vapor-extraction well 77. Sample port 105 is used to collect these vapor samples. When the hydrocarbon concentration in these vapors has fallen below a critical level, the soil has been remediated.
Because the volatile hydrocarbons removed from the soil are generally hazardous, state and federal laws often prohibit their release into the atmosphere without treatment. Treating the hydrocarbon vapors drawn from the soil, however, raises the cost of vapor extraction. In addition, heating the soil also raises the cost of vapor extraction. The instant art accomplishes both treatment of the vapors withdrawn from the soil and heating of the soil in a very simple and cost-effective manner. Further, because there are no emissions to the atmosphere, an operating permit from an agency regulating atmospheric emissions is not even required. All of this is accomplished by using the vapors drawn from the soil as fuel for the fire well.
Donnelly, in the previously mentioned U.S. Pat. No. 4,982,788 attempts to employ the advantages of the present invention, yet falls short in several aspects. Although there are no emissions to the atmosphere, the heat recovered from the emission-control device, which is a simple refrigerated coil driven by a heat pump, is minimal. A secondary heat source, such as an electric heater, is needed to significantly raise the temperature of the soil. The cost of operating the electric heater is a drawback. Additionally, although a portion of the hydrocarbons extracted from the ground are recovered, the condensed liquid has little, if any value. The water vapor naturally present in the soil condenses with the hydrocarbons, forming a mixture of water and hydrocarbons. Such a mixture must often be discarded as a hazardous waste, further adding to the cost of the process. Finally, the concentration of hydrocarbons in the vapors extracted from the contaminated soil is typically less than 1,000 parts per million. Consequently, unless it is operated in the cryogenic range, the condensing coil used to remove hydrocarbons from the extracted vapor will operate inefficiently, and hydrocarbon vapors will be reinjected into the contaminated soil. In summary, at best, the Donnelly process does little to offset the cost of non-thermal vapor extraction, and at worst may be both ineffective and more expensive.
By comparison, the present invention has no waste products to dispose of, and the fuel value of the extracted hydrocarbons is utilized to help to power the process. It represents a clear advance over both the current art in conventional, non-thermal vapor extraction practiced by Payne, Bernhardt et al., Koerner et al., and Visser et al., and the current art in thermal vapor extraction, practiced by Donnelly. In comparison to the Shu process, virtually all of the vapors drawn from the extraction well employed by the present invention are reinjected back into the soil through an injection well containing a burner. Essentially all of the energy in the vapors drawn from the extraction well is used as fuel to operate the burner, unlike the Shu process which uses formation ignition surrounding the well sustained only by injecting an appropriate amount of oxygen into the formation.
While the present invention has been described in terms of a vapor extraction system for removing hydrocarbons from soil, one skilled in the art will realize that the structure and techniques of the present invention can be applied to many situations. The present invention may be applied in any situation where vaporous species need removal.
Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art. | 4y
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FIELD OF THE INVENTION
The present invention relates generally to the field of chemical vapor deposition (CVD) in semiconductor device manufacturing, and more specifically to a method for cleaning and preconditioning a dome in a CVD system.
BACKGROUND OF THE INVENTION
Chemical vapor deposition (CVD) processes are used widely in the manufacture of semiconductor devices. Generally, CVD involves exposing a semiconductor wafer to a reactive gas under carefully controlled conditions including elevated temperatures, sub-ambient pressures and uniform reactant gas flow rate, resulting in the deposition of a thin, uniform layer or film on the surface of the substrate. The undesired gaseous byproducts of the reaction are then pumped out of the deposition chamber. The CVD reaction may be driven thermally or by a reactant plasma, or by a combination of heat and plasma. CVD systems in which the reaction is driven by a reactant plasma are known as plasma-assisted or plasma-enhanced.
A typical plasma-enhanced CVD system is a single-wafer system utilizing a high-throughput CVD chamber. The chamber typically comprises an aluminum oxide (Al 2 O 3 ) dome, an induction coil that is provided in an expanding spiral pattern adjacent to the dome and outside the chamber, at least one gas injection nozzle, and a vacuum pump for evacuating the gaseous byproducts of the CVD process from the chamber. RF power is applied to the induction coil to generate a reactive plasma within the chamber. A cooling fluid, such as cooling water, is also typically flowed through the induction coil, either from the bottom of the dome to the top of the dome, or from the top of the dome to the bottom of the dome.
A typical CVD process begins with heating of the CVD chamber. A semiconductor substrate is placed in the chamber on a receptor, also known as a susceptor, which is typically made of ceramic or anodized aluminum. Next, reactant gases are introduced into the chamber, while regulating the chamber pressure. The gases react in the chamber to form a deposition layer on the surface of the wafer.
In a typical deposition process, reactant gases enter the reaction chamber and produce films of various materials on the surface of a substrate for various purposes, such as for dielectric layers, insulation layers, etc. The various materials deposited include epitaxial silicon, polysilicon, silicon nitride, silicon oxide, and refractory metals such as titanium, tungsten and their suicides. Much of the material produced from the reactant gases is deposited on the wafer surface. However, some material also is inevitably deposited on other surfaces inside the chamber. These deposits must be removed periodically to prevent them from building up to the point where particulate contamination is generated, which can cause opens or shorts in the microelectronic device.
The material which is deposited on the interior chamber walls is usually deposited with a nonuniform thickness. This nonuniformity in thickness results in part from a temperature gradient in the dome produced by cooling water flowing through the induction coil. For example, if cooling water enters the induction coil at the bottom of the dome and exits at the top of the dome, then the dome will be slightly cooler at the bottom than at the top, because the cooling water is gradually heated as it flows through the coil. This temperature gradient within the dome will result in a deposition thickness which is greater at the bottom than at the top.
In a typical CVD system, after one or more deposition processes wherein a film is deposited onto a semiconductor substrate and the substrate is removed from the chamber, a cleaning gas or mixture of cleaning gases is purged through the reaction chamber in order to clean unwanted deposits from the chamber interior surfaces, including the chamber walls and the susceptor. For cleaning silicon dioxide (SiO 2 ) films from the chamber interior, a typical cleaning gas system comprises fluorinecontaining gases, such as a mixture of nitrogen trifluoride (NF 3 ) and hexafluoroethane (C 2 F 6 ). A plasma gas is typically ignited in the chamber to enhance the efficiency of the cleaning gas mixture. The plasma creates fluorine radicals which react with the SiO 2 film under the influence of ion bombardment to form SiF 4 and other volatile compounds, which are then pumped out of the reaction chamber by the vacuum pump.
However, some of the fluorine-containing species in the cleaning gas also react with the Al 2 O 3 in the dome to form AlF 3 , especially in areas of the dome where SiO 2 coverage is thinner. For example, if the direction of cooling water flow is from the bottom of the dome to the top, then SiO 2 coverage will be thinner at the top. Therefore, with uniform cleaning rates throughout the chamber, the SiO 2 at the top of the dome will be removed before it is completely removed at the bottom of the dome. To achieve complete removal of deposited SiO 2 at the bottom of the dome, the top of the dome will be “over-cleaned,” resulting in conversion of Al 2 O 3 at the top of the dome to AlF 3 .
This problem of over-cleaning is exacerbated by the temperature gradient in the dome discussed previously. If the direction of cooling water flow is from the bottom of the dome to the top, then the dome is slightly cooler at the bottom, resulting in poorer cleaning efficiency at the bottom. To achieve complete removal of deposited SiO 2 at the bottom of the dome, over-cleaning to an even greater extent will result at the top of the dome.
Therefore, after each cleaning step, it is necessary to precondition or passivate the dome, in order to convert the AlF 3 species on the dome back to Al 2 O 3 . A typical preconditioning process comprises introducing H 2 , and then a mixture of H 2 and O 2 into the chamber. It is believed that the initial amount of H 2 reacts with AlF 3 species on the dome to partially passivate the dome, producing some Al 2 O 3 and intermediate Al y O x and Al y O x F z species. (In the variable stoichiometric formulas presented throughout this document, such as Al y O x and Al y O x F z , the variables x, y and z represent, independently, integer or fractional numbers, and may be the same or different.) The subsequent mixture of activated H 2 and O 2 reacts with these intermediate species to form Al 2 O 3 . Byproducts of this reaction include hydrofluoric acid (HF) and water. The production of water as a byproduct severely limits the passivation reaction, because water is a contaminant which is very difficult to remove once absorbed on the dome surface. In addition, HF combines with water to form aqueous HF, which is also a very difficult species to remove once absorbed. Therefore, the presence of water and aqueous HF prevent overpassivation and often result in incomplete passivation of the dome, leaving some of the AlF 3 species on the dome.
The presence of some AlF 3 species on the dome during subsequent processing in the CVD chamber can cause significant particulate contamination. During deposition, the AlF 3 species may react with process gases to form gaseous byproducts, which will release particulate contamination. Specifically, it is believed that AlF 3 reacts with process gases such as N 2 , SiH 4 and H 2 to form gaseous byproducts such as HF, SiF 4 and NF 3 . The conversion of AlF 3 to these gaseous byproducts causes the release of films which have been deposited on top of the AlF 3 species. The release of these films creates particulate contamination, which can severely impact microelectronic device yield and reliability.
The problem of incomplete passivation is of particular concern when depositing silicon nitride (SiN) films. Because SiN forms a different bond with Al 2 O 3 and AlF 3 than does SiO 2 , particle formation as a result of weaker adhesion of subsequently deposited films during deposition is more likely. For example, particulate contamination may be generated as a result of stress-induced de-adhesion of pre-coat during the deposition of product.
SUMMARY OF THE INVENTION
The present invention eliminates the aforementioned problems by providing a method for cleaning and preconditioning the dome of a CVD chamber.
In a first aspect of the present invention, a method is provided for preconditioning a dome of a chemical vapor deposition chamber, comprising the steps of: introducing hydrogen gas into said chamber; generating a reactive plasma of said hydrogen gas in said chamber; introducing a mixture of hydrogen gas and nitrogen gas into said chamber; and generating a reactive plasma of said mixture of hydrogen gas and nitrogen gas in said chamber.
In another aspect of the present invention, a method is provided for cleaning a dome of a chemical vapor deposition chamber, wherein said dome is cooled during deposition by flowing a cooling fluid in a first direction through an induction coil having multiple windings provided in an expanding spiral pattern in said dome. The method comprises the steps of: flowing said cooling fluid in a second direction through said induction coil, such that said second direction is opposite said first direction; introducing at least one cleaning gas into said chamber; and generating a reactive plasma of said cleaning gas.
In yet another aspect of the present invention, a method is provided for cleaning and preconditioning a dome of a chemical vapor deposition chamber, wherein said dome is cooled during deposition by flowing a cooling fluid in a first direction through an induction coil having multiple windings provided in an expanding spiral pattern in said dome. The method comprises the steps of: flowing said cooling fluid in a second direction through said induction coil, such that said second direction is opposite said first direction; introducing at least one cleaning gas into said chamber; generating a reactive plasma of said cleaning gas; evacuating said cleaning gas from said chamber; flowing said cooling fluid in said first direction through said induction coil; introducing hydrogen gas into said chamber; generating a reactive plasma of said hydrogen gas in said chamber; introducing a mixture of hydrogen gas and nitrogen gas into said chamber; and generating a reactive plasma of said mixture of hydrogen gas and nitrogen gas in said chamber.
A preferred apparatus for cooling a dome of a chemical vapor deposition chamber is also provided, wherein said dome has a top and a bottom, and said dome comprises an induction coil which is comprised of copper tubing and has multiple windings provided in an expanding spiral pattern in said dome. The apparatus comprises a first connection point at a first end of said copper tubing, for connecting a cooling fluid supply to said copper tubing; a second connection at a second end of said copper tubing, for connecting a cooling fluid return to said copper tubing; first and second valves provided between and in fluid communication with said first connection point and said dome, wherein said first valve is in fluid communication with the top of said dome and said second valve is in fluid communication with the bottom of said dome; third and fourth valves provided between and in fluid communication with said second connection point and said dome, wherein said third valve is in fluid communication with the top of said dome, and said fourth valve is in fluid communication with the bottom of said dome.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The drawings are for illustration purposes only and are not drawn to scale. Furthermore, like numbers represent like features in the drawings. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic view of a typical CVD system;
FIG. 2 is a more detailed view of a portion of a typical CVD system; and
FIG. 3 is a schematic view of a CVD system which includes a cleaning apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The problems of over-cleaning and incomplete passivation can be eliminated by using the cleaning and preconditioning method of the present invention.
FIG. 1 shows a typical CVD system 100 comprising a dome 101 , wafer susceptor 102 , process gas injector 103 , cleaning gas injector 104 , and exhaust manifold 105 . Dome 101 is typically made of an insulating dielectric, such as Al 2 O 3 . Dome 101 includes an induction coil 110 , which is provided in an expanding spiral pattern. FIG. 2 shows a detail of the expanding spiral pattern of induction coil 110 . RF power 111 is applied to induction coil 110 to generate a reactive plasma inside the chamber. Induction coil 110 is typically made of copper tubing, within which a cooling fluid, such as cooling water, is flowed. Cooling water may enter the copper tubing at connection 112 at the bottom of the dome, passing through valve 113 , and then exit the copper tubing at connection 114 at the top of dome, passing through valve 115 . Alternatively, cooling water may flow through the copper tubing from connection 114 at the top of the dome to connection 112 at the bottom of the dome.
A typical CVD process begins with heating of the CVD chamber. A semiconductor substrate is placed on susceptor 102 , which is shown in FIG. 1 in an upper position 102 a and a lower position 102 b . A semiconductor wafer is placed on susceptor 102 while in lower position 102 b , and then susceptor 102 is raised into the chamber to upper position 102 a . Next, reactant gases are introduced into the chamber through process gas injector 103 . Often, as many as eight process gas injectors may be present in the chamber, although only one injector 103 is shown for simplicity. The process gases react in the chamber to form a deposition layer, such as SiO 2 or SiN, on the surface of the wafer. The deposition process may be assisted or enhanced by the generation of a reactive plasma inside the chamber. A plasma maybe generated by applying RF power 111 to induction coil 110 .
In addition to forming a deposition layer on the surface of the wafer, the CVD process also forms a film on the interior surfaces of dome 101 . During deposition, if cooling water is flowed through induction coil 110 from connection 112 at the bottom of the dome to connection 114 at the top of the dome, then the deposited film on dome 101 will be thicker at the bottom of the dome than at the top of the dome.
Following deposition of a film, such as SiO 2 or SiN, the CVD chamber is generally cleaned using a conventional cleaning process wherein at least one fluorine-containing cleaning gas is introduced into the chamber through cleaning gas injector 104 . More than one cleaning gas injector may be present in the chamber, although only one injector 104 is shown for simplicity. As discussed previously, in areas of the dome where the film deposition is thinner, some of the Al 2 O 3 dome is often converted to AlF 3 during a conventional cleaning. This nonuniformity in film thickness results from a temperature gradient in the dome during deposition caused by the flow of cooling water through the induction coil. To achieve complete cleaning of areas on the dome having thickest deposition coverage, areas with thinner coverage will be over-cleaned, resulting in conversion of Al 2 O 3 to AlF 3 . The same temperature gradient during cleaning results in nonuniform cleaning efficiency, thus exacerbating the problem of over-cleaning.
For example, if cooling water flows through induction coil 110 from connection 112 at the bottom of the dome to connection 114 at the top of the dome, then a temperature gradient will be created wherein the bottom of the dome is slightly cooler than the top of the dome. As a result, the deposition layer will be thickest at the bottom of the dome, but the cleaning efficiency also will be poorer at the bottom of the dome. To achieve complete cleaning of the thickest films at the bottom of the dome, the top of the dome will be over-cleaned, resulting in conversion of some Al 2 O 3 to AlF 3 at the top of the dome.
This problem of over-cleaning can be addressed by the cleaning method of the present invention, which comprises reversing the direction of flow of the cooling water. For example, if during deposition the cooling water flows through induction coil 110 from the bottom of the dome to the top of the dome, then during the cleaning method of the present invention the cooling water flows in the opposite direction, from the top of the dome to the bottom of the dome.
Reversing the direction of flow of the cooling water can be accomplished, for example, by simply disconnecting the water supply from connection 112 and reconnecting it to connection 114 . Alternatively, reversing the direction of cooling water flow can be accomplished by using the apparatus shown in FIG. 3 . In FIG. 3, two cooling water connections 112 and 114 are provided which are in fluid communication with induction coil 110 . Two valves 113 and 116 are provided between and in fluid communication with connection 112 and induction coil 110 . Valve 113 is in fluid communication with the bottom of the dome, and valve 116 is in fluid communication with the top of the dome. Similarly, two valves 115 and 117 are provided between and in fluid communication with connection 114 and induction coil 110 . Valve 115 is in fluid communication with the top of the dome, and valve 117 is in fluid communication with the bottom of the dome. If it is desired to flow cooling water from the bottom of the dome to the top of the dome during deposition, this can accomplished by either of two arrangements. First, cooling water may be supplied through connection 112 , with valves 113 and 115 in the open position, and valves 116 and 117 in the closed position. During cleaning, valves 113 and 115 are closed, and valves 116 and 117 are opened, thereby flowing cooling water from the top of the dome to the bottom of the dome. In the second arrangement, cooling water may be supplied through connection 114 , with valves 117 and 116 in the open position, and valves 115 and 113 in the closed positions. During cleaning, valves 117 and 116 are closed, and valves 115 and 113 are opened. Using either of these arrangements, the cooling water supply need not be disconnected and reconnected between deposition and cleaning steps.
When the flow of cooling water is reversed, the temperature gradient in the dome is also reversed, so that the bottom of the dome is slightly warmer than the top during cleaning. As a result, the cleaning efficiency is slightly greater at the bottom of the dome where the deposition film is thickest. The thicker film at the bottom of the dome will be removed at a faster rater than the thinner film at the top of the dome, resulting in reduced over-cleaning of areas with thinner deposits, and reduced conversion of Al 2 O 3 to AlF 3 .
Nevertheless, even with the flow of cooling water reversed during cleaning, to ensure complete cleaning it is inevitable that some Al 2 O 3 will be converted to AlF 3 . Preconditioning of the dome to convert the AlF 3 species back to Al 2 O 3 prior to further CVD processing is therefore necessary. As discussed previously, conventional preconditioning processes produce undesirable contaminants such as water and aqueous HF, therefore precluding overpassivation and often resulting in incomplete passivation. “Overpassivation” in this context can be defined as passivation past the stoichiometric equivalence point in localized areas within the dome, but not necessarily past the overall average endpoint throughout the dome.
In the preconditioning method of the present invention, no undesirable contaminants are produced. Therefore, the passivation reaction need not be limited, and overpassivation is possible. After evacuating the cleaning gases from the chamber, the preconditioning method of the present invention begins with an initial H 2 passivation step comprising introduction of H 2 through cleaning gas injector 104 , and generation of a reactive plasma of the H 2 by applying RF power 111 to induction coil 110 . It is believed that this initial H 2 passivation step produces some Al 2 O 3 as well as intermediate Al y O x and Al y O x F z species. Then, a mixture of H 2 and N 2 is introduced into the chamber through cleaning gas injector 104 , and a plasma of this mixture is generated by applying RF power 111 . It is believed that the intermediate Al y O x and Al y O x F z species react with N 2 to form Al y O x N z and AlN. All other byproducts of the reaction, such as NH 3 , NH 4 F, NF 3 , and various excited NF x and AlF y species, are gaseous and are therefore removed from the chamber through exhaust manifold 105 by the vacuum pump. No undesirable water or other aqueous byproducts are formed. Thus, the passivation reaction need not be limited to prevent production of undesirable byproducts, and the dome can be completely passivated.
An added advantage of this preconditioning method can be realized during subsequent deposition of SiN films. It is believed that following preconditioning by the method of the present invention, the dome is comprised of an outer Al 2 O 3 layer, an intermediate Al y O x N z layer, and an inner AlN layer exposed to the chamber. When a SiN film is subsequently deposited on the exposed AlN layer of the dome, it is believed that an intermediate Si y Al x N z species is formed between the AlN and SiN, thereby providing a stronger bond between the AlN and SiN. This stronger interface reduces the likelihood that portions of the SiN film will be released, causing particulate contamination.
The initial H 2 passivation step of the preconditioning method should be performed for a time, at a flowrate, and using an RF power sufficient to partially passivate the AlF 3 species on the dome and form intermediate Al y O x and Al y O x F z species. Specifically, the H 2 gas may be flowed into the chamber for a time ranging from about 20 seconds to about 240 seconds, at a flowrate ranging from about 200 standard cubic centimeters per minute (sccm) to about 1000 sccm. Preferably, the H 2 gas is flowed into the chamber at a flowrate of about 600 sccm for about 120 seconds. In addition, sufficient RF power should be applied to generate a plasma of the H 2 gas. Specifically, an RF power ranging from about 1000 watts to about 3600 watts, preferably about 2400 watts, may be applied.
The H 2 /N 2 passivation step should be performed for a time, at a flowrate, and using an RF power sufficient to completely convert the intermediate Al y O x and Al y O x F z species to Al y O x N z and AlN. Specifically, the H 2 gas may be flowed into the chamber for a time ranging from about 20 seconds to about 240 seconds, at a flowrate ranging from about 200 sccm to about 1000 sccm. The N 2 gas may be flowed into the chamber for a time ranging from 30 seconds to about 600 seconds, at a flowrate ranging from about 200 sccm to about 1000 sccm. Preferably, both the H 2 and N 2 are flowed into the chamber at a flowrate of about 600 sccm for about 120 seconds. The H 2 and N 2 gases may be mixed either prior to introduction into the chamber, or upon introduction into the chamber. In addition, sufficient RF power should be applied to generate a plasma of the H 2 /N 2 mixture. Specifically, an RF power ranging from about 1000 watts to about 3600 watts, preferably about 2400 watts, may be applied.
During preconditioning in accordance with the method of the present invention, the direction of cooling water flow may be the same as during cleaning. That is, if during deposition the direction of cooling water flow is from the bottom of the dome to the top of the dome, and during cleaning the direction is reversed such that cooling water flows from top to bottom, then during preconditioning the cooling water may remain flowing from top to bottom.
However, it is preferred that the direction of cooling water flow is again reversed during preconditioning, such that it is opposite the direction during cleaning and the same as the direction during deposition. As discussed previously, if the direction of cooling water flow during deposition is from the bottom of the dome to the top of the dome, then the film coverage will be thinner at the top of the dome. During a subsequent cleaning step, even with the direction of cooling water flow reversed, over-cleaning is more likely to occur at the top of the dome where film coverage is thinner. That is, conversion of Al 2 O 3 to AlF 3 will be greater at the top of the dome. During preconditioning to convert AlF 3 to Al 2 O 3 and AlN, flowing the cooling water from the bottom of the dome to the top of the dome will result in a slightly greater rate of passivation at the top of the dome where more AlF 3 species are located.
Thus, during preconditioning, it is preferred that the direction of cooling water flow is opposite the direction during cleaning and the same as the direction during deposition. If the direction of flow during deposition is from the bottom of the dome to the top of the dome, then the direction during cleaning will be from top to bottom, and the direction during preconditioning is preferably from bottom to top.
While the present invention has been particularly described in conjunction with a preferred embodiment and other alternative embodiments, it is evident that numerous alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore intended that the appended claims embrace all such alternatives, modifications and variations as falling within the true scope and spirit of the present invention. | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part (CIP) of U.S. application Ser. No. 14/568,418, filed on Dec. 12, 2014, which is a continuation-in-part (CIP) of and claims the benefit of U.S. application Ser. No. 13/847,342, filed on Mar. 19, 2013, which claims the benefit of U.S. Provisional Application No. 61/614,455, filed Mar. 22, 2012, wherein all of these priority applications are incorporated herein by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] The present invention relates generally to a wave energy reduction method and apparatus for creating moderately quiescent water in which planted emergent salt marsh wetland grasses can endure and eventually become established. To this end, the present invention reduces wave energy without completely eliminating it while allowing the passage of soil and sediment through the apparatus to buttress the root structures of the emergent salt marsh wetland grasses.
[0005] Spartina alterniflora is a perennial deciduous grass that is found in intertidal wetlands, particularly estuarine salt marshes. S. alterniflora is the primary emergent salt marsh wetlands grass in many parts of the United States. S. alterniflora is an emergent grass growing out of the water at the seaward edge of beaches with low wave energy. Ninety percent of its biomass is believed to be underground; as such, S. alterniflora naturally accumulates sediment. Over time, this gradual accumulation of sediment builds the level of the land at the seaward edge of the salt marsh, thereby combating shoreline erosion. S. alterniflora is only one of numerous species of grasses that can be found in intertidal wetlands throughout the world; all of these grasses play an important role in stabilizing shorelines and providing buffers against storm surges and general erosion.
[0006] In many coastal locations where S. alterniflora and other salt marsh wetland grasses once existed, excessive wave energy in coastal waters due to conditions such as increased boating traffic and the creation of deeper channels makes it difficult, if not impossible, for such grasses to be reestablished on their own without reducing wave energy. Attempts to establish salt marsh wetland grasses along the shoreline without wave reduction typically result in mechanical damage to the plant leaves and, ultimately death to the plant itself. As a result, the failure to reestablish salt marsh wetland grasses compounds the problem of shoreline erosion.
[0007] Several solutions currently exist for preventing shoreline erosion, but these methods hardly address the issue of reestablishing emergent salt marsh wetland grasses. Instead, these solutions tend to focus upon protecting the ground itself.
[0008] One solution is to utilize barriers, such as concrete, rocks or other non-porous objects, by placing them between the coastal waters and the reestablishing emergent salt marsh wetland grasses to block wave energy. Such barriers are expensive to purchase, difficult to place, and difficult to remove. Concrete is heavy, and as such, the time and manpower to add these barriers can be prodigious.
[0009] Another solution is to place biodegradable fiber logs comprising a quantity of loose fibers retained in a tubular casing end-to-end on the shoreline between the coastal waters and the salt marsh wetland grasses. One example of this solution is taught by Spangler et al. (U.S. Pat. No. 6,547,493). This solution, while capable of abating wave energy, creates the costly step of packing fibers into the tubular casing. Furthermore, such fiber logs are difficult, if not impossible, to reuse since they are biodegradable. Beyond this, the logs restrict the accumulation of sediment around the salt-marsh wetland grasses, thereby undermining the very stability of these grasses. As such, they do not aid in the establishment of emergent salt marsh wetland grasses.
[0010] Mikell (U.S. Pat. Nos. 6,422,787 and 6,464,428) teaches two methods and apparatuses in which packed carpet fibers are formed into a body member, with said body member being rolled up into the form of a synthetic hay bale. The synthetic hay bale, in turn, is fastened to the ground in a water flow path. Although these methods and apparatuses would slow the flow of water, thereby reducing wave energy, like the Spangler apparatus, they would also restrict the flow of sediment to the salt-marsh wetlands grasses, thereby undermining the stability of these grasses.
[0011] A number of other solutions involve the use of tubing formed from geotextiles. However, these have several disadvantages. Most require the inclusion of some type of fill material, making them relatively complex to construct and often impractical for installation and removal by limited numbers of personnel. Also, the use of fill material will necessarily limit the amount of sediment allowed to pass through the barriers, which in turn will compromise the establishment of emergent salt marsh wetland grasses.
[0012] The flow of sediment-filled water in a reduced wave energy environment is necessary for emergent salt marsh wetland grasses to become established. As water with sediment passes over the grasses, the sediment is deposited around the grasses, strengthening the support structure for the grasses. Unlike other inventions, the present invention helps to break the speed of the water across the grasses to allow sediment to be deposited more readily.
[0013] Theisen (U.S. Pat. No. 7,883,291) teaches a process/apparatus wherein a mat of natural fibers is wound in the form of a log to form fiber filtration tubes. The Theisen process/apparatus further employs a flocculating agent to flocculate fine particles, thereby accomplishing a high-degree of sediment control. In sharp contrast, the present invention uses no flocculating agent since the flocculation of sediment particles within the apparatus would prevent sediment from accumulating around emergent salt marsh wetland grasses. The accumulation of sediment particles around emergent salt marsh wetland grasses is essential for the long-term stability of these plants. Therefore by incorporating the use of a flocculant, the Theisen process/apparatus would compromise the establishment of emergent salt marsh wetland grasses, which is the stated purpose of this invention.
[0014] While Myrowich (U.S. App. 2009/0020639) teaches a rolled erosion control blanket, and a process for manufacturing such a blanket, this process is directed to optimizing the ability of such a blanket to be rolled up for transportation purposes. It envisions the unrolling of the blankets at the work site. This shares the same problem as the teaching of Carpenter (U.S. Pat. No. 7,695,219), viz: a blanket placed flat on the ground is largely useless for protecting salt marsh wetland grasses from wave energy.
[0015] It would be desirable to have a method and/or apparatus that will enable emergent salt marsh wetland grasses to establish and grow without totally eliminating the energy of occurring waves or blocking the flow of sediment-rich water across the grasses. Furthermore, it would also be desirable to have a method and/or apparatus that are inexpensive to utilize. Still further, it would be desirable to have a method and/or apparatus that are simple to relocate and reuse. Therefore, there currently exists a need in the industry for an inexpensive method and/or apparatus that can (A) protect emergent salt marsh wetland grasses from excessive wave energy while concomitantly allowing sediment to deposit onto these grasses, and (B) be relocated to other shores for reuse when these grasses become stable enough to withstand incoming wave energy.
BRIEF SUMMARY OF THE INVENTION
[0016] The present invention advantageously fills the aforementioned deficiencies by providing a wave energy reduction method and apparatus in which emergent salt marsh wetland grasses located between the wave energy reduction apparatus and the shoreline can endure and eventually establish without the need for the total elimination of the energy of occurring waves or the restriction of sediment passage.
[0017] Highly-porous geotextile materials (such as, but not limited to, ENKAMAT fabric, which is known to have a porosity of at least 95%) are assembled into rolls. These rolls are bound with cable ties, preferably ties that can withstand ultraviolet light, to maintain their cylindrical shape. The rolls are placed out into water that is at least 12-14 inches (30-36 cm) deep on the soil end to end without space between them, forming a line of geotextile material rolls.
[0018] Multiple anchors, preferably comprised of steel, are then placed into the soil on one side of the line of rolls, preferably on that side closest to the shoreline. These anchors are referred to throughout this specification as “steel anchors.” However, the use of the word steel or any other description thereto should not be deemed as limiting the composition of the anchors to any one type of material.
[0019] Multiple strands of rope, preferably comprised of polypropylene, are inserted into multiple layers of tubing, preferably polyethylene tubing. Each rope-and-tubing combination is inserted, yet again, into another layer of tubing, preferably polyethylene tubing, to form multiple “rope ties.”
[0020] Each rope tie is then looped through a unique anchor and underneath the line of rolls to form the shape roughly similar to that of the letter “U” such that both ends of each rope tie are pointing straight up. The ends of each rope tie are then tied together, thereby securing the line of rolls to the anchors.
[0021] Although the preferred embodiment for this invention utilizes polypropylene rope combined with polyethylene tubing, the invention may use any type of rope, with or without polyethylene tubing. Likewise, the invention may use any type of tubing to cover the rope, regardless of whether the same is made of polyethylene, or no tubing at all. Furthermore, the invention may use any type of cable ties, whether or not they can resist ultraviolet light. Still further, the invention may use any type of anchor, regardless of its composition.
[0022] This method and/or apparatus reduce the size and force of incoming waves as the waves pass through the line of geotextile material rolls. As a result, moderately quiescent water is created whereby salt marsh wetland grasses can be established and endure. After these grasses have been established, the user may then remove the rolls of geotextile material, along with the steel anchors and the rope ties, and place them elsewhere.
[0023] This invention is functionally different from other solutions because it attempts to abate wave energy, not eliminate it altogether. Research has shown plant stems and trunks are stronger when subjected to some movement caused by wind and waves. Moreover, by allowing water to pass through the wave energy reduction barrier, sediment returning from the coastal waters is not inhibited from accumulating around the emergent salt marsh wetland grasses, further aiding in the prevention of shoreline erosion.
[0024] This invention is structurally different from other solutions because it comprises materials that are readily accessible and cost-effective to utilize. These lightweight materials are easy to transport and are inexpensive to obtain. As such, it only takes one person a short time to install, and later remove, a wave energy reduction system.
[0025] Among other things, it is an object of the present invention to protect emergent salt marsh wetland grasses from wave energy without incurring any of the problems or deficiencies associated with prior solutions.
[0026] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description and any preferred and/or particular embodiments specifically discussed or otherwise disclosed. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and will fully convey the full scope of the invention to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows a perspective view of the preferred embodiment of the apparatus.
[0028] FIG. 2 shows a cross section view of the preferred embodiment of the apparatus, particularly depicting the attachment to the anchor.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The preferred embodiment of the invention is described as follows:
[0030] To create the wave energy reduction system 10 , assemble 8-feet-by-27 feet (2.44 m×8.2 m) of geotextile fabric having a porosity of at least 95% and no flocculant into a cylindrical roll that is 12-14 inches (30-36 cm) in diameter and 8 feet (2.44 m) in length. The roll is tied together with black cable ties 11 to maintain the cylindrical shape of the roll. Tie the roll together with 48-inch (1.22 m) long and ¼-inch (6.35 mm) wide black cable ties. The black cable ties should have ultraviolet light inhibitors and a 175 psi (1.21 MPa) tensile stress rating. Locate the two end-of-the-roll cable ties 12 inches (30.5 cm) from each end of the roll. Evenly space the remaining cable ties 18 inches (45.72 cm) apart along the roll. Cable ties will be pulled tightly against the geotextile fabric to secure the material into a rolled form.
[0031] When setting the wave reduction system in position, place them in water that is at least 12-14 inches (30-36 cm) deep, on the soil, so the exposed cut edge is beneath the roll and facing toward the mainland. This will protect against the possibility of wave action forces opening up the roll.
[0032] Steel anchors 12 secured into the soil serve as the method for holding the wave energy reduction system in place. Install the ½-inch (12.7 mm) diameter steel anchors with tensile strength of 1400 psi (9.65 MPa) into the soil to the point where the eye of the anchor is just above the soil level. Use three 30-inch (76 cm) long anchors for each 8-foot (2.4 m) long roll. Locate the anchors 24 inches (61 cm) from each end of the roll and the third anchor at the center of the roll.
[0033] Two sizes of black polyethylene tubing and polypropylene rope are the fastening elements for attaching the wave energy reduction system to the earth anchors. Together these materials create a technology that has proven effective in establishing emergent marsh grasses.
[0034] Attach the roll to each anchor with a 6-foot (1.8 m) long piece of ½-inch (12.7 mm) polypropylene rope 13 threaded into the polyethylene tubing as further described herein. The rope will have a tensile stress of 425 pounds per square inch (2.93 MPa). The ends of the rope will be heat treated to resist fraying and becoming unraveled. Thread the 6-foot long piece of rope through a 24-inch (61 cm) long section of 0.62 ID×0.71 OD inch (15.7 ID×18.0 OD mm) polyethylene tubing 14 . Thread the aforementioned tubing into a 21-inch (53 cm) section of 83 ID×0.92 OD inch (21.1 ID×23.4 OD mm) tubing 15 . The combined tubing layers protect the polypropylene rope from abrasion against the steel anchor eyelet. Thread the rope and tubing combination through the eyelet and around the wave energy reduction system. Position the polyethylene tubing in a rough “U” shape around the roll with the “U” pointing upward. The tubing will extend approximately half way up the sides of the roll, and the rope will extend to a point above the roll where it can be pulled tightly and tied. When tying the rope together, pull the rope ends tightly against the top of the roll and secure the rope to the wave reduction system with 6-8 overhand knots. Secure each knot tightly before tying the next knot.
[0035] The best mode for utilizing the invention is described as follows:
[0036] It is recommended that the invention be used to protect emergent salt marsh wetland grasses by placing the wave energy reduction system out into water that is at least 12-14 inches (30-36 cm) deep as described in the preferred embodiment above. It is further recommended that multiple systems be placed end-to-end, as needed, to protect greater areas of emergent salt marsh wetland grasses.
[0037] The drawings are further described as follows:
[0038] Referring to the figures, FIG. 1 shows the preferred embodiment of the wave energy reduction system. Notice how the roll 10 , being comprised of geotextile material having a porosity of at least 95% (preferably ENKAMAT material), is rolled such that the exposed edge of the roll is pointed to the shoreline and away from the incoming waves. The cylindrical shape of the roll is maintained by cable ties 11 that are wrapped and tied around the roll.
[0039] In the preferred embodiment, five cable ties are spaced along the roll with the third cable tie being located at the center. Further notice the anchors 12 that are spaced along the side of the roll. Further notice that rope ties 13 are looped through the anchors and under the rolls. Further notice that these rope ties are tied at the top of the roll, thereby securing the roll to the soil.
[0040] FIG. 2 shows the cross-section view of the preferred embodiment of the apparatus 10 . Notice that the cross-section is cut where a rope tie 13 is looped through a steel anchor. Further notice that the preferred embodiment uses a rope tie mechanism that comprises a rope, which is fed through a 24-inch (61 cm) length of polyethylene tube 14 , which is further fed through a 21-inch (53 cm) length of a larger-diameter polyethylene tube 15 . The ends of the rope are tied together at the top of the wave energy reduction system. The multiple layers of polyethylene tubing serve to insulate the rope from fraying the geotextile mat. Please note that the polyethylene tubing is optional, and as such, the specification is understood to describe the apparatus without the tubing.
[0041] While the present invention has been described above in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. Upon reading the teachings of this disclosure many modifications and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure and the appended claims. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings. | 4y
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TECHNICAL FIELD
The present invention relates to composite particles having high fluidity and liquid carrying properties, and keeping compactibility and fluidity of the particles even after retention of the liquid to prevent tableting problems.
BACKGROUND ART
Conventionally, in the fields of pharmaceuticals, foods, and other chemical industries, cellulose powder is widely used as an excipient for molding when a molded article containing an active ingredient is prepared. In addition, in the case where the active ingredient is a liquid ingredient, the liquid ingredient is carried by a single inorganic compound to obtain a powder. The obtained powder is molded into a molded article by using a cellulose powder as an excipient.
Unfortunately, the single inorganic compound has an excessively large apparent specific volume, which limits the amount of the active ingredient to be powdered at one time. There is also a handling problem such that the inorganic compound scatters, or the like. For this reason, use of cellulose-inorganic compound porous composite particles as the excipient has been examined.
Patent Literature 1 describes an invention of fine particles produced by co-processing a microcrystalline cellulose particle and calcium carbonate having a particle size less than 30 μm in a specific mass ratio in order to reduce cost of a pharmaceutical excipient.
Patent Literature 2 describes an invention of an excipient composition composed of a fine particle agglomerates including a microcrystalline cellulose and silicon dioxide as a pharmaceutical excipient having improved compressibility.
Patent Literature 3 describes an invention of cellulose inorganic compound porous composite particles which are an aggregate of a specific cellulose dispersed particle and a water-insoluble inorganic compound particle, and having an intraparticle pore volume of 0.260 cm 3 /g or more. According to Patent Literature 3, the cellulose and the inorganic compound are formed into composite particles to obtain a particle having a large intraparticle pore volume, and high compactibility, disintegration properties, and fluidity.
Patent Literature 4 describes an invention of a solid formulation which is not a composite product but a physical mixture of an inorganic compound and a microcrystalline cellulose, and comprises a drug, calcium silicate, and starch and/or microcrystalline cellulose, in which 10 to 45% by weight of calcium silicate is blended based on the drug, and 40 to 250% by weight of starch and/or microcrystalline cellulose is blended based on calcium silicate. According to the description, even if a drug having poor compactibility such as phenacetin and acetaminophen is directly tableted, 70 to 90 parts by weight of the drug can be blended without capping.
CITATION LIST
Patent Literature
Patent Literature 1: U.S. Pat. No. 4,744,987
Patent Literature 2: JP 10-500426 A
Patent Literature 3: JP 2005-232260 A
Patent Literature 4: JP 3-52823 A
SUMMARY OF INVENTION
Technical Problem
Usually, a tablet is produced by tableting by filling a powder into a die and compressing the powder with a punch. In the case where the drug easily adheres to the punch, it causes a phenomenon called sticking such that the surface of the molded article is peeled off. Usually, a single inorganic compound is used as an excipient, but the single inorganic compound cannot always prevent the sticking. Moreover, because the single inorganic compound has a large apparent specific volume, flushing properties of the powder are increased in tableting to reduce filling properties into the die, leading to problems such as variation in the weight of the molded article and a phenomenon called capping: part of the molded article is peeled off. For this reason, a large amount of the inorganic compound cannot be added.
Cellulose powder is an excipient having high compactibility. Once the cellulose powder gets wet, however, the compactibility is reduced, the function as the excipient is no longer demonstrated. Moreover, compared to the inorganic compound, the cellulose powder has lower liquid retention. Moreover, the composite products of cellulose and an inorganic compound known in the related art have a low liquid retention rate, and low fluidity of the particle after retention of the liquid. In addition, problems such as sticking and capping cannot be sufficiently eliminated.
An object of the present invention is to provide composite particles having a high liquid retention rate and having high fluidity of the particles even after retention of a liquid. In addition, another object of the present invention is to provide composite particles that can be tableted with gravity feeder in a direct tableting method, hardly cause tableting problems, and have high compactibility. Further another object of the present invention is to provide a molded article in which the weight of the molded article and the content of an active ingredient are uniform, hardness is high, and friability is low when the composite particles and the active ingredient are formed into the molded article.
Solution to Problem
In order to solve the problems above, the present inventors have found out that if cellulose and an inorganic compound are formed into a composite product, the apparent specific volume, the pore volume, and the liquid retention rate can be increased, and compactibility and fluidity of the particles even after retention of a liquid can be increased. Thus, the present invention has been made.
Namely, the present invention is as follows.
(1) Composite particles comprising a cellulose and an inorganic compound, and having an apparent specific volume of 7 to 13 cm 3 /g. (2) The composite particles according to (1), wherein the cellulose has an average width of 2 to 30 μm and an average thickness of 0.5 to 5 μm. (3) The composite particles according to (1) or (2), comprising 10 to 60 parts by mass of the cellulose and 40 to 90 parts by mass of the inorganic compound. (4) The composite particles according to any one of (1) to (3), wherein the inorganic compound is at least one selected from the group consisting of silicon dioxide hydrate, light anhydrous silicic acid, synthetic aluminum silicate, magnesium hydroxide-aluminum hydroxide co-precipitate, magnesium aluminometasilicate, magnesium aluminosilicate, calcium silicate, non-crystalline silicon oxide hydrate, magnesium silicate, and magnesium silicate hydrate. (5) The composite particles according to any one of (1) to (4), wherein the inorganic compound is calcium silicate. (6) The composite particles according to any one of (1) to (5), wherein a pore size is 0.003 to 1 μm, and a pore volume is 1.9 to 3.9 cm 3 /g. (7) The composite particles according to any one of (1) to (6), wherein a retention rate of tocopherol acetate is 500 to 1000%. (8) The composite particles according to any one of (1) to (7), wherein a weight average particle size is 30 to 250 μm. (9) The composite particles according to any one of (1) to (8), further comprising starch. (10) A molded article comprising the composite particles according to any one of (1) to (9) and an active ingredient. (11) The molded article according to (10), wherein the active ingredient is an ingredient for a medicament or an ingredient for health food. (12) A molded article comprising composite particles comprising a cellulose and an inorganic compound, and an active ingredient, wherein the active ingredient is a liquid having a viscosity at 25° C. of 3 to 10000 mPa·s, and the molded article contains 105 to 250 mg of the active ingredient per 500 mg of one molded article. (13) The molded article according to (12), wherein the liquid ingredient is tocopherol acetate.
Advantageous Effects of Invention
The composite particles according to the present invention have a large apparent specific volume and pore volume, and a high retention rate of tocopherol acetate as an index of the liquid retention rate. Scattering properties are reduced by forming a composite product, providing good operability. Thereby, the composite particles of the present invention can be used as an adsorption carrier of the liquid ingredient. By forming a composite product, high fluidity after retention of the liquid can be provided, a uniformity in weight of the molded article and content of the active ingredient can be provided among molded articles, and a large content of the liquid ingredient can be contained in the molded article. In addition, the molded article according to the present invention has sufficient hardness, can prevent sticking and capping, and provide a molded article having low friability.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles B according to Example 2.
FIG. 2 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles D according to Example 4.
FIG. 3 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles G according to Example 7.
FIG. 4 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles I according to Example 9.
FIG. 5 is an enlarged SEM photograph at a magnification of 200 times of a dried product of a cellulose WET cake.
FIG. 6 is an enlarged SEM photograph at a magnification of 500 times of calcium silicate according to Reference Example 2.
FIG. 7 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles K according to Example 11.
FIG. 8 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles M according to Example 13.
FIG. 9 is an enlarged SEM photograph at a magnification of 200 times of Composite Particles H according to Example 8.
FIG. 10 is an enlarged SEM photograph at a magnification of 100 times of a mixture of cellulose and calcium silicate.
DESCRIPTION OF EMBODIMENTS
Hereinafter, an embodiment for implementing the present invention (hereinafter, simply referred to as “the present embodiment”) is described in detail with reference to the drawings when necessary. The present embodiment below is only an example for describing the present invention, and is not intended to limit the present invention to the contents below. Moreover, the attached drawings show an example of the embodiment, and the present embodiment should not be construed to be limited to the drawings. The present invention can be properly modified without departing from the gist, and implemented.
The composite particles according to the present embodiment comprise a cellulose and an inorganic compound formed into a composite product and having a specific apparent specific volume.
In the present embodiment, the cellulose refers to fibrous materials containing a natural polymer obtained from natural products. In the present embodiment, the cellulose preferably has a crystal structure of a cellulose type I. Preferably, the cellulose has an average width of 2 to 30 μm and an average thickness of 0.5 to 5 μm. If the average width and average thickness of the cellulose are within the ranges above, preferably, the pore within the particle can be sufficiently developed by forming a composite product. More preferably, the cellulose has an average width of 2 to 25 μm and an average thickness of 1 to 5 μm.
The cellulose in the present invention includes microcrystalline cellulose. The microcrystalline cellulose used in the present invention is a white crystalline powder obtained by partially depolymerizing α-cellulose obtained as pulp obtained from a fibrous plant with mineral acid, and purifying the partially depolymerized product. The microcrystalline cellulose has various grades. In the present invention, the microcrystalline cellulose having a polymerization degree of 100 to 450 is preferable. As a commercially available product, “Ceolus” PH grade, “Ceolus” KG grade, and “Ceolus” UF grade (all made by Asahi Kasei Chemicals Corporation) can be used. The UF grade is most preferable.
Preferably, the cellulose has a volume average particle size of 10 to 100 μm. The volume average particle size is preferably 10 to 50 μm, and more preferably 10 to 40 μm.
The cellulose preferably has an average polymerization degree of 10 to 450. The average polymerization degree is more preferably 150 to 450.
In the present embodiment, the inorganic compound is not particularly limited as long as the inorganic compound is insoluble in water and has an apparent specific volume of 10 to 50 cm 3 /g. For example, silicon dioxide hydrate, light anhydrous silicic acid, synthetic aluminum silicate, magnesium hydroxide-aluminum hydroxide co-precipitate, magnesium aluminometasilicate, magnesium aluminosilicate, calcium silicate, non-crystalline silicon oxide hydrate, magnesium silicate, and magnesium silicate hydrate are preferable. Preferably, the inorganic compound has a volume average particle size of 10 to 50 μm because the concentration of the dispersion liquid of the cellulose and the inorganic compound can be increased. Particularly preferably, the inorganic compound is calcium silicate. Calcium silicate is composed of CaO, SiO 2 , and H 2 O. Those represented by the formula 2CaO.3SiO 2 .mSiO 2 .nH 2 O (1<m<2, 2<n<3) are preferable. As a commercially available product, a product name Florite R (made by Tokuyama Corporation), a product name Florite RE (CaO 2 is 50% or more, CaO is 22% or more, available from Eisai Food & Chemical Co., Ltd.), and the like are available. Calcium silicate is a white powder, and water-insoluble. Calcium silicate is a substance having a high liquid absorbing ability and good compactibility. The volume average particle size is preferably 10 to 40 μm, and more preferably 20 to 30 μm.
From the viewpoint of prevention of sticking, it is thought that when the inorganic compound has a larger apparent specific volume and specific surface area, higher properties can be demonstrated. Light anhydrous silicic acid has higher physical properties described above than those of calcium silicate. As a result of extensive research of an inorganic compound used with the cellulose as the composite particles in the present invention, however, it was found that the highest sticking-preventing effect is demonstrated in the case where calcium silicate is used.
The present inventors found out that the inorganic compound and the cellulose are formed into a composite product to make the apparent specific volume as large as possible; thereby, a retention rate of tocopherol acetate as an index of the liquid retention rate can be maximized.
Single calcium silicate has a retention rate of tocopherol acetate of 800 to 900%, and has a high retention rate among the inorganic compounds. The retention rate of tocopherol acetate by the cellulose is 200 to 250%. For this reason, it is thought that a mixture having a retention rate of more than 800% cannot be obtained even if calcium silicate is simply mixed with the cellulose. It was found, however, that the pore within the particle is sufficiently developed by forming a composite product to provide a retention rate higher than a simple arithmetic average value.
As an example, the retention rate of tocopherol acetate is compared between a mixture of cellulose and calcium silicate, in which the amount of calcium silicate to be blended is approximately 50%, and the composite particles. In the case of the mixture, the logical value of the retention rate of tocopherol acetate is approximately 550%. Meanwhile, the composite particles having the same blending amount of calcium silicate has an extremely high retention rate of approximately 740%.
In other words, by forming the cellulose and calcium silicate into a composite product, the liquid retention rate is improved, and further, the properties of the cellulose are successfully given to the composite particles. Thereby, the composite particles having a high liquid retention rate and given compactibility and fluidity that the cellulose has can be provided.
Preferably, the composite particles according to the present embodiment contain 10 to 60 parts by mass of the cellulose and 40 to 90 parts by mass of the inorganic compound. More preferably, the composite particles according to the present embodiment contain 15 to 45 parts by mass of the cellulose and 55 to 85 parts by mass of the inorganic compound. If the inorganic compound is 40 parts by mass or more, a large intraparticle pore volume can be given to the obtained composite particles including the cellulose and the inorganic compound to provide sufficient liquid retention. Moreover, compression compactibility after retention of the liquid is improved. If the inorganic compound is 90 parts by mass or less, flushing properties can be suppressed, and variation in the weight of the molded article and the content of the active ingredient and reduction in compactibility can be suppressed.
In the present embodiment, the composite particles are not simply a mixture of the cellulose and the inorganic compound. The composite particles need to contain a single aggregate larger than a single particle, the aggregate being composed of several particles of the cellulose and several particles of the inorganic compound. When the surfaces of the composite particles according to the present embodiment are observed using an SEM (magnification of 200 to 500 times), particles of the cellulose and particles of the inorganic compound are observed individually. It can be found that several particles of the cellulose and several particles of the inorganic compound collect to form the aggregate (see FIG. 9 ). For comparison, a simple mixture is shown in FIG. 10 . The aggregate is larger than a single particle of the cellulose and a single particle of the inorganic compound. Meanwhile, in the simple mixture of the cellulose powder and the inorganic compound powder, primary particles of the cellulose and primary particles of the inorganic compound individually exist, and no aggregate is formed. For this reason, in the case of the simple mixture, high compactibility and fluidity as demonstrated by the composite particles according to the present embodiment are not obtained. Formation of the composite particles can be determined by observation with an SEM, or the weight proportion of the particles remaining on a sieve when the particles are sieved with the sieve having an opening of 75 μm. If the proportion of the particles remaining on the 75 μm sieve is 5 to 70% by weight, and preferably 10 to 70% by weight, it is determined that the composite particles are formed. The composite particles can have pores formed within the particle. Thereby, the composite particles can carry the amount of the liquid ingredient more than the amount of the liquid ingredient that can be carried by individual particles of the cellulose and individual particles of the inorganic compound. As formation of the composite product is progressed, the amount of the pores within the particles is increased, leading to a higher ability to carry the liquid ingredient. For example, the degree of formation of the composite product can be measured by comparing the retention rate of tocopherol acetate. In the simple physical mixture of the cellulose and the inorganic compound, the retention rate of tocopherol acetate is only an arithmetic average value based on the composition ratio of the cellulose and the inorganic compound. Meanwhile, as formation of the composite product is progressed, the amount of the pores within the particles is increased. For this reason, the composite particles have a higher retention rate of tocopherol acetate.
The composite particles according to the present embodiment need to have an apparent specific volume of 7 to 13 cm 3 /g. At an apparent specific volume of 7 cm 3 /g or more, the liquid retention rate is improved. At an apparent specific volume of 13 cm 3 /g or less, increase in flushing properties can be suppressed, and variation in the content of the active ingredient and reduction in compactibility can be suppressed. More preferably, the apparent specific volume is 8 to 12 cm 3 /g.
The composite particles according to the present embodiment preferably have a pore size of 0.003 to 1 μm. Here, the pore size means the size of the pore on the surface of the composite particle. More preferably, the pore size is 0.05 to 0.5 μm.
The composite particles according to the present embodiment preferably have a pore volume of 1.9 to 3.9 cm 3 /g. Here, the pore volume means the volume of fine pores that the composite particles have. A pore volume of 1.9 cm 3 /g or more improves the liquid retention rate. At a pore volume of 3.9 cm 3 /g or less, increase in flushing properties can be suppressed, and variation in the content of the active ingredient and reduction in compactibility can be suppressed. More preferably, the pore volume is 2 to 3.5 cm 3 /g.
The pore volume contributes to the compression compactibility of the composite particles and the liquid retention of the molded article. At a large pore volume, the composite particles are likely to be crushed during compression, leading to improved plastic deformability and enhanced hardness of the molded article. Moreover, a large pore volume promotes penetration of the liquid into the composite particles, leading to improved liquid retention.
Preferably, the composite particles according to the present embodiment have a porosity of 15 to 50%. Here, the porosity means a proportion of the pore volume to the volume of the composite particles. A porosity of 15% or more provides a high liquid retention rate, thus it is preferable. A porosity of 50% or less can suppress increase in flushing properties and reduction in compactibility, thus it is preferable. More preferably, the porosity is 20 to 40%.
The composite particles according to the present embodiment preferably have a weight average particle size of 30 to 250 μm. From the viewpoint of fluidity, the weight average particle size is preferably 30 μm or more. From the viewpoint of suppression in separation and segregation, the weight average particle size is preferably 250 μm or less. More preferably, the weight average particle size is 40 to 100 μm. Here, separation and segregation mean that the active ingredient is not uniformly mixed with the composite particles, and that a uniformly mixed state is not kept.
The composite particles according to the present embodiment preferably have a retention rate of tocopherol acetate of 500 to 1000%. At a high retention rate of tocopherol acetate, namely, a high liquid retention rate, the content of the active ingredient in the molded article can be increased. At a retention rate of tocopherol acetate less than 500%, the amount of the liquid to be carried is small. From the viewpoint of liquid retention, the retention rate of tocopherol acetate is preferably as high as possible, but approximately 1000% at best. The retention rate of tocopherol acetate is more preferably 600 to 1000%, and particularly preferably 700 to 1000%.
From the viewpoint of fluidity, the composite particles according to the present embodiment preferably have a repose angle of 45° or less. The repose angle is preferably as small as possible, and the lower limit is not particularly limited. From the viewpoint of suppression in separation and segregation of the active ingredient during continuous compression at a high speed, the repose angle is preferably 25°. More preferably, the repose angle is 25 to 40°. Similarly, from the viewpoint of fluidity, preferably, the composite particles after retention of the liquid have a repose angle of 45° or less, and preferably 25 to 40°.
The composite particles according to the present embodiment preferably have a hardness of 200 to 340 N. Here, the hardness is a value obtained by measurement of a cylindrical molded article obtained by compressing 0.5 g of the composite particles at a pressure of 10 MPa with a punch having a circular flat surface having a diameter of 1.1 cm by a Schleuniger hardness tester.
Preferably, the composite particles according to the present embodiment further include starch. Starch has binding properties, thus contributes to keeping a composite state of the cellulose and the inorganic compound. Thereby, a granulation state is fixed. Accordingly, addition of starch is preferable. As starch, for example, dextrin, soluble starch, corn starch, potato starch, partly pregelatinized starch, pregelatinized starch, and the like can be used. Those having binding properties are preferable. As starch contributing to improvement in disintegration properties, a “SWELSTAR (trademark) WB-1 (made by Asahi Kasei Chemicals Corporation)” is particularly preferable because the outer shell is a glue ingredient having binding properties and the inner shell is a disintegrable particle. 5 parts by mass to 15 parts by mass of starch is preferably contained based on 100 parts by mass of the composite particles including starch. At this time, 85 to 95 parts by mass of the microcrystalline cellulose and the inorganic compound in total are preferably contained.
The composite particles according to the present embodiment have a large apparent specific volume, a high liquid retention rate, and high fluidity. Further, the composite particles according to the present embodiment can be suitably used for a direct tableting method and a wet tableting method. The composite particles according to the present embodiment also have reduced scattering properties and high operability to prevent tableting problems such as sticking and capping.
The composite particles according to the present embodiment are particularly suitable for an active ingredient having low fluidity and difficulties to provide hardness of the tablet. Specific examples thereof include essence powders of over-the-counter drugs such as cold medicines and Kampo medicines, and drugs easy to be deactivated by a compression force or friction with an excipient such as enzymes and proteins.
The composite particles according to the present embodiment are also suitable for tablets easy to have tableting problems such as breakage or chips of the surface of the tablet, peel off from the inside, and cracks. Specific examples of the tablets include small tablets, non-circular deformed tablets having a portion such as a constriction of an edge to which a compression force is difficult to be uniformly applied, tablets containing a large amount of various drugs, and tablets containing coating granules.
Hereinafter, a method for producing the composite particles according to the present embodiment is described.
The composite particles according to the present embodiment are obtained by dispersing the cellulose and the inorganic compound in a medium, and drying the obtained dispersion liquid. Alternatively, the composite particles according to the present embodiment can also be obtained by strongly stirring the cellulose and the inorganic compound by a wet method (i.e., formation of a composite product, co-processing).
A raw material for the cellulose is natural products containing a cellulose. Examples of the raw material for the cellulose include wood materials, bamboo, wheat straw, rice straw, cotton, ramie, bagasse, kenaf, beet, hoya, and bacterial cellulose. The raw material may be of plant or animal origin, and two or more thereof may be mixed. Alternatively, the raw material may be hydrolyzed. Particularly in the case of hydrolysis, examples thereof include acid hydrolysis, alkali oxidative decomposition, hydrothermal decomposition, and steam explosion. These may be used in combination.
In the hydrolysis, a medium for dispersing the solid content containing the cellulose is not particularly limited as long as the medium is industrially used. As such medium, water or an organic solvent can be used. Examples of the organic solvent include alcohols such as methanol, ethanol, isopropyl alcohol, butyl alcohol, 2-methyl butyl alcohol, and benzyl alcohol; hydrocarbons such as pentane, hexane, heptane, and cyclohexane; and ketones such as acetone and ethyl methyl ketone. Particularly, the organic solvent is preferably those used for pharmaceuticals. Examples of the organic solvent include those classified as solvents in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited). The medium is preferably water. Water and the organic solvents may be used in combination. Alternatively, the cellulose and the inorganic compound may be dispersed in one medium once, and the medium may be removed; then, the cellulose and the inorganic compound may be dispersed in a different medium.
The cellulose in the present invention preferably has an average width of 2 to 30 μm and an average thickness of 0.5 to 5 μm. The method is not particularly limited as long as it is a method for tearing the cellulose mainly in the longitudinal length. The average width and average thickness of the cellulose can be controlled within specific ranges by treating wood pulp with a high-pressure homogenizer, and when necessary, performing a mechanical treatment such as grinding and sorting, or combining these two properly. Alternatively, for example, a pulp whose cellulose has an average width of 2 to 30 μm and an average thickness of 0.5 to 5 μm may be selected and used. The volume average particle size of a water-dispersed cellulose is preferably 10 to 100 μm. The volume average particle size is preferably 10 to 50 μm, and more preferably 10 to 40 μm. Patent Literature 3 describes a cellulose for composing in which the cellulose dispersed in water has an L/D of 2.0 or more in a 10 to 100 μm fraction. As shown in Examples in Patent Literature 3, the cellulose cannot attain a high apparent specific volume as in the present application. Further, the cellulose of Patent Literature 3 is inferior to the composite product according to the present invention with respect to the pore volume and the retention rate of tocopherol acetate. The cellulose having a specific average width and average thickness is preferable for increasing the amount of the pores within the particles.
Examples of a method for obtaining a cellulose having a volume average particle size of 10 to 100 μm in the state of the cellulose dispersed in water include:
i) a method of shearing, grinding, crushing, and pulverizing a cellulose to adjust a particle size, ii) a method of performing a high pressure treatment such as explosion on a cellulose to separate the cellulose particles in the direction along their long axis, and when necessary, applying a shear force to adjust a particle size, and iii) a method of performing a chemical treatment on a cellulose to adjust a particle size.
Any of the methods described above may be used, and two or more methods described above may be used in combination. The methods i) and ii) may be performed by a wet method or a dry method. These wet and dry methods may be used in combination.
Examples of the methods i) and ii) include shearing methods using a stirring blade of a one-direction rotation type, a multi-axis rotation type, a reciprocal inversion type, a vertical movement type, a rotation+vertical movement type, or a piping type such as a portable mixer, a three-dimensional mixer, and a side-wall mixer; a jet type stirring/shearing method such as a line mixer; a treatment method using a high-shear homogenizer, a high-pressure homogenizer, and an ultrasonic homogenizer; and an axial rotation extrusion type shearing method such as a kneader.
Particularly, examples of a pulverizing method include a screen type pulverizing method such as a screen mill and a hammer mill, a blade rotation shearing screen type pulverizing method such as a flush mill, an air stream type pulverizing method such as a jet mill, a ball type pulverizing method such as a ball mill and a vibratory ball mill, and a blade stirring type pulverizing method. Two or more methods among them may be used in combination.
The volume average particle size of the cellulose can also be controlled within a desired range by adjusting a condition on a step of hydrolyzing or dispersing the cellulose, particularly, adjusting a stirring force applied to the solution containing the cellulose. Generally, if the concentrations of an acid and an alkali in the hydrolysis solution are increased or the reaction temperature is increased, the polymerization degree of the cellulose is likely to be reduced to provide a smaller volume average particle size of the cellulose in the dispersion liquid. If the stirring force applied to the solution is stronger, the cellulose particle is likely to have a smaller volume average particle size.
Next, a method for producing a dispersion liquid containing the cellulose and the inorganic compound is described. The dispersion liquid can be produced by dispersing the cellulose and the inorganic compound in a medium. Specifically, examples of the method include:
i) a method of adding a mixture of the cellulose and the inorganic compound in a medium to prepare a dispersion liquid, ii) a method of adding the inorganic compound to a cellulose dispersion liquid to prepare a dispersion liquid, iii) a method of adding the inorganic compound to a dispersion liquid prepared by mixing a third ingredient such as starch with cellulose particles to prepare a dispersion liquid, iv) a method of adding the inorganic compound to a mixture of a third ingredient such as starch and a cellulose dispersion liquid to prepare a dispersion liquid, and v) a method of adding the cellulose to a dispersion liquid having the inorganic compound added to prepare a dispersion liquid.
A method for adding the respective ingredients is not particularly limited as long as it is a method usually performed. Specifically, examples of the addition method include those using a small size suction transport apparatus, an air transport apparatus, a bucket conveyor, a pneumatic transport apparatus, a vacuum conveyer, a vibration type quantitative metering feeder, a spray, a funnel, or the like. The respective ingredients may be continuously added, or added in batch.
A mixing method is not particularly limited as long as it is a method usually performed. Specifically, a vessel rotation type mixer such as V-type, W-type, double cone type, and container tack type mixers, a stirring type mixer such as high speed stirring type, universal stirring type, ribbon type, pug type, and Nauta-type mixers, a high speed fluid type mixer, a drum type mixer, and a fluidized bed type mixer may be used. Alternatively, dispersing methods using vessel shaking type mixer such as a shaker, and a stirring blade of a one-direction rotation type, a multi-axis rotation type, a reciprocal inversion type, a vertical movement type, a rotation+vertical movement type, or a piping type such as a portable mixer, a three-dimensional mixer, a side-wall mixer, a jet type stirring/dispersing method such as a line mixer, a treatment method using a high-shear homogenizer, a high-pressure homogenizer, or an ultrasonic homogenizer, and an axial rotation extrusion type shearing method such as a kneader may be used, for example. Two or more methods among them may be used in combination.
The concentration of the cellulose, inorganic compound, and starch in the dispersion liquid obtained by the above-described operation is preferably 5 to 40% by mass. From the viewpoint of fluidity of the composite particles obtained by drying the dispersion liquid, the concentration is preferably 5% by mass or more. From the viewpoint of compression compactibility, the concentration is preferably 40% by mass or less. The concentration is more preferably 5 to 30% by mass, and still more preferably 5 to 20% by mass.
The dispersion liquid obtained by the above-described operation is dried to obtain the composite particles according to the present embodiment. A drying method is not particularly limited. Examples thereof include lyophilization, spray drying, drum drying, shelf drying, air stream drying, and vacuum drying. Two or more methods among them may be used in combination. A spraying method during spray drying may be any spray drying method such as a disc type drying method, a pressure nozzle type drying method, a compressed two-fluid nozzle type drying method, and a compressed four-fluid nozzle type drying method. Two or more methods among them may be used in combination.
During the spray drying, a slight amount of a water-soluble polymer and a surfactant may be added in order to reduce the surface tension of the dispersion liquid. In order to accelerate the vaporization rate of the medium, a foaming agent or a substance to generate a gas may be added, or a gas may be added to the dispersion liquid. Specific examples of the water-soluble polymer, the surfactant, the foaming agent, the substance to generate a gas, and the gas are shown below, respectively. The water-soluble polymer, the surfactant, and the substance to generate a gas may be added before drying, and the order of addition is not particularly limited. Two or more of water-soluble polymers, surfactants and the substances to generate a gas respectively may be used in combination.
Examples of the water-soluble polymer include water-soluble polymers described in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as hydroxypropyl cellulose, hydroxypropyl methylcellulose, polyacrylic acid, carboxyvinyl polymers, polyethylene glycol, polyvinyl alcohol, polyvinylpyrrolidone, methylcellulose, acacia, and starch paste.
Examples of the surfactant include those classified as a surfactant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as phosphoruslipid, glycerin fatty acid ester, polyethylene glycol fatty acid ester, sorbitan fatty acid ester, polyoxyethylene hardened castor oil, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether, polyoxyethylene nonylphenyl ether, polyoxyethylene polyoxypropylene glycol, polyoxyethylene sorbitan monolaurate, polysorbate, sorbitan monooleate, glyceride monostearate, monooxyethylene sorbitan monopalmitate, monooxyethylene sorbitan monostearate, polyoxyethylene sorbitan monooleate, sorbitan monopalmitate, and sodium lauryl sulfate.
Examples of the foaming agent include foaming agents described in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as tartaric acid, sodium hydrogencarbonate, potato starch, anhydrous citric acid, medical soap, sodium lauryl sulfate, lauric acid diethanolamide, and Lauromacrogol.
Examples of the substance to generate a gas include bicarbonates that generate a gas by pyrolysis such as sodium hydrogen carbonate and ammonium hydrogen carbonate; and carbonates that react with an acid to generate a gas such as sodium carbonate and ammonium carbonate. In use of the carbonates, the carbonates are preferably used with an acid. Examples of the acid include organic acids such as citric acid, acetic acid, ascorbic acid, and adipic acid; proton acids such as hydrochloric acid, sulfuric acid, phosphoric acid, and nitric acid; and Lewis acids such as boron fluoride. Particularly, those used in pharmaceuticals and foods are preferable.
As the gas, gases such as nitrogen, carbon dioxide, liquefied petroleum gas, and dimethyl ether may be impregnated into the dispersion liquid.
The composite particles according to the present embodiment are formed by simultaneously drying the cellulose and the inorganic compound in the state where the inorganic compound exists in the dispersion liquid containing the cellulose. It is thought that if the medium is vaporized in the state where the cellulose and the inorganic compound are uniformly associated, capillary condensation acts to aggregate the cellulose and the inorganic compound densely. Even if only the cellulose is dried and the inorganic compound is added to and mixed with the dried cellulose, or only the inorganic compound is dried and the cellulose is added to and mixed with the dried inorganic compound, a composite product is not formed, thus the aggregate structure cannot be obtained. In the case where the cellulose in the dispersion liquid has a specific average width and average thickness, the cellulose has a large suppressing effect on excessive aggregation of particles caused by capillary condensation during drying, and can provide a large pore volume within the composite particles. When the composite particles according to the present embodiment are produced, cellulose particles and inorganic compound particles also remain in the dried powders. These cellulose particles and inorganic compound particles may be used as they are without separation.
The molded article according to the present embodiment is obtained by molding the composite particles according to the present embodiment and an active ingredient. Hereinafter, the molded article according to the present embodiment is described.
In the molded article, the proportion of the active ingredient to be used is in the range of 0.001 to 99%, and the proportion of the composite particles to be used is in the range of 1 to 99.999%. From the viewpoint of ensuring an amount effective in treatment, the proportion of the active ingredient is preferably 0.001% or more. From the viewpoint of practical hardness, friability, and disintegration properties, the proportion of the active ingredient is preferably 99% or less. More preferably, the molded article contains 1 to 90% of the composite particles. In the case where the active ingredient is a liquid, tableting problems such as sticking and capping occur. For this reason, the content of the active ingredient in the molded article is limited. The composite product according to the present invention has high liquid retention and compactibility, and can be blended with more than 20% of a liquid ingredient. The proportion of the liquid ingredient is preferably 21 to 50%, and particularly preferably 21 to 30%. The largest content of tocopherol acetate in the commercially available molded articles at present is 100 mg/500 mg of the total amount of the tablet. No commercially available molded articles contain more than 20% of tocopherol acetate. By use of the composite product according to the present invention, at a blending amount of the liquid ingredient of 21 to 50%, the molded article can be downsized in the range of 250 to 480 mg. Moreover, at a weight of a tablet of 500 mg, the amount of the liquid ingredient can be increased in the range of 105 to 250 mg. The amount of the liquid ingredient is preferably 120 to 200 mg, and more preferably 120 to 150 mg.
The molded article according to the present embodiment can be processed by a known method such as granulation, sizing, and tableting. Particularly, the composite particles according to the present embodiment are suitable for molding by tableting. If the composite particles according to the present embodiment and the active ingredient are contained in the ranges as described above, a molded article having sufficient hardness can be produced by the direct tableting method. In addition to the direct tableting method, the composite particles according to the present embodiment are also suitable for a dry granule compression method, a wet granule compression method, a compression method with extragranular addition of an excipient, a method of producing a multicore tablet using a tablet which is compressed in advance as an inner core, and a method of layering a plurality of molded articles compressed in advance and compressing the layered molded articles again to produce a multilayer tablet.
In the present embodiment, examples of the active ingredient include ingredients for a medicament, ingredients for health food, pesticide ingredients, fertilizer ingredients, livestock food ingredients, food ingredients, cosmetic ingredients, dyes, flavoring agents, metals, ceramics, catalysts, and surfactants. Ingredients for a medicament and ingredients for health food are suitable active ingredients.
The ingredients for a medicament are used in substances orally administered such as antipyretic analgesic anti-inflammatory, sedative hypnotic, drowsiness preventing, dizziness suppressing, children's analgesic, stomachic, antacid, digestive, cardiotonic, antiarrhythmic, hypotensive, vasodilator, diuretic, antiulcer, intestinal function-controlling, bone-building, antitussive expectorant, antiasthmatic, antimicrobial, pollakiuria-improving, analeptic drugs, and vitamins. Active pharmaceutical ingredients may be used alone, or two or more of ingredients may be used in combination. Specifically, examples of the medicinal ingredients can include ingredients for a medicament described in “Japanese Pharmacopeia,” “Japanese Pharmaceutical Codex (JPC),” “USP,” “NF,” and “EP” such as aspirin, aspirin aluminium, acetaminophen, ethenzamide, sasapyrine, salicylamide, lactylphenetidin, isotibenzyl hydrochloride, diphenylpyraline hydrochloride, diphenhydramine hydrochloride, difeterol hydrochloride, triprolidine hydrochloride, tripelenamine hydrochloride, thonzylamine hydrochloride, fenethazine hydrochloride, methdilazine hydrochloride, diphenhydramine salicylate, carbinoxamine diphenyldisulfonate, alimemazine tartrate, diphenhydramine tannate, diphenylpyraline teoclate, mebhydrolin napadisylate, promethazine methylenedisalicylate, carbinoxamine maleate, chlorpheniramine dl-maleate, chlorpheniramine d-maleate, difeterol phosphate, alloclamide hydrochloride, cloperastine hydrochloride, pentoxyverine citrate (carbetapentane citrate), tipepidine citrate, dibunate sodium, dextromethorphan hydrobromide, dextromethorphan-phenolphthalic acid, tipepidine hibenzate, chloperastine fendizoate, codeine phosphate, dihydrocodeine phosphate, noscapine hydrochloride, noscapine, di-methylephedrine hydrochloride, dl-methylephedrine saccharin salt, potassium guaiacolsulfonate, guaifenesin, caffeine and sodium benzoate, caffeine, anhydrous caffeine, vitamin B1 and its derivatives and their salts, vitamin B2 and its derivatives and their salts, vitamin C and its derivatives and their salts, hesperidin and its derivatives and their salts, vitamin B6 and its derivatives and their salts, nicotinic acid amide, calcium pantothenate, aminoacetic acid, magnesium silicate, synthetic aluminum silicate, synthetic hydrotalcite, magnesia oxide, dihydroxyaluminum-aminoacetate (aluminum glycinate), aluminium hydroxide gel (as dried aluminium hydroxide gel), dried aluminium hydroxide gel, aluminium hydroxide-magnesium carbonate mixed dried gel, aluminium hydroxide-sodium hydrogen carbonate coprecipitation products, aluminium hydroxide-calcium carbonate-magnesium carbonate coprecipitation products, magnesium hydroxide-potassium aluminum sulfate coprecipitation products, magnesium carbonate, magnesium aluminometasilicate, ranitidine hydrochloride, cimetidine, famotidine, naproxen, diclofenac sodium, piroxicam, azulene, indometacin, ketoprofen, ibuprofen, difenidol hydrochloride, diphenylpyraline hydrochloride, diphenhydramine hydrochloride, promethazine hydrochloride, meclizine hydrochloride, dimenhydrinate, diphenhydramine tannate, fenethazine tannate, diphenylpyraline teoclate, diphenhydramine fumarate, prometthazine methylenedisalicylate, scopolamine hydrobromide, oxyphencyclimine hydrochloride, dicyclomine hydrochloride, methixene hydrochloride, atropine methylbromide, anisotropine methylbromide, scopolamine methylbromide, methyl-1-hyoscyamine bromide, methylbenactyzium bromide, belladonna extract, isopropamide iodide, diphenylpiperidinomethyldioxolan iodide, papaverine hydrochloride, aminobenzoic acid, cesium oxalate, ethyl piperidinoacetylaminobenzoate, aminophyllin, diprophylline, theophylline, sodium hydrogen carbonate, fursultiamine, isosorbide nitrate, ephedrine, cefalexin, ampicillin, sulfixazole, sucralfate, allyl isopropylacetyl urea, bromovalerylurea and the like, ephedra herb, Nandina fruit, yellow bark, polygala root, licorice, platycodon root, plantago seed , plantago herb, senega root, fritillaria bulb, fennel, phellodendron bark, coptis rhizome, zedoary, matricaria, cassia bark, gentian, oriental bezoar, beast gall (containing bear bile), adenophorae radix, ginger, atractylodes lancea rhizome, clove, citrus unshiu peel, atractylodes rhizome, earthworm, panax rhizome, ginseng, japanese valerian, moutan bark, zanthoxylum fruit and extracts thereof, insulin, vasopressin, interferon, urokinase, serratio peptidase, and somatostatin. One selected from the above may be used alone, or two or more ingredients selected from the above may be used in combination.
The ingredients for health food are not limited as long as these are an ingredient blended for the purpose of augmenting. Examples thereof include powdered green juice, aglycone, agaricus, ashwagandha, astaxanthin, acerola, amino acids (valine, leucine, isoleucine, lysine, methionine, phenylalanine, threonine, tryptophan, histidine, cystine, tyrosine, arginine, alanine, aspartic acid, powdered seaweed, glutamine, glutamic acid, glycin, proline, serine, etc.), alginic acid, ginkgo biloba extract, sardine peptides, turmeric, uronic acid, echinacea , Siberian ginseng, oligosaccharides, oleic acid, nucleoproteins, dried skipjack peptides, catechin, potassium, calcium, carotenoid, garcinia cambogia , L-carnitine, chitosan, conjugated linoleic acid, Aloe arborescens, Gymnema sylvestre extract, citric acid, Orthosiphon stamineus , glycerides, glycenol, glucagon, curcumin, glucosamine, L-glutamine, chlorella , cranberry extract, Uncaria tomentosa , germanium, enzymes, Korean ginseng extract, coenzyme Q10, collagen, collagen peptides, coleus blumei, chondroitin, powdered psyllium husks, Crataegi fructus extract, saponin, lipids, L-cystine, Japanese basil extract, citrimax, fatty acids, phytosterol, seed extract, spirulina , squalene, Salix alba , ceramide, selenium, St. John's wort extract, soy isoflavone, soy saponin, soy peptides, soy lecithin, monosaccharides, proteins, chaste tree extract, iron, copper, docosahexaenoic acid, tocotrienol, nattokinase, Bacillus natto culture extract, sodium niacin, nicotine acid, disaccharides, lactic acid bacterium, garlic, saw palmetto, sprouted rice, pearl barley extract, herb extract, valerian extract, pantothenic acid, hyaluronic acid, biotin, chromium picolinate, vitamin A and A2, vitamin B1, B2 and B6, vitamin B12, vitamin C, vitamin D, vitamin E, vitamin K, hydroxytyrosol, bifidobacterium , beer yeast, fructo oligosaccharides, flavonoid, Butcher's broom extract, black cohosh, blueberry, prune concentrate, proanthocyanidin, proteins, propolis, bromelain, probiotics, phosphatidylcholine, phosphatidylserine, β-carotene, peptides, safflower extract, Grifola frondosa extract, maca extract, magnesium, milk thistle, manganese, mitochondria, mineral, mucopolysaccharides, melatonin, Fomes yucatensis , powdered melilot extract, molybdenum, vegetable powder, folic acid, lactose, lycopene, linolic acid, lipoic acid, phosphorus, lutein, lecithin, rosmarinic acid, royal jelly, DHA, and EPA
The active ingredient may be any form of powdery, crystalline, liquid, and semi-solid forms. A liquid active ingredient is suitable. The active ingredient may be coated or encapsulated for control of elution, reduction in bitterness, or the like. In use of the active ingredient, the active ingredient may be dissolved, suspended, or emulsified in a medium. A plurality of active ingredients may be used in combination.
Examples of the liquid active ingredient include ingredients for a medicament described in “Japanese Pharmacopeia,” “JPC,” “USP,” “NF,” and “EP” such as teprenone, indomethacin-farnesyl, menatetrenone, phytonadione, vitamin A oil, fenipentol, vitamins such as vitamin D and vitamin E, higher unsaturated fatty acids such as DHA (docosahexaenoic acid), EPA (eicosapentaenoic acid), and liver oil, coenzyme Qs, and oil-soluble flavorings such as orange, lemon, and peppermint oils. Moreover, vitamin E has various homologues and derivatives thereof. Examples thereof can include dl-α-tocopherol, dl-α-tocopherol acetate, tocopherol acetate, and d-α-tocopherol acetate. The homologues and derivatives of vitamin E are not particularly limited as long as these are a liquid at 25° C. These having a viscosity in the range of 3 to 10000 mPa·s are preferable. If a homologue or derivative of vitamin E has a proper viscosity, it preferably provides a good balance between compactibility and fluidity of the composite particles after the liquid ingredient is carried by the composite product. Tocopherol acetate is particularly preferable.
Examples of the semi-solid active ingredient can include, Kampo medicines or crude drug extracts such as earthworm, licorice, cassia bark, peony root, moutan bark, japanese valerian, zanthoxylum fruit, ginger, citrus unshiu peel, ephedra herb, nandina fruit, yellow bark, polygala root, platycodon root, plantago seed, plantago herb, shorttube lycoris, senega root, fritillaria bulb, fennel, phellodendron bark, coptis rhizome, zedoary, matricaria , gentian, oriental bezoar, beast gall, adenophorae radix, ginger, atractylodes lancea rhizome, clove, citrus unshiu peel, atractylodes rhizome, panax rhizome, ginseng, kakkonto, keishito, kousosan, saiko-keishito, shosaikoto, shoseiryuto, bakumondoto, hangekobokuto, and maoto, an oyster meat essence, propolis or an extract thereof, and coenzyme Qs.
The crystal of the active ingredient after molding may have the same shape as that before molding, or may have a shape different from that before molding. Preferably, the shape of the crystal after molding is the same as that before molding from the viewpoint of stability.
In addition to the active ingredient and the composite particles, the molded article according to the present embodiment freely contains excipients such as an excipient, a disintegrant, a binder, a fluidizing agent, a lubricant, a corrigent, a flavoring agent, a coloring agent, and a sweetener when necessary. Two or more excipients among them may be used in combination.
Examples of the excipient include those classified as an excipient in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as acrylated starch, L-asparagic acid, aminoethyl sulfonic acid, aminoacetate, wheat gluten (powder), acacia, powdered acacia, alginic acid, sodium alginate, pregelatinized starch, inositol, ethyl cellulose, ethylene-vinyl acetate copolymer, sodium chloride, olive oil, kaolin, cacao butter, casein, fructose, light gravel granule, carmellose, carmellose sodium, silicon dioxide hydrate, dry yeast, dried aluminum hydroxide gel, dried sodium sulfate, dried magnesium sulfate, agar, agar powder, xylitol, citric acid, sodium citrate, disodium citrate, glycerin, calcium glycerophosphate, sodium gluconate, L-glutamine, clay, clay grain, croscarmellose sodium, crospovidone, magnesium aluminosilicate, calcium silicate, magnesium silicate, light anhydrous silicic acid, light liquid paraffin, cinnamon powder, microcrystalline cellulose, microcrystalline cellulose-carmellose sodium, microcrystalline cellulose (grain), brown rice malt, synthetic aluminum silicate, synthetic hydrotalcite, sesame oil, wheat flour, wheat starch, wheat germ powder, rice powder, rice starch, potassium acetate, calcium acetate, cellulose acetate phthalate, safflower oil, white beeswax, zinc oxide, titanium oxide, magnesium oxide, β-cyclodextrin, dihydroxyaluminum aminoacetate, 2,6-dibutyl-4-methylphenol, dimethylpolysiloxane, tartaric acid, potassium hydrogen tartrate, plaster, sucrose fatty acid ester, magnesium hydroxide-aluminum hydroxide co-precipitate, aluminum hydroxide gel, aluminum hydroxide/sodium hydrogen carbonate coprecipitate, magnesium hydroxide, squalane, stearyl alcohol, stearic acid, calcium stearate, polyoxyl stearate, magnesium stearate, purified gelatine, purified shellac, purified sucrose, purified sucrose spherical granulated powder, cetostearyl alcohol, polyethylene glycol 1000 monocetyl ether, gelatine, sorbitan fatty acid ester, D-sorbitol, tricalcium phosphate, soybean oil, unsaponified soy bean, soy bean lecithin, powdered skim milk, talc, ammonium carbonate, calcium carbonate, magnesium carbonate, neutral anhydrous sodium sulfate, low substitution degree hydroxypropylcellulose, dextran, dextrin, natural aluminum silicate, corn starch, powdered tragacanth, silicon dioxide, NEWKALGEN 204, calcium lactate, lactose, par filler 101, white shellac, white vaseline, white clay, sucrose, sucrose/starch spherical granulated powder, naked barley green leaf extract powder, dried powder of bud and leaf juice of naked barley, honey, paraffin, potato starch, semi-digested starch, human serum albumin, hydroxypropyl starch, hydroxypropylcellulose, hydroxypropylcellulose, hydroxypropyl methylcellulose phthalate, phytic acid, glucose, glucose hydrate, partially pregelatinized starch, pullulan, propylene glycol, starch syrup of reduced malt sugar powder, powdered cellulose, pectin, bentonite, sodium polyacrylate, polyoxyethylene alkyl ethers, polyoxyethylene hydrogenated castor oil, polyoxyethylene (105) polyoxypropylene (5) glycol, polyoxyethylene (160) polyoxypropylene (30) glycol, sodium polystyrene sulfonate, polysorbate, polyvinylacetal diethylamino acetate, polyvinylpyrrolidone, polyethylene glycol (molecular weight of 1500 to 6000), maltitol, maltose, D-mannitol, water candy, isopropyl myristate, anhydrous lactose, anhydrous dibasic calcium phosphate, anhydrous dibasic calcium phosphate granulated substance, magnesium aluminometasilicate, methyl cellulose, cottonseed powder, cotton oil, haze wax, aluminum monostearate, glyceryl monostearate, sorbitan monostearate, pharmaceutical carbon, peanut oil, aluminum sulfate, calcium sulfate, granular corn starch, liquid paraffin, dl-malic acid, calcium monohydrogen phosphate, calcium hydrogenphosphate, calcium hydrogenphosphate granulated substance, sodium hydrogenphosphate, potassium dihydrogen phosphate, calcium dihydrogen phosphate, and sodium dihydrogen phosphate.
Examples of the disintegrant include those classified as a disintegrant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as croscarmellose sodium, carmellose, carmellose calcium, carmellose sodium, celluloses such as low substitution degree hydroxypropylcellulose, starches such as sodium carboxymethyl starch, hydroxypropyl starch, rice starch, wheat starch, corn starch, potato starch, and partly pregelatinized starch, and synthetic polymers such as crospovidone and crospovidone copolymer.
Examples of the binder include those classified as a binder in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) sugars such as sucrose, glucose, lactose and fructose, sugar alcohols such as mannitol, xylitol, maltitol, erythritol, and sorbitol, water-soluble polysaccharides such as gelatine, pullulan, carrageenan, locust bean gum, agar, glucomannan, xanthan gum, tamarind gum, pectin, sodium alginate, and acacia, celluloses such as microcrystalline cellulose, powdered cellulose, hydroxypropylcellulose and methyl cellulose, starches such as cornstarch, potato starch, pregelatinized starch and starch paste, synthetic polymers such as polyvinylpyrrolidone, carboxyvinyl polymer and polyvinyl alcohol, and inorganic compounds such as calcium hydrogenphosphate, calcium carbonate, synthetic hydrotalcite, and magnesium aluminosilicate.
Examples of the fluidizing agent include those classified as a fluidizing agent in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as silicon compounds such as silicon dioxide hydrate and light anhydrous silicic acid, wet silicas such as sodium silicates, calcium silicate, and sodium stearyl fumarate (trade name “PRUV” made by JRS).
Examples of the lubricant include those classified as a lubricant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as magnesium stearate, calcium stearate, stearic acid, sucrose fatty acid ester, talc, Fujicalin, and sodium stearyl fumarate (trade name “PRUV” made by JRS).
Examples of the corrigent include those classified as a corrigent in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as glutamic acid, fumaric acid, succinic acid, citric acid, sodium citrate, tartaric acid, malic acid, ascorbic acid, sodium chloride, and 1-menthol.
Examples of the flavoring agent include those classified as aromatics and flavoring agents in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as orange, vanilla, strawberry, yogurt, menthol, oils such as fennel oil, cinnamon bark oil, orange peel oil, and peppermint oil, and green tea powder.
Examples of the colorant include those classified as a colorant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as edible dyes such as edible red 3, edible yellow 5, and edible blue 1, sodium copper chlorophyllin, titanium oxide, and riboflavin.
Examples of the sweetener include those classified as a sweetener in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as aspartame, saccharin, dipotassium glycyrrhizinate, stevia, maltose, maltitol, starch syrup, and powdered sweet hydrangea leaf.
Examples of a form of the molded article include solid preparations such as tablets, powders, subtle granules, granules, and pills when the molded article is used for pharmaceuticals.
Hereinafter, a tablet is described as a suitable specific example of the molded article according to the present embodiment.
The tablet refers to a molded article containing the composite particles according to the present embodiment, the active ingredient, and when necessary other excipients, and obtained by tableting. The composite particles according to the present embodiment have high compression compactibility. Accordingly, a tablet for practical use can be obtained at a relatively low compression force. The composite particles according to the present embodiment can be molded and tableted at a low compression force. For this reason, the tablet can keep gaps (water introducing pipes) inside thereof. Such a tablet is suitable for an orally disintegrating tablet rapidly disintegrated in an oral cavity. In addition, the composite particles according to the present embodiment are suitable for multilayer tablets and core tablets obtained by compressing ingredients in several compositions at one stage or at multi stages. The composite particles according to the present embodiment have high effects of imparting high hardness to the molded article, and suppressing tableting problems, peel off between interlayers, and cracks. Further, the composite particles according to the present embodiment themselves have high dividing properties, thus a tablet formed of the composite particles according to the present embodiment is easy to be divided uniformly. Accordingly, the composite particles according to the present embodiment are also suitable for a scored tablet and the like.
The composite particles according to the present embodiment have a porous structure, and the composite particles themselves have high retention of the liquid ingredient such as fine particle drugs, suspended drugs, and liquid ingredients. For this reason, the molded article of the composite particles according to the present embodiment also has high retention of the liquid ingredient. For this reason, when a suspended or liquid ingredient is layered and coated on the tablet, the tablet also has a preventive effect on peel off of an outer layer such as a coating layer. Accordingly, the composite particles according to the present embodiment are also suitable for a layered tablet and a tablet having a coating layer (such as sugar-coated tablets, and tablets having a layered ingredient such as calcium carbonate).
Hereinafter, a method of producing a molded article containing the active ingredient and the composite particles according to the present embodiment is described. This is only an example, and the present invention is not limited to the description below.
Examples of a method for molding a molded article include a method of mixing the active ingredient with the composite particles according to the present embodiment, and compressing the mixture. At this time, the excipients other than the above-described active ingredient may be blended when necessary. The order of addition is not particularly limited. Examples of the method include:
1) a method in which the active ingredient is mixed with the composite particles according to the present embodiment and, when necessary, an excipient in batch, and the mixture is compressed; 2) a method in which the active ingredient is mixed with an excipient such as a fluidizing agent or a lubricant, and then mixed with the composite particles according to the present invention and, when necessary, an additional excipient, and the mixture is compressed; and 3) a method in which a lubricant is further mixed with the mixed powder for compression obtained by 1) or 2), and the obtained mixture is compressed.
A method for adding ingredients is not particularly limited as long as the method is a method usually performed. The ingredients may be added continuously or in batch using a small size suction transport apparatus, an air transport apparatus, a bucket conveyor, a pneumatic transport apparatus, a vacuum conveyer, a vibration type quantitative metering feeder, a spray, a funnel, or the like.
A mixing method is not particularly limited as long as the method is a method usually performed. A vessel rotation type mixer such as V-type, W-type, double cone type, and container tack type mixers, or a stirring type mixer such as high speed stirring type, universal stirring type, ribbon type, pug type, and Nauta-type mixers, a high speed fluid type mixer, a drum type mixer, or a fluidized bed type mixer may be used. Alternatively, a vessel shaking type mixer such as a shaker can be used.
A compression method is not particularly limited as long as the method is a method usually performed. The method may be a method of compressing ingredients into a desired shape using a die and a punch, or a method of compressing ingredients into a sheet form in advance and cutting the sheet into a desired shape. A usable compression machine is, for example, a compressor such as a hydrostatic press, a roller type press such as a briquetting roller type press or a smoothing roller type press, a single-punch tableting machine, or a rotary tableting machine.
In the case where an active ingredient poorly-soluble in water is used, generally, examples of the compression method include:
A) a method in which the active ingredient is pulverized, and mixed with the composite particles according to the present embodiment and, when necessary, other ingredient; and the obtained mixture is compressed; and B) a method in which the active ingredient is dissolved or dispersed in water, an organic solvent, or a solubilizing agent, and mixed with the composite particles according to the present embodiment and, when necessary, other excipients; when necessary, water or the organic solvent is removed; and the obtained mixture is compressed.
The composite particles according to the present embodiment are suitable for the above-described method B). In the method B), the active ingredient poorly-soluble or insoluble in water is once dissolved or dispersed. For this reason, the active ingredient can be carried by the composite particles securely. Thereby, separation or elution of the active ingredient during compression can be prevented to suppress sticking. The composite particles according to the present embodiment have high compression compactibility and fluidity. For this reason, in the case of the method B), the composite particles according to the present embodiment can be formed into a tablet at little variation in the weight by the compression.
The method B) is more suitable in the case where the active ingredient in the drug is used for pharmaceuticals and a liquid medium such as polyethylene glycol is used in combination as a dispersion medium. Polyethylene glycol or the like is used in order to keep the efficacy of the active ingredient which is easily metabolizable in the liver by coating the active ingredient with polyethylene glycol in the blood when the active ingredient is absorbed in a human body.
In the method B), in order to assist dissolution, it is effective to use a water-soluble polymer or a surfactant as a solubilizing agent in combination to disperse the active ingredient in a medium.
The organic solvent is not particularly limited as long as it is used for pharmaceuticals. Examples of the organic solvent include those classified as a solvent in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as alcohols such as methanol and ethanol, and ketones such as acetone. Two or more organic solvents among them are freely used in combination.
Examples of the water-soluble polymer as the solubilizing agent in the method B) include water-soluble polymers described in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as hydroxypropyl cellulose, hydroxypropyl methylcellulose, polyacrylic acid, carboxyvinyl polymer, polyethylene glycol, polyvinyl alcohol, polyvinylpyrrolidone, methylcellulose, ethylcellulose, acacia, and starch paste. Two or more water-soluble polymers among them are freely used in combination.
Examples of oils and fats as the solubilizing agent include oils and fats described in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as monoglyceride stearate, triglyceride stearate, sucrose stearic acid ester, paraffins such as liquid paraffin, carnauba wax, hydrogenated oils such as hydrogenated castor oil, castor oil, stearic acid, stearyl alcohol, and polyethylene glycol. Two or more oils and fats among them are freely used in combination.
Examples of the surfactant in the solubilizing agent include those classified as a surfactant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as phospholipid, glycerin fatty acid ester, polyethylene glycol fatty acid ester, sorbitan fatty acid ester, polyoxyethylene hardened castor oil, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether, polyoxyethylene nonylphenyl ether, polyoxyethylene polyoxypropylene glycol, polyoxyethylene sorbitansan monolaurate, polysorbate, sorbitan monooleate, glyceride monostearate, monooxyethylene sorbitansan monopalmitate, monooxyethylene sorbitan monostearate, polyoxyethylene sorbitan monooleate, sorbitan monopalmitate, and sodium lauryl sulfate. Two or more surfactants among them are freely used in combination.
In the method B), a dissolving or dispersing method is not particularly limited as long as it is a dissolving or dispersing method usually performed. A stirring/mixing method using a stirring blade of a one-direction rotation type, a multi-axis rotation type, a reciprocal inversion type, a vertical movement type, a rotation+vertical movement type, or a piping type such as a portable mixer, a three-dimensional mixer, and a side-wall mixer; a jet type stirring/mixing method such as a line mixer; a gas-blowing stirring/mixing method; a mixing method using a high-shear homogenizer, a high-pressure homogenizer, or an ultrasonic homogenizer; or a vessel shaking type mixing method using a shaker, or the like may be used.
The composite particles according to the present embodiment have a porous structure, and the composite particles themselves have high retention of the drug. For this reason, the particles carrying the drug within pores may be used as they are as fine granules, may be granulated as used for granules, or may be compressed.
A method for carrying a drug is not particularly limited as long as it is a known method. Examples of the method include:
i) a method in which the composite particles according to the present embodiment are mixed with a fine particle drug to be carried within pores; ii) a method in which the composite particles according to the present embodiment are mixed with a powdery drug at a high speed to be forcibly carried within pores;
iii) a method in which the composite particles according to the present embodiment are once mixed with a drug prepared as a solution or a dispersion liquid, the drug is carried within pores, and the obtained one is dried if necessary;
iv) a method in which the composite particles according to the present embodiment are mixed with a sublimation drug, and the mixture is heated and/or the pressure is reduced, thereby, the drug is sublimated and adsorbed within pores; and v) a method in which the composite particles according to the present embodiment are mixed with a drug before or during heating, and molten.
Two or more methods as described above may be used in combination.
Besides use as the tablet thus compressed, the composite particles according to the present embodiment may be used as granules or powders particularly in order to improve fluidity, blocking resistance, and aggregation resistance because the composite particles according to the present embodiment also have high retention of a solid or liquid ingredient. The above-described fine granules and the granules may be further coated.
As a method for producing granules and powders, the same effect is obtained even if any of dry granulation, wet granulation, heating granulation, spray drying, and microencapsulation is used, for example.
Moreover, the composite particles according to the present embodiment have proper moisture retention and oil retention. Accordingly, other than the excipient, the composite particles according to the present embodiment can be used as a core particle for layering and coating, and have a suppressing effect on aggregation of particles in a layering or coating step. The layering and coating may be a dry method or a wet method.
The composite particles according to the present embodiment are also used for foods such as confectionery, health foods, texture-improving agents, and dietary fiber-reinforcing agent, cake makeups, bath agents, animal drugs, diagnostic reagents, agricultural chemicals, fertilizers, and ceramic catalysts, and the like.
EXAMPLES
The present invention is described based on Examples. Embodiments of the present invention are not limited to the description of these Examples. In Examples and Comparative Examples, methods for measuring physical properties are as follows.
(1) Average Width of Cellulose (μm)
Cellulose primary particles formed of a natural cellulose were dried when necessary, and placed on a sample stage to which a carbon tape was attached. Platinum palladium was vacuum deposited (the membrane thickness of the deposited membrane at this time was 20 nm or less). Using a JSM-5510LV (trade name) made by JASCO Corporation, the cellulose primary particles were observed at an accelerating voltage of 6 kV and at a magnification of 250 times. A short diameter in the vicinity of the center of a long diameter of a cellulose particle was considered as a representative width, and the width was measured. The widths of three representative cellulose primary particles were measured, and the average was defined as the average width of the cellulose.
(2) Average Thickness of Cellulose (μm)
Cellulose primary particles formed of a natural cellulose were dried when necessary, and placed on a sample stage to which a carbon tape was attached. Gold was vacuum deposited. Then, using a focused ion beam processing apparatus (made by Hitachi, Ltd., FB-2100 (trade name)), a cross section of the cellulose primary particles was cut out with a Ga ion beam, and observed at an accelerating voltage of 6 kV and a magnification of 1500 times. A shorter diameter in the cross section of the cellulose particles was measured, and the obtained value was defined as the thickness (the cross section was cut out such that a longer diameter corresponded to the short diameter of the cellulose particle). The thicknesses of three representative cellulose primary particles were measured, and the average value thereof was defined as the thickness of the cellulose.
(3) Volume Average Particle Size of Cellulose or Inorganic Compound (μm)
The cellulose or the inorganic compound was dispersed in water to prepare a dispersion liquid. The volume average particle size of the cellulose or inorganic compound was defined as a 50% cumulative volume of particles in the dispersion liquid measured using a laser diffraction particle size distribution analyzer (made by HORIBA, Ltd., LA-910 (trade name)) wherein a measurement mode at 4 stirrings and 5 circulations was selected and the measurement condition was the transmittance of around 85%, an ultrasonic treatment for 1 minute, and the refractive index of 1.20. The measurement value as obtained above does not always correlate with the particle size distribution of dried particles obtained by the following Ro-Tap type apparatus because the measurement principles are totally different from each other. The volume average particle size measured by laser diffraction is measured from volume frequencies depending on the long diameter of fibrous particles while the weight average particle size obtained by the Ro-Tap type apparatus depends on the short diameter of fibrous particles because the obtained powder is shaken on a sieve and fractionated. Thus, there is a case that the value measured by the laser diffraction type apparatus depending on the long diameter of fibrous particles is larger than that measured by the Ro-Tap type apparatus depending on the short diameter of fibrous particles.
(4) Weight Average Particle Size of Composite Particles (μm)
10 g of a powder sample (dried composite particles) was sieved for 10 minutes using a Ro-Tap type sieve shaker (made by Taira Kosakusho Ltd., trade name “Sieve Shaker type A”) with a JIS standard sieve (Z8801-1987) to measure particle size distribution, and the weight average particle size of the powder sample was defined as a 50% cumulative weight particle size. The particle size distribution was determined using a 300 μm sieve, a 212 μm sieve, a 177 μm sieve, a 150 μm sieve, a 106 μm sieve, a 75 μm sieve, and a 38 μm sieve.
(5) Pore Size (μm), Intraparticle Pore Volume (cm 3 /g), Porosity (%)
Pore distribution was determined using a trade name “Autopore type 9520” made by SHIMADZU Corporation according to mercury porosimetry. Approximately 0.03 g to 0.05 g of each of sample powders used in the measurement was placed in a standard cell, and the pore distribution was measured twice on the condition of an initial pressure of 7 kPa (corresponding to approximately 1 psia, pore diameter of approximately 18 μm). From the obtained pore distribution, a volume at a pore size in the specific range of 0.003 to 1.0 μm was calculated as the pore volume. The porosity is the proportion of the pore volume to the volume of the sample when mercury is pressed into pores having a diameter of approximately 180 μm at an initial atmospheric pressure.
(6) Repose Angle (°)
Using a Sugihara-type repose angle measuring instrument (slit size depth 10×width 50×height 140 mm, a protractor was set at a position of 50 mm in width), a sample was continuously deposited in a measurement part little by little (3 g/min as a guideline) with an electromagnetic feeder (MF-1 type/TSUTSUI SCIENTIFIC INSTRUMENTS CO., LTD.). Thus, an inclined surface was formed. Immediately when an excessive sample started falling and the inclined surface became substantially linear, the feeder was turned off. The angle of the inclined surface was measured with the set protractor, and defined as the repose angle.
(7) Method for Compressing Sample
0.5 g of a sample was weighed, and placed in a die (Kikusui Seisakusho Ltd., a material used was SUS2,3). The sample was compressed with a punch having a circular flat surface having a diameter of 1.1 cm (made by Kikusui Seisakusho Ltd., a material of SUS2,3 was used) until the pressure reached 10 MPa (made by AIKOH ENGINEERING CO., LTD., a trade name “PCM-1A”, compression rate of 1 cm/min), and kept at a target pressure for 10 seconds to produce a cylindrical molded article.
(8) Hardness of Tablet (N)
Using a Schleuniger hardness tester (made by Freund Corporation, trade name “8M type”), a load was applied to a cylindrical molded article or a tablet in the diameter direction of the cylindrical molded article or tablet, and the load when the cylindrical molded article or tablet was broken was measured. The hardness of the tablet was defined as the average value obtained from ten samples.
(9) Apparent Specific Volume (cm 3 /g)
A 25 cm 3 container was set in a Scott Volumeter (made by VWR SCIENTIFIC, S64985 type). Next, using an electromagnetic feeder (MF-1 type/TSUTSUI SCIENTIFIC INSTRUMENTS CO., LTD.), a sample was put into the container at a rate of 10 to 20 g/min. When the sample overflowed from the set container, the container was taken out. An excessive amount of the sample was leveled off, and the mass of the sample was measured. The apparent specific volume was defined as a value (cm 3 /g) obtained by dividing the volume of the container (25 cm 3 ) by the mass of the sample. The sample was measured twice, and the average value was used.
(10) Retention Rate of Tocopherol Acetate (%)
2 g of a sample was weighed. While the sample was kneaded, tocopherol acetate (viscosity at 25° C.: 3300 mPa·s) was dropped on the sample little by little. The end point was defined as the amount of the liquid when the liquid eluted on the surface of the sample. The retention rate of tocopherol acetate is represented by the following expression: retention rate of tocopherol acetate (%)=amount of dropped liquid g/2 g of sample×100 The measurement value was defined as the average value of measurement values obtained from two samples.
(11) The Number of Capping to be Occurred
50 tablets after tableting were arbitrarily sampled, and the number of the tablets cracked or partially peeled was counted.
(12) Sticking Occurrence Rate (%)
50 tablets were examined visually, and the number of the tablets having peel-off or damages on the surface was counted. The sticking occurrence rate (%) was defined as the proportion of the number of tablets having sticking.
(13) Weight CV Value
10 tablets after tableting were arbitrarily sampled, and the weights of the samples were measured. From the average value and standard deviation of the measured values, the weight CV value was defined as weight CV value=(standard deviation/average value)×100[%]. A larger weight CV value causes larger variation in the weight, leading to increase in variation in the content of the drug and reduced yield of products. At a weight CV value of more than 1.0%, practical problems arise.
(14) Scanning Electron Microscope Photograph (Hereinafter, Abbreviated to SEM)
Measurement was performed using an electron microscope (made by JEOL, Ltd., JSM-551OLV type). A sample was mounted on a sample moving stage. According to a gold deposition method (AUTO FINE COATER, made by JEOL, Ltd., JFC-1600 type), the surface of the sample is thinly and uniformly coated with metal particles. Then, the sample moving stage was installed within a sample chamber. The inside of the sample chamber was made to be vacuum. The sample position was irradiated with an electron beam, and an enlarged image of the portion to be observed was output.
(15) Average Polymerization Degree
The average polymerization degree was defined as the value measured by a copper ethylenediamine solution viscosity method described in the Identification Test for Microcrystalline Cellulose (3) of The Japanese Pharmacopoeia, Fourteenth Edition.
(16) L/D of Cellulose Particles Dispersed in Water
The average L/D of cellulose particles dispersed in water was measured as follows. Using a JIS standard sieve (Z8801-1987), an aqueous dispersion liquid of the cellulose was passed through a 75 μm sieve. In the particles remaining on a 38 μm sieve, an optical microscope image of the remaining particles was subjected to an image analysis processing (made by Inter Quest Co., Ltd., apparatus: Hyper 700, software: Imagehyper). The L/D of a particle was defined as the ratio of a longer side to a shorter side (longer side/shorter side) of the rectangle having the smallest area among rectangles circumscribed about the particle. The average L/D of the particle was obtained using the average value of L/D obtained from at least 100 particles.
Example 1
A broad leaf tree was subjected to known pulping and bleaching treatments to obtain a pulp (the average width of the cellulose primary particle was approximately 19 μm, and the average thickness of the cellulose primary particle was approximately 3 μm). 4.5 kg of the chipped pulp and 30 L of a 0.2% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 124° C. for 1 hour to obtain an acid insoluble residue (hereinafter, referred to as a Wet cake). The volume average particle size of the cellulose particle was measured by a laser diffraction/scattering particle size distribution analyzer (made by HORIBA, Ltd., trade name “LA-910”) at a refractive index of 1.20. The obtained volume average particle size was 25 μm.
Pure water was introduced into a plastic bucket. While pure water was stirred by a 3-1 motor, the Wet cake was added and mixed. Next, calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 μm) was added and mixed. The mass ratio was cellulose/calcium silicate=28.6/71.4 (based on the solid content), and the concentration of the total solid content was approximately 8.5% by mass. The obtained mixture was spray dried (dispersion liquid feed rate of 6 kg/hr, inlet temperature of 180 to 220° C., outlet temperature of 70 to 95° C., number of rotation of an atomizer of 15000 rpm) to obtain Composite Particles A. The physical properties of Composite Particles A are shown in Table 1.
Examples 2 and 3
A broad leaf tree was subjected to known pulping treatment and bleaching treatments to obtain a pulp (the average width of the cellulose primary particle was approximately 19 μm, and the average thickness of the cellulose primary particle was approximately 3 μm). 4.5 kg of the chipped pulp and 30 L of a 0.2% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 124° C. for 1 hour to obtain an acid insoluble residue (hereinafter, referred to as a Wet cake). The volume average particle size of the cellulose particle was measured by a laser diffraction/scattering particle size distribution analyzer (made by HORIBA, Ltd., trade name “LA-910”) at a refractive index of 1.20. The obtained volume average particle size was 25 μm.
Pure water was introduced into a plastic bucket. While pure water was stirred by a 3-1 motor, starch (made by Asahi Kasei Chemicals Corporation, trade name “SWELSTAR” WB-1) was added and mixed. Next, the Wet cake was added and mixed. Next, calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 μm) was added and mixed. The mass ratio was starch/cellulose/calcium silicate=10/20/1970 (based on the solid content), and the concentration of the total solid content was approximately 8.5% by mass (pH was 10.2). The obtained mixture was spray dried (dispersion liquid feed rate of 6 kg/hr, inlet temperature of 180 to 220° C., outlet temperature of 70 to 95° C., number of rotation of an atomizer of 15000 rpm, 30000 rpm). Thus, Composite Particles B (number of rotation of an atomizer of 15000 rpm) and Composite Particles C (number of rotation of an atomizer of 30000 rpm) were obtained. The physical properties of Composite Particles B and C are shown in Table 1.
Examples 4 and 5
A broad leaf tree was subjected to known pulping and bleaching treatments to obtain a pulp (the average width of the cellulose primary particle was approximately 19 μm, and the average thickness of the cellulose primary particle was approximately 3 μm). 4.5 kg of the chipped pulp and 30 L of a 0.2% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 124° C. for 1 hour to obtain an acid insoluble residue (hereinafter, referred to as a Wet cake). The volume average particle size of the cellulose particle was measured by a laser diffraction/scattering particle size distribution analyzer (made by HORIBA, Ltd., trade name “LA-910”) at a refractive index of 1.20. The obtained volume average particle size was 25 μm.
Pure water was introduced into a plastic bucket. While pure water was stirred by a 3-1 motor, the Wet cake was added and mixed. Next, calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 μm) was added and mixed. The mass ratio was cellulose/calcium silicate=20/80 (based on the solid content), and the concentration of the total solid content was approximately 8.5% by mass. The mixture was spray dried (dispersion liquid feed rate of 6 kg/hr, inlet temperature of 180 to 220° C., outlet temperature of 70 to 95° C., number of rotation of an atomizer of 15000 rpm and 30000 rpm). Thus, Composite Particles D (number of rotation of an atomizer of 15000 rpm), and Composite Particles E (number of rotation of an atomizer of 30000 rpm) were obtained. The physical properties of Composite Particles D and E are shown in Table 1.
Examples 6 and 7
Composite particles F (number of rotation of an atomizer of 15000 rpm) and Composite Particles G (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Examples 2 and 3 except that the mass ratio was starch/cellulose/calcium silicate=5/40/55 (based on the solid content). The physical properties of Composite Particles F and G are shown in Table 1.
Examples 8 and 9
Composite Particles H (number of rotation of an atomizer of 15000 rpm) and Composite Particles I (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Examples 2 and 3 except that the mass ratio was starch/cellulose/calcium silicate=7/43/50 (based on the solid content), and the concentration of the total solid content was 9.3% by mass. The physical properties of Composite Particles H and I are shown in Table 1.
Examples 10 and 11
Composite particles J (number of rotation of an atomizer of 15000 rpm) and Composite Particles K (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Examples 4 and 5 except that the mass ratio was cellulose/calcium silicate=60/40 (based on the solid content), and the concentration of the total solid content was 11.7% by mass. The physical properties of Composite Particles J and K are shown in Table 1.
Examples 12 and 13
Composite particles L (number of rotation of an atomizer of 8000 rpm) and Composite Particles M (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Examples 2 and 3 except that the mass ratio was starch/cellulose/calcium silicate=3/60/37 (based on the solid content), the concentration of the total solid content was 11.7% by mass, and the number of rotation of an atomizer was 8000 rpm and 30000 rpm. The physical properties of Composite Particles L and M are shown in Table 1.
Example 14
Composite particles N (number of rotation of an atomizer of 15000 rpm) were obtained in the same manner as in Example 2 except that the mass ratio was starch/cellulose/calcium silicate=2.5/72.5/25 (based on the solid content), and the concentration of the total solid content was 11.7% by mass. The physical properties of Composite Particles N are shown in Table 1.
Example 15
Composite particles O (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Example 5 except that the mass ratio was cellulose/light anhydrous silicic acid=50/50 (based on the solid content), and the concentration of the total solid content was 4% by mass. The physical properties of Composite Particles O are shown in Table 1.
Example 16
Composite particles P (number of rotation of an atomizer of 15000 rpm) were obtained in the same manner as in Example 4 except that the mass ratio was cellulose/magnesium aluminometasilicate=30/70 (based on the solid content), and the concentration of the total solid content was 5% by mass. The physical properties of Composite Particles P are shown in Table 1.
Example 17
Composite particles Q (number of rotation of an atomizer of 15000 rpm) were obtained in the same manner as in Example 4 except that the mass ratio was cellulose/magnesium silicate hydrate=50/50 (based on the solid content), and the concentration of the total solid content was 5% by mass. The physical properties of Composite Particles Q are shown in Table 1.
TABLE 1
Inorganic
Cellulose
compound
volume
volume
Cellulose
Cellulose
average
average
Inorganic
Starch
average
average
particle
particle
Cellulose
compound
Kind of
parts
width
thickness
size
size
parts by
parts by
inorganic
by
Table 1
[μm]
[μm]
[μm]
[μm]
mass
mass
compound
mass
Example 1
A
19
3
25
25
28.6
71.4
Calcium silicate Ca
—
Example 2
B
19
3
25
25
20
70
Calcium silicate Ca
10
Example 3
C
19
3
25
25
20
70
Calcium silicate Ca
10
Example 4
D
19
3
25
25
20
80
Calcium silicate ca
—
Example 5
E
19
3
25
25
20
80
Calcium silicate Ca
—
Example 6
F
19
3
25
25
40
55
Calcium silicate Ca
5
Example 7
G
19
3
25
25
40
55
Calcium silicate Ca
5
Example 8
H
19
3
25
25
43
50
Calcium silicate Ca
7
Example 9
I
19
3
25
25
43
50
Calcium silicate Ca
7
Example 10
J
19
3
25
25
60
40
Calcium silicate Ca
—
Example 11
K
19
3
25
25
60
40
Calcium silicate Ca
—
Example 12
L
19
3
25
25
60
37
Calcium silicate Ca
3
Example 13
M
19
3
25
25
60
37
Calcium silicate Ca
3
Example 14
N
19
3
25
25
72.5
25
Calcium silicate Ca
2.5
Example 15
O
19
3
20
0.016
50
50
Light anhydrous
—
silicic acid
Example 16
P
19
3
25
12
30
70
Magnesium
—
aluminometasilicate
Example 17
Q
19
3
50
0.07
50
50
Magnesium silicate
—
hydrate Mg
Weight
Retention
Apparent
average
rate of
Hardness
specific
Repose
Pore
particle
tocopherol
of
volume
angle
Volume
Porosity
size
acetate
tablet
Table 1
[cm 3 /g]
[°]
[cm 3 /g]
[%]
[μm]
[%]
[N]
Example 1
A
10.8
35
2.71
33.1
48
860
240
Example 2
B
10.4
34.5
2.70
32.4
38
830
233
Example 3
C
10.7
37.5
2.81
33.1
55
860
244
Example 4
D
11.5
35
3.15
35.5
31
915
325
Example 5
E
11.6
36.5
3.15
35.5
32
875
312
Example 6
F
8.7
32
1.97
27.4
80
703
243
Example 7
G
8.8
34
2.09
28.2
60
738
261
Example 8
H
9.4
30
2.32
29.8
90
725
264
Example 9
I
8.7
33
2.05
28.0
70
760
240
Example 10
J
8.2
35
1.84
26.5
65
575
239
Example 11
K
7.7
39
1.63
25.0
50
520
220
Example 12
L
7.1
35
1.43
23.8
210
590
190
Example 13
M
7.2
35.5
1.48
24.1
61
530
200
Example 14
N
7.1
38.5
1.44
23.9
49
485
236
Example 15
O
12.5
41
1.50
25.1
29
500
150
Example 16
P
10.5
37
1.55
24.9
40
510
170
Example 17
Q
11.6
38
1.21
20.2
38
450
148
Reference Example 1
100 g of pure water was introduced into a stainless steel jug. While pure water was stirred by a 3-1 motor, calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 to 30 μm) was added little by little with a dispensing spoon and stirred. When the amount of calcium silicate added reached 10.7 g, stirring became impossible.
Reference Example 2
Pure water was introduced into a stainless steel jug. While pure water was stirred by a 3-1 motor, the Wet cake obtained in Example 1 was added and mixed. Next, while SiO 2 (trade name: Aerosil 200, made by Nippon Aerosil Co., Ltd., volume average particle size of 0.016 μm) was added little by little with a dispensing spoon, the materials were stirred and mixed. The mass ratio was cellulose/light anhydrous silicic acid=29.3/70.7 (based on the solid content), and the concentration of the total solid content was 8.5% by mass (pH was 10.2). The obtained product was gluey, and could not be spray dried.
Reference Example 3
Pure water was introduced into a stainless steel jug. While pure water was stirred by a 3-1 motor, the Wet cake obtained in Example 1 was added and mixed. Next, magnesium aluminometasilicate (trade name: Neusilin, made by Fuji Chemical Industry Co., Ltd.) was mixed. The mass ratio was cellulose/magnesium aluminometasilicate=31.0/69.0 (based on the solid content), and the concentration of the total solid content was 11.7% by mass (pH was 10.2). The obtained product was creamy, and could not be spray dried.
Comparative Example 1
The physical properties of calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 μm) are shown in Table 2.
Comparative Example 2
Composite particles R were obtained in the same manner as in Example 4 except that the mass ratio was starch/cellulose/calcium silicate=2.5/72.5/25 (based on the solid content), and the concentration of the total solid content was 11.7% by mass. The physical properties of Composite Particles R are shown in Table 2.
Comparative Example 3
2 kg of a chipped commercially available dissolved pulp (acicular tree pulp, average width of the cellulose primary particle was approximately 39 μm, average thickness of the cellulose primary particle was approximately 8 μm) and 30 L of a 0.4% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 116° C. for 1 hour to obtain an acid insoluble residue (the volume average particle size of the cellulose dispersed particle was 51 and L/D was 3.4). The obtained acid insoluble residue and silicon dioxide (made by Tokuyama Corporation, trade name, FINESEAL, volume average particle size of 5 μm) as a water insoluble inorganic compound were introduced into a 90 L plastic bucket at an amount ratio of 30/70 (based on the solid content). Pure water was added such that the concentration of the total solid content became 20% by weight. While the materials were stirred by a 3-1 motor, the materials were neutralized with aqueous ammonia (pH after neutralization was 7.5 to 8.0). The obtained product was spray dried (dispersion liquid feed rate of 6 kg/hr, inlet temperature of 180 to 220° C., outlet temperature of 50 to 70° C., number of rotation of an atomizer of 30000 rpm) to obtain Composite Particles S (corresponding to Example 2 in Patent Literature 3). The physical properties of Composite Particles S are shown in Table 2.
Comparative Example 4
2 kg of a chipped commercially available pulp (acicular tree pulp, average width of the cellulose primary particle was approximately 39 μm, average thickness of the cellulose primary particle was approximately 8 μm) and 30 L of a 0.2% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30 LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 116 ° C. for 1 hour to obtain an acid insoluble residue (the volume average particle size of the cellulose dispersed particle was 72 μM, and L/D was 4.0). The acid insoluble residue (solid content) and talc (made by Wako Pure Chemical Industries, Ltd., prepared so as to have a volume average particle size of 5 μm) were introduced into a 90 L plastic bucket at an amount ratio of 98/2 (based on the solid content). Pure water was added such that the concentration of the total solid content became 10% by weight. While the materials were stirred by a 3-1 motor, the materials were neutralized with aqueous ammonia (pH after neutralization was 7.5 to 8.0). The obtained product was spray dried in the same manner as that in Comparative Example 3 to obtain Composite Particles T (corresponding to example 6 in Patent Literature 3). The physical properties of Composite Particles T are shown in Table 2 .
Comparative Example 5
Ceolus PH-101 (made by Asahi Kasei Chemicals Corporation) was used as a microcrystalline cellulose. The cellulose and calcium silicate at a mass ratio of cellulose/calcium silicate=28.6/71.4 were sufficiently mixed in a plastic bag for 3 minutes to obtain Mixture U of cellulose/calcium silicate (the mixture having the largest amount of silicic acid to be blended which is described in Patent Literature 4). The physical properties of Mixture U are shown in Table 2.
Comparative Example 6
Ceolus PH-101 (made by Asahi Kasei Chemicals Corporation) was used as a microcrystalline cellulose. The cellulose and calcium silicate at a mass ratio of cellulose/calcium silicate=71.4/28.6 were sufficiently mixed in a plastic bag for 3 minutes to obtain Mixture V of cellulose/calcium silicate (the mixture having the smallest amount of silicic acid to be blended which is described in Patent Literature 4). The physical properties of Mixture V are shown in Table 2.
TABLE 2 Inorganic Cellulose Cellulose compound Inorganic average average Cellulose particle Cellulose compound Starch width thickness particle size size parts by parts by Kind of inorganic parts by [μm] [μm] [μm] [μm] mass mass compound mass Comparative — — — — 25 — 100 Calcium silicate Ca — Example 1 Comparative R 19 3 22-27 25 72.5 25 Calcium silicate Ca 2.5 Example 2 Comparative S 39 8 51 5 30 70 Silicon dioxide — Example 3 Comparative T 39 8 72 5 98 2 Talc — Example 4 Comparative U 39 8 38 25 28.6 71.4 Calcium silicate Ca — Example 5 Comparative V 39 8 38 25 71.4 28.6 Calcium silicate Ca — Example 6 Retention Apparent Average rate of specific Repose Pore particle tocopherol Hardness volume angle volume Porosity size acetate of tablet [cm 3 /g] [°] [cm 3 /g] [%] [μm] [%] [N] Comparative — 13.7 40 3.95 41.0 56 885 348 Example 1 Comparative R 6.9 40.5 1.37 23.3 50 440 215 Example 2 Comparative S 5.1 32 1.25 22.1 52 400 45 Example 3 Comparative T 6 45 0.29 17.2 45 204 110 Example 4 Comparative U 11 42 1.88 27.1 29 687 265 Example 5 Comparative V 7.4 38 1.00 20.4 39 390 145 Example 6
<SEM Photograph>
Using a “JSM-5510LV type” electron microscope made by JEOL, Ltd., Composite Particles B, D, G, I, K, and M were observed by SEM.
It is found that the particle has relatively few irregularities on the surface, and has a shape close to a sphere in Composite Particles B in Example 2 (see FIG. 1 ), Composite Particles D in Example 4 (see FIG. 2 ), Composite Particles G in Example 7 (see FIG. 3 ), and Composite Particles I in Example 9 (see FIG. 4 ). It is also found that the cellulose WET cake (see FIG. 5 ) and calcium silicate in Reference Example 2 (see FIG. 6 ) are formed into a composite product which has gaps. The gaps can provide a molded article having high liquid retention rate and hardness.
Meanwhile, the particle has irregularities on the surface in Composite Particles K in Example 11 ( FIG. 7 ) and Composite Particles M in Example 13 (see FIG. 8 ).
<Evaluation of Prevention of Sticking>
Ibuprofen is a representative example of a drug easy to stick. Using ibuprofen, comparison was made about the sticking-preventing effect. Granulated granules having ibuprofen blended were produced by the following method.
In the total amount of ingredients of 1000 g, 45% of ibuprofen (made by API Corporation), 38% of lactose hydrate (trade name: lactose 200M, made by DMV International), and 17% of corn starch (GRDE: ST-C, made by NIPPON STARCH CHEMICAL CO., LTD.) were weighed and mixed in a polyethylene bag for 3 minutes. Then, the mixture was placed in a vertical granulator (made by Powrex Corporation, FM-VG-10P type) and mixed (blade at 200 rpm, chopper at 2100 rpm). 200 g of a hydroxypropyl cellulose (trade name: HPC-L, made by NIPPON SODA CO., LTD.) 6% solution was poured over 30 seconds. Further, the ingredients were mixed (granulated) for 3 minutes, and taken out from the granulator. Next, the mixture was dried using a MULTIPLEX (made by Powrex Corporation, MP-01 type). The drying was completed when the temperature of exhaust air reached 40° C. Then, a granulated product was extracted. The granulated product was sieved with a sieve having an opening of 710 μm, and used as a test sample (hereinafter, referred to as granulated granules).
Example 18
88% by mass of the granulated granules, 2% by mass of croscarmellose sodium (made by NICHIRIN CHEMICAL INDUSTRIES, LTD.), “KICCOLATE” ND-2HS), and 10% by mass of Composite Particles C of Example 3 were mixed in a polyethylene bag for 3 minutes. Next, based on the total weight of the mixed powder, 0.5% by mass of magnesium stearate (made by TAIHEI CHEMICAL INDUSTRIAL CO., LTD.) was added, and mixed slowly for 30 seconds. Using a rotary tableting machine (made by Kikusui Seisakusho Ltd., CLEANPRESS CORRECT 12HUK), the mixed powder was tableted with a punch having a diameter of 0.8 cm and 12R on the condition of the number of rotation of the turn table of 54 rpm, a compression force of 5 to 15 kN, and open feed. Thus, a tablet having a weight of 180 mg was produced. The physical properties of the tablet are shown in Table 3.
Example 19
The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Composite Particles H of Example 8. The physical properties of the tablet are shown in Table 3.
Comparative Example 7
The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by light anhydrous silicic acid (made by Nippon Aerosil Co., Ltd., Aerosil 200). The physical properties of the tablet are shown in Table 3.
Comparative Example 8
The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Composite Particles S of Comparative Example 3. The physical properties of the tablet are shown in Table 3.
Comparative Example 9
The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Composite Particles T of Comparative Example 4. The physical properties of the tablet are shown in Table 3.
Comparative Example 10
The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Mixture U of Comparative Example 5. The physical properties of the tablet are shown in Table 3.
Comparative Example 11
The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Mixture V of Comparative Example 6. The physical properties of the tablet are shown in Table 3.
TABLE 3
Sticking occurrence
Number of
Items
Hardness [N]
Mass CV [%]
Friability [%]
rate [%]
cappings occurred
Compression force [kN]
5
10
15
5
10
15
5
10
15
15
15
Example 18
Composite particles C
59
85
102
0.5
0.6
0.5
0.45
0.15
0.11
0
None
Example 19
Composite particles H
70
90
79
0.9
0.5
0.9
0.16
0.08
0.17
0
None
Comparative
Light anhydrous silicic
30
53
38
2.2
2.1
1.6
0.39
0.43
2.85
0
2
Example 7
acid
Comparative
Composite particles S
20
35
40
1.9
2.3
1.5
2.50
1.90
1.20
5
25
Example 8
Comparative
Composite particles T
20
48
60
2.8
1.8
3.4
2.40
1.00
0.80
20
5
Example 9
Comparative
Mixture U
26
40
30
1.5
1.4
1.9
1.00
0.90
0.80
10
25
Example 10
Comparative
Mixture V
20
37
43
1.8
1.6
2.1
1.8
1.20
0.70
50
40
Example 11
In Examples 18 and 19, tablets having a practical hardness of 50 N or more, the weight CV value of 1.0% or less, and no tableting problems (sticking, capping) were obtained. Meanwhile, in Comparative Example 7, tableting problems (no sticking, but two cappings) were occurred. The weight CV value was more than 1.0%. Accordingly, the tablet in Comparative Example 7 is not suitable for practical use. In Comparative Examples 8 to 11, the weight CV value was more than 1.0%, and tableting problems (sticking, capping) were remarkable. Accordingly, the tablets in Comparative Examples 8 to 11 are not suitable for practical use.
In Comparative Example 9, a practical hardness of 50 N or more was obtained at the compression force of 15 kN while the friability was 0.8% and did not satisfy the practical level of 0.5% or less.
The disintegrating time of the tablet was measured in the respective tablets, but no remarkable difference was found among the tablets.
<Method for Producing Emulsion Solution>
360 g of Riken tocopherol acetate (Riken Vitamin Co., Ltd.) as an liquid active ingredient, Tween 80 (Wako Pure Chemical Industries, Ltd.), and 1000 g of pure water were weighed, and stirred and mixed with a TK homomixer (PRIMIX Corporation, MARK2 2.5 type) at 10000 rpm for 15 minutes to produce an emulsified solution.
Example 20
360 g of Composite Particles C of Example 3 was put into a vertical granulator (made by Powrex Corporation, FM-VG-10P). While Composite Particles C were mixed on the condition of a blade at 200 rpm and a chopper at 2100 rpm, 360 g of the emulsified solution produced above was poured in 30 seconds. The obtained mixture was granulated for 6 minutes, and discharged. Next, the granulated product was dried with an oven (made by Tabai Espec Corp., ESPEC Oven PV-211), and passed through a sieve having an opening of 710 μm (made by Iida Seisakusho K.K., sieve for a test) to obtain a dried product. The dried product was used as a test sample (hereinafter, referred to as VE granules). The repose angle of the VE granules was 35° and good.
35% by mass of the VE granules, 45% by mass of a microcrystalline cellulose (made by Asahi Kasei Chemicals Corporation, UF-711), 18% by mass of anhydrous dibasic calcium phosphate (made by Fuji Chemical Industry Co., Ltd., Fujicalin), and 2% by mass of croscarmellose sodium (made by NICHIRIN CHEMICAL INDUSTRIES, LTD, “KICCOLATE” ND-2HS) were mixed in a polyethylene bag for 3 minutes. Next, based on the total weight of the mixed powder, 2.0% by mass of magnesium stearate (made by TAIHEI CHEMICAL INDUSTRIAL CO., LTD.) was added, and further mixed slowly for 30 seconds. Using a rotary tableting machine (made by Kikusui Seisakusho Ltd., LIBRA2), the mixed powder was tableted using a punch having a diameter of 0.8 cm and 12R on the condition of the number of rotation of the turn table of 30 rpm, the compression force of 2 to 7 kN, and open feed to produce a tablet having a weight of 200 mg. The physical properties of the tablet are shown in Table 4.
Comparative Example 12
The operation was performed in the same manner as in Example 20 except that Composite Particles C were replaced by calcium silicate (made by Tokuyama Corporation, product name: Florite Grade(R), volume average particle size (which was measured at the state of aggregated particles) of 25 to 30 μm). The physical properties of the tablet are shown in Table 4. The repose angle of the VE granules was 41°. Fluidity was inferior to that in the case where Composite Particles C were used.
Comparative Example 13
The operation was performed in the same manner as in Example 20 except that Composite Particles C were replaced by Composite Particles S. The physical properties of the tablet are shown in Table 4.
Comparative Example 14
The operation was performed in the same manner as in Example 20 except that Composite Particles C were replaced by Mixture U. The physical properties of the tablet are shown in Table 4.
TABLE 4
Items
Sticking occurrence rate [%]
Compression force [kN]
2
3
4
5
6
7
Example 20
Composite particles C
0
0
0
Comparative
Calcium silicate
31.0
11.3
75.0
Example 12
Comparative
Composite particles S
Powder cannot be obtained
Example 13
Comparative
Mixture U
Powder cannot be obtained
Example 14
In Example 20, a tablet having a practical hardness of 50 N or more, a weight CV value of 1.0% or less, and no tableting problems (sticking, capping) were obtained. Meanwhile, in Comparative Example 12, the sticking occurrence rate was not 0 at all of the compression forces. Accordingly, the tablet is not suitable for practical use. In Comparative Examples 13 and 14, the retention rate of tocopherol acetate was low, and powder could not be obtained.
Industrial Applicability
The composite particles according to the present invention have extremely high compactibility and fluidity. For this reason, the composite particles according to the present invention have high uniformity of mixing with the active ingredients when the composite particles according to the present invention are used as an excipient mainly in the pharmaceutical field in production of a molded article containing a variety of active ingredients. Moreover, the composite particles according to the present invention can keep the compactibility and fluidity of the particles even after retention of the liquid to prevent tableting problems. In addition, the weight of the molded article according to the present invention is hardly fluctuated. The molded article according to the present invention has high uniformity of the active ingredients contained, high sufficient hardness, and low friability. | 4y
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FIELD OF THE INVENTION
[0001] The present invention relates to a method of and a device for storing data values in a memory unit.
[0002] This invention may be used in portable apparatuses adapted to render graphical objects such as, for example, video decoders, 3D graphic accelerators, video game consoles, personal digital assistants or mobile phones.
BACKGROUND OF THE INVENTION
[0003] Texture mapping is a process for mapping an input image onto a surface of a graphical object to enhance the visual realism of a generated output image including said graphical object. Intricate detail at the surface of the graphical object is very difficult to model using polygons or other geometric primitives, and doing so can greatly increase the computational cost of said object. Texture mapping is a more efficient way to represent fine detail on the surface of the graphical object. In a texture mapping operation, a texture data item of the input image is mapped onto the surface of the graphical object as said object is rendered to create the output image.
[0004] In conventional digital images, the input and output images are sampled at discrete points, usually on a grid of points with integer coordinates. The input image has its own coordinate space (u,v). Individual elements of the input image are referred to as “texels”. Said texels are located at integer coordinates in the input coordinate system (u,v). Similarly, the output image has its own coordinate space (x,y). Individual elements of the output image are referred to as “pixels”. Said pixels are located at integer coordinates in the output coordinate system (x,y).
[0005] The process of texture mapping conventionally includes filtering texels from the input image so as to compute an intensity value for a pixel in the output image. Conventionally, the input image is linked to the output image via an inverse affine transform T −1 .
[0006] The output image is made, for example, of a plurality of rectangles also referred to as tiles defined by the positions of their vertices. The tiles of the output image correspond to quadrilateral also referred to as inverse tiles in the input image also defined by the positions of their vertices. Said positions define a unique affine transform between a quadrilateral in the input image and a rectangle in the output image. To generate the output image, each output rectangle is scan-converted to calculate the intensity value of each pixel of the quadrilateral on the basis of intensity values of texels.
[0007] FIG. 1 shows a block diagram of a conventional rendering device. Said rendering device is based on a hardware coprocessor realization. This coprocessor is assumed to be part of a shared memory system. A dynamic memory access unit DMA interfaces the coprocessor with an external memory (not represented). A controller CTRL controls the internal process scheduling. An input memory IM contains a local copy of part of the input image. An initialization unit INIT accesses geometric parameters, i.e. the vertices of the different tiles, through the dynamic memory access unit DMA. From said geometric parameters, the initialization unit INIT computes affine coefficients for the scan-conversion process. These affine coefficients are then processed by a rendering unit REN, which is in charge of scan-converting the inverse tiles. The result of the scan-conversion process is stored in a local output memory OM.
[0008] The coprocessor further comprises an address memory block AM, an initialization memory InitM and a loading area determination block LAD. In order to fill the input memory IM, the loading area determination block LAD computes texture addresses that are stored and converted into global memory addresses by the address memory block AM. It permits to load from the external memory the relevant area matching the needs for further processing.
[0009] However, such a coprocessor performs the rendering on a tile basis. From rendering one tile to the next one, the continuity of the texture needed for geometric transformation is globally assured depending on the tile scan order. But due to memory alignment constraint and filter footprint, the relevant texture area determined by the address memory block AM is extended. As a matter of fact, the whole area determined by the address memory block AM is loaded into the input memory IM. This is not efficient from the point of view of both memory access and power consumption.
SUMMARY OF THE INVENTION
[0010] It is an object of the invention to propose a method of storing data values in a memory unit, which is more efficient both in terms of memory bandwidth and in terms of power consumption.
[0011] To this end, the method in accordance with the invention is characterized in that the memory unit is adapted to store temporarily at least two sets of data values and in that said method comprises the steps of:
storing a first set of data values in a first area of the memory unit, storing a second set of data values spatially adjacent to the first set of data values in a horizontal and/or in a vertical direction in such a way that a first part of the second set of data values is stored in a second area of the memory unit adjacent to the first area in a horizontal and/or in a vertical direction, respectively, and that the other part of the second set of data values to be stored which exceeds the memory unit size in a horizontal and/or in a vertical direction, respectively, is stored in at least one other area of the memory unit according to a torus principle.
[0014] As it will be explained in more detail hereinafter, the shared area between successive tiles is not re-accessed from the external memory, as only a second set of data values spatially adjacent to the first set of data values is loaded from an external memory into the memory unit. Moreover, no data collision occurs when reading and writing data in the memory unit, as the memory unit is adapted to store temporarily at least two sets of data values. Finally, the continuity of the data values and of the memory physical addresses is ensured modulo the horizontal and vertical sizes of the memory unit thanks to the storage according to the torus principle. Thus, the method of storing data values is more efficient than the one of the prior art both in terms of memory bandwidth and in terms of power consumption, as the amount of data values loaded from the external memory has been reduced.
[0015] According to a first embodiment of the invention, the memory unit is adapted to store temporarily at least four sets of data values, and the other part of the second set of data values comprises a second part which is stored in a bottom left area of the memory unit, a third part which is stored in the top right area of the memory unit and a fourth part which is stored in the top left area of the memory unit.
[0016] According to another embodiment of the invention, the memory unit is divided into two sub-parts of equal size, the method further comprising the steps of:
updating a writing memory during a current time cycle so as to indicate in which sub-part of the memory unit the second set of data values is stored, copying the content of the writing memory at the end of the current time cycle into a read-only memory.
[0019] The present invention also relates to a memory management unit implementing such a method, said memory management unit comprising a memory unit which is adapted to store temporarily at least two sets of data values, and a controller which is configured such that it is able to store a first set of data values in a first area of the memory unit, and to store a second set of data values spatially adjacent to the first set of data values in a horizontal and/or in a vertical direction in such a way that a first part of the second set of data values is stored in a second area of the memory unit adjacent to the first area in a horizontal and/or in a vertical direction, respectively, and that the other part of the second set of data values to be stored which exceeds the memory unit size in a horizontal and/or in a vertical direction, respectively, is stored in at least one other area of the memory unit according to a torus principle.
[0020] Beneficially, the memory unit is divided into two sub-parts of equal size, said memory management unit further comprising a writing memory which is updated during a current time cycle to indicate in which sub-part of the memory unit the second set of data values is stored, and a read-only memory in which the content of the writing memory is copied at the end of the current time cycle, data values being read out of the memory unit based on the content of said read-only memory.
[0021] The present invention also relates to a portable apparatus comprising said memory management unit.
[0022] Said invention finally relates to a computer program product comprising program instructions for implementing said method of temporarily storing data values in a memory.
[0023] These and other aspects of the invention will be apparent from and will be elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention will now be described in more detail, by way of example, with reference to the accompanying drawings, wherein:
[0025] FIG. 1 shows a block diagram of a conventional rendering device;
[0026] FIG. 2 illustrates a conventional method of texture mapping;
[0027] FIG. 3 shows a block diagram of a memory management unit in accordance with the invention;
[0028] FIG. 4 illustrates an embodiment of a method of storing data in accordance with the invention; and
[0029] FIG. 5 illustrates another embodiment of a method of storing data in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention relates to a method of and a device for temporarily storing data. Although the following description is based on the example of texture mapping, this invention is more generally related to systems requiring a local memory refreshment mechanism.
[0031] FIG. 2 illustrates a conventional method of texture mapping.
[0032] An output image comprises a first tile B(t) to be reconstructed. A first inverse tile BB(t) is associated with the first tile B(t) via a first inverse affine transform T −1 . In order to reconstruct the first tile, the texels corresponding to a first bounding box BB(t) are loaded from an external memory into a local memory. Said first bounding box BB(t) has a width W 1 and a height H 1 and corresponds to the smallest rectangle which includes the first tile B(t).
[0033] The output image comprises a second tile B(t+1) to be reconstructed, said second tile being adjacent to the first tile. Similarly, a second inverse tile BB(t+1) is associated with the second tile B(t+1) via a second inverse affine transform T 2 −1 . Similarly, in order to reconstruct the second tile, the texels corresponding to a second bounding box BB(t+1) are loaded from an external memory into a local memory. Said second bounding box BB(t+1) has a width W 2 and a height H 2 , and corresponds to the smallest rectangle which includes the second tile B(t+1).
[0034] It can be clearly seen from FIG. 2 that the first bounding box BB(t) and the second bounding box BB(t+1) share a common area CA. Said common area CA can be derived from the shift (dx,dy) of the top left corner of the first bounding box BB(t) having coordinates (ur[i],vr[i]) to the top left corner of the second bounding box BB(t+1) having coordinates (ur[i+1],vr[i+1]). Instead of loading independently and successively from the external memory the contents of the bounding boxes BB(t) and BB(t+1), the present invention proposes to load only an additional area LS(t+1) corresponding to the second bounding box area minus the common area, said additional area being in general L-shaped.
[0035] Once the affine coefficients of the inverse affine transforms have been computed, the mapping method in accordance with the invention is adapted to determine, for an output point of a tile, an input transformed point in the corresponding inverse tile using the inverse affine transform. The input transformed point belonging to the inverse tile is in general not located on a grid of texels with integer coordinates. A filtered intensity value corresponding to said input transformed point is then derived according to a step of filtering a set of texels of the inverse tile surrounding said input transformed point. The filtering step is based, for example, on the use of a bilinear filter adapted to implement a bilinear interpolation.
[0036] FIG. 3 shows a block diagram of a memory management unit in accordance with the invention. Said memory management unit MMU encapsulates a local input memory IM. Said memory management unit interfaces an external memory through a dynamic memory access unit DMA and further processing blocks requiring accesses to local memory data.
[0037] Said memory management unit MMU comprises a memory controller CTRL which is adapted to compute the shift (dx,dy) of an external memory area, corresponding to the second bounding box, from a previous one, corresponding to the first bounding box, and then to determine the L-shaped area as defined in FIG. 2 . Said L-shaped area is then loaded from the external memory into the local input memory IM. This controller CTRL maintains an internal physical space coordinates system and performs the conversion between this internal physical space system, the external memory space system and the internal logical space system used by other processing blocks.
[0038] In order to fill the input memory IM, a loading area determination block LAD computes texture addresses that are stored in an address memory block of the FIFO (for first in first out) type. According to an embodiment of the invention, said FIFO memory can be seen at a given time as being divided in three parts, the first part (@t+2) containing texture addresses to be rendered during a time cycle t+2; the second part (W@t+1) containing texture addresses to be written in the input memory during a time cycle t so as to be read out and processed during a time cycle t+1; and the third part (R@t) containing texture addresses to be read out and processed during a time cycle t.
[0039] As described before, the controller CTRL first determines the area shift (dx,dy) from one bounding box to the next one in order to determine the L-shaped area LS(t+1) to be loaded from the external memory into the local input memory IM. Considering rectangular areas, this shift is determined by the top left corner (ur[i+1],vr[i+1]) of the rectangle which represent the new origin of the internal logical space system. As shown in FIG. 2 , said L-shaped area is defined by a partial width Wp and two partial heights Hp and Hp′, meaning that Wp texel values ( 3 in the example of FIG. 2 ) needs to be loaded from the external memory for the first Hp lines ( 4 in our example) and W 2 texel values ( 7 in our example) needs to be loaded from the external memory for the Hp′ subsequent lines ( 2 in our example).
[0040] Using the area shift, the correspondence between the new logical origin and the internal physical coordinates is performed. As it will be seen in more detail hereinafter, the internal physical space system can be seen as a torus where the address are automatically wrapped around when reaching the border of the local input memory IM. The size of said local input memory IM is chosen such that the data values of the L-shaped area LS(t+1) do not overwrite the data values of the bounding box BB(t) during a time cycle t. The memory management unit thus ensures that no data collision occurs and that the continuity of the data values and of the memory physical addresses is ensured modulo the horizontal and vertical sizes of the local input memory IM.
[0041] As described before, the L-shaped area LS(t+1) is loaded from the external memory into the local input memory IM while the previous area BB(t) stored in the local input memory IM is accessed for rendering purpose according to a well-known pipeline process. For this purpose, the local input memory IM is a double-port memory.
[0042] According to an embodiment of the invention, a local input memory four times larger than the memory necessary to store any bounding box is used so that no data collision happens, as illustrated in FIG. 4 . For example, if a tile is a square of 16×16 pixels, the bounding box corresponding to an inverse tile will not be larger than 23×23 pixels (the first integer higher than 16√2) using an affine transform. If each pixel comprises 4 components (luminance Y, chrominances U and V, transparency a), each component comprising 8 bits, the minimum size of the memory required to store any bounding box will thus be equal to 23×23 words of 32 bits, and the size of the local input memory will be equal to 46×46 words of 32 bits. It is to be noted that said size can be doubled if a zoom out function is used for rendering.
[0043] FIG. 4 illustrates a method of storing data using a local input memory IM four times larger than the memory necessary to store any bounding box, dotted lines showing the virtual separation of said local input memory into 4 equal-size sub-parts A 1 to A 4 .
[0044] During a time cycle t−1, a first bounding box BB(t) has been stored in the local input memory IM.
[0045] During a time cycle t, a first L-shaped area LS(t+1) is loaded into the local input memory IM, said first L-shaped area fitting in said memory. During this time cycle t, the content of the first bounding box BB(t) is accessed for rendering purpose.
[0046] During a time cycle t+1, a second L-shaped area LS(t+2) is loaded into the local memory IM, said second L-shaped area still fitting in the local input memory. During this time cycle t+1, the content of a second bounding box BB(t+1), including the first L-shaped area LS(t+1) and the area common to the first bounding box BB(t) and said second bounding box BB(t+1), is accessed for rendering purpose.
[0047] During a time cycle t+2, a third L-shaped area LS(t+3) is loaded into the local input memory IM, only a first part P 1 of said third L-shaped area fitting in the fourth area A 4 of said local input memory. The other parts of the third L-shaped area are stored in the local input memory according to a torus principle as follows. A second part P 2 of the third L-shaped area is stored in the bottom left corner of the third area A 3 . A third part P 3 of the third L-shaped area is stored in the top right corner of the second area A 2 . Finally, a fourth part P 4 of the third L-shaped area is stored in the top left corner of the first area A 4 . This storage process is iterated until the picture or the complete sequence of pictures has been processed. During this time cycle t+2, the content of the third bounding box BB(t+2) is accessed for rendering purpose.
[0048] The memory size increase can be limited to two times the size of the memory necessary to store any bounding box, using a double-buffer memory combined with two binary memories. FIG. 3 illustrates this other embodiment of the method of storing data in accordance with the invention.
[0049] When reading the double-buffer memory IM, a read-only memory RO indicates in which part of the double-buffer memory the data is available. When writing the L-shaped area LS(t+1) from the external memory into the double-buffer memory during a time cycle t, a writing memory W is updated so as to indicate in which part of the double-buffer memory IM the writing is performed. At the end of the time cycle t, the content of the writing memory W is copied into the read-only memory RO in order to be used for reading the bounding box BB(t+1) during time cycle t+1. These memories RO and W are only a single bit per memory slot.
[0050] FIG. 5 illustrates this other embodiment of the method of storing data in accordance with the invention in more detail. A dotted line shows the virtual separation of the double-buffer memory IM into 2 equal-size sub-parts IM(R) and IM(L).
[0051] During a time cycle t−1, the content of the first bounding box BB(t) has been loaded from the external memory through the dynamic memory access unit DMA into the left part IM(L) of the double-buffer memory IM. The values of the writing memory W have been set to 1 (white part) when data of the first bounding box have been loaded via the dynamic memory access unit DMA into the double-buffer memory. As shown in FIG. 5A , said first bounding box fits in said left part IM(L). At the end of the writing process, the content of the writing memory W is copied into the read-only memory RO for the next processing step.
[0052] During a time cycle t, the content of the first bounding box BB(t) is read out from the double-buffer memory IM based on the binary values stored in the read-only memory RO. As shown in FIG. 5B , if the output of the read-only memory RO is equal to 1 (white part), data are read out of the left part IM(L) of the double-buffer memory IM and if the output of the read-only memory RO is equal to 0 (black part), data are read out of the right part IM(R) of the double-buffer memory IM.
[0053] During said time cycle t, the content of the L-shaped area LS(t+1) is loaded from the external memory through the dynamic memory access unit DMA into the double-buffer memory IM. Each time a data item has to written in the double-buffer memory IM, the corresponding bit of the writing memory W is reversed (from 1 to 0 or from 0 to 1) so as to be sure the write said data item in the appropriate memory part. In the example of FIG. 5B , the values of the writing memory W are set to 1 (white part) when a data item is loaded from the external memory into the left part IM(L) of the double-buffer memory, and the values of the writing memory W are set to 0 (black part) when a data item is loaded from the external memory into the right part IM(R) of the double-buffer memory. As a consequence, data are stored in the double-buffer memory according to a torus principle, as follows:
if there are memory slots which are not occupied by the bounding box BB(t), data are stored in the left part IM(L) (see FIG. 5B : LS 0 , LS 2 , LS 3 and LS 5 ) if there is no place available in said left part IM(L) because the corresponding area is filled with the first bounding box BB(t), data are stored in the right part IM(R) of the double buffer memory at a same location they would have been stored in the left part IM(L) if said location has been available (see FIG. 5B : LS 1 , LS 4 and LS 6 ).
At the end of the writing process, the content of the writing memory W is copied into the read-only memory RO for the next processing step.
[0056] The process is iterated until the picture or the complete sequence of pictures has been processed.
[0057] Several embodiments of the present invention have been described above by way of examples only, and it will be apparent to a person skilled in the art that modifications and variations can be made to the described embodiments without departing from the scope of the invention as defined by the appended claims. Further, in the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The term “comprising” does not exclude the presence of elements or steps other than those listed in a claim. The terms “a” or “an” does not exclude a plurality. The invention can be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In a device claim enumerating several means, several of these means can be embodied by one and the same item of hardware. The mere fact that measures are recited in mutually different independent claims does not indicate that a combination of these measures cannot be used to advantage. | 4y
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FIELD OF THE INVENTION
The present invention relates to a magnetic recording medium, and more particularly, it relates to a magnetic recording medium of a thin metal film type having markedly improved weather resistance or anti-corrosive properties.
BACKGROUND OF THE INVENTION
Hitherto, a so-called coated type magnetic recording medium has been widely used. The coated type medium has been prepared by dispersing a magnetic powder of oxides such as γ-Fe 2 O 3 , Co-doped γ-Fe 2 O 3 , F 3 O 4 , Co-doped Fe 3 O 4 , Bertholide compounds of γ-Fe 2 O 3 and Fe 3 O 4 , Co-doped Bertholide compounds or CrO 2 , or a ferromagnetic alloy powder mainly composed of Fe, Ni or Co in an organic binder such as copolymer of vinyl chloride and vinyl acetate, a copolymer of styrene and butadiene, an epoxy resin or a polyurethane resin to obtain a coating solution, coating the resulting magnetic coating composition on a non-magnetic support and drying to form a magnetic film.
Recently, with the increase in the amount of information to be recorded, practical use of a magnetic recording medium which is suitable for high density recording has been greatly desired. Attention has been drawn to a so-called thin film type magnetic recording medium which is prepared by forming a ferromagnetic thin metal film on the above described support in accordance with methods such as a vacuum deposition method, a sputtering method, an ion plating method or a metal plating method without using the above described binders. Further various attempts have been made through extensive research and development to put the products into practical use.
However, a ferromagnetic thin metal film tends to corrode easily. This is a serious problem which affects reliability as a medium, and the means to solve the problem has not yet been found.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a thin metal film magnetic recording medium having improved weather resistance and anti-corrosive properties.
This and other objects have been achieved by providing a magnetic recording medium comprising a non-magnetic support, a thin magnetic metal film on the support, and a protective layer on the thin magnetic metal film, the protective layer containing chromium and iron, the chromium being present in an amount of 6 to 40 wt % and the iron being the remainder. The protective layer can additionally contain nickel, the nickel being present in an amount of not more than 20 wt %.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure of the magnetic recording medium in accordance with the present invention is illustrated by reference to FIGS. 1 to 3.
FIG. 1 is a schematic view showing the structure of a conventional magnetic recording medium of a thin metal film type,
FIGS. 2 and 3 are schematic views showing the structure of the magnetic recording medium of the present invention, and
FIG. 4 is results of Comparative Example 1.
In the Figures, a conventional magnetic recording medium of a thin metal film type 1 is composed of a support 2 and a thin magnetic metal film 3 provided on the support, as shown in FIG. 1, whereas a magnetic recording medium 1' in accordance with the present invention has a protective layer 4 which is provided on a thin magnetic metal film 3. A lubricating layer 5 can additionally be provided over the protective layer 4.
DETAILED DESCRIPTION OF THE INVENTION
Suitable non-magnetic supports which can be used in the present invention preferably include a plastic support such as polyethylene terephthalate, polyimide, polyamide, polyvinyl chloride, cellulose triacetate, polycarbonate or polyethylene naphthalate. In addition, a non-magnetic metal such as aluminum, Cu or SUS (stainless) or an inorganic material such as glass or ceramic can be also used as a support.
Most preferred supports include a flexible plastic film having a surface roughness (Ra) of 0.012 μm or less.
A layer containing an inorganic particle (e.g., calcium carbonate, carbon particles) and an organic binder (e.g., nitrocellulose, polyurethane, isocyanate, polyester or a mixture thereof) can be provided on the surface of the support opposite to the ferromagnetic thin metal film.
Magnetic metal materials which can be used as a thin metal film in the present invention include a metal such a Fe, Co or Ni, or a ferromagnetic alloy mainly containing Fe-Co, Fe-Ni, Co-Ni, Fe-Co-Ni, Fe-Rh, Fe-Cu, Co-Cu, Co-Au, Co-Y, Co-La, Co-Pr, Co-Gd, Co-Sm, Co-Pt, Ni-Cu, Mn-Bi, Mn-Sb, Mn-Al, Fe-Cr, Co-Cr, Ni-Cr, Fe-Co-Cr, Ni-Co-Cr, or Fe-Co-Ni-Cr. Of these materials, Co or a Co-containing alloy which includes not less than 75 wt % of cobalt is preferred. In addition, W, Mo, Ta, Mg, Si or Al can be included in small proportions. A non-metal such as C, B, O, N or P can also be included in small proportions. The metals can be included in a basic material which forms a magnetic thin film or can be added to a component for a gas atmosphere which is used for forming a thin film.
The magnetic thin metal film should have a thickness which is sufficient to provide a satisfactory output and sufficient to carry out high density recording. In general, the thin magnetic metal film has a thickness of about 0.02 μm to 2 μm and preferably about 0.05 μm to 1 μm.
The methods of forming a thin magnetic metal film are described, for example, in U.S. Pat. Nos. 2,671,034, 3,329,601, 3,342,632, 3,342,633, 3,156,860, 361,591, etc.
Further, the thin magnetic metal film can be a single layer or multi-layered structure having two or more layers. When the film is composed of multi-layers, a nonmagnetic intermediate layer can be interposed between the layers of the multi-layered structure. An under-coating layer can also be provided between the non-magnetic support and the thin magnetic metal film. A thin magnetic metal film can be provided on opposite both surfaces of the non-magnetic support.
Vapor deposition methods used for forming the thin magnetic metal film and the protective layer in the present invention include not only the general vacuum evaporation method which is disclosed in U.S. Pat. No. 3,342,632 but also the method wherein vapor stream is ionized and vaporization is accelerated in a magnetic field, in an electric field or by electron beam radiation, whereby vaporized molecules can move freely and form a thin film on a support. For example, a method of deposition in an electric field as disclosed in Japanese Patent Publication (Unexamined) No. 149008/76, and a method of deposition by ionization which is disclosed in Japanese Patent Publication (Examined) Nos. 11525/68, 20484/71, 26579/72, 45439/74, Japanese Patent Publication (Unexamined) Nos. 33890/74, 34483/74 and 54235/74, J. Vac. Sci. Tech., 10 (1), p 47 (1973) can be used in the present invention. Additionally, a sputtering method can be used in the present invention as described in U.S. Pat. No. 3,282,815.
The protective layer which is formed on a thin metal film is composed of Cr, Ni and Fe in a mixing ratio of 6 to 40 wt % Cr, 0 to 20 wt % Ni, the remainder being Fe, preferably the mixing ratio of 10 to 40 wt % Cr, 0 to 10 wt % Ni, the remainder being Fe, and has a thickness of 10 Å to 200 Å, preferably 30 Å to 150 Å, more preferably 100 Å to 150 Å. If the thickness is more than 200 Å, electromagnetic properties are poor in that spacing loss is increased. However, the property of weather resistance is continuously improved. Accordingly, a thickness of more than 200 Å is not suitable for practical use. Further, if the amount of Cr is more than 40 wt %, the film tends to scrape and is not suitable for practical use.
A lubricating layer 5 as shown in FIG. 3 can additionally be provided on a magnetic recording medium in the present invention. The lubricating layer must have functions which improve running properties and properties of durability during still mode use. A lubricating layer 5 which is additionally formed on a protective layer 4 preferably includes higher fatty acids, fatty acid esters and combinations thereof. Preferable higher fatty acids include lauric acid, myristic acid, palmitic acid, stearic acid, behenic acid, oleic acid, linolic acid, linolenic acid, arachidonic acid and the like. Suitable fatty acid esters include methyl stearate, ethyl palmitate, monoglyceride stearate and the like.
The lubricating layer 5 can be formed by vapor deposition method such as an ion plating method or by a general coating method.
As hereinbefore described, in the present invention corrosion can greatly be prevented by providing a protective layer having a thickness of 10 Å to 200 Å on a thin magnetic metal film without the accompanying disadvantages which conventional methods generally have had.
For example, conventional magnetic recording media using a thin magnetic metal film have the disadvantage that a hydroxyl group (OH - ) can penetrate through an over-coating layer such as a lubricating layer and come into contact directly with a thin magnetic metal film causing the thin magnetic metal film to heavily corrode.
It was found in the present invention that corrosion of a thin magnetic metal film can markedly be prevented by providing a protective layer which is composed of Cr, Ni and Fe in a mixing ratio of 6 to 40 wt % Cr, 0 to 20 wt % Ni, the remainder being Fe. It is believed that the protective layer is firmly and closely overcoated on the thin magnetic metal film and that the thin magnetic metal film itself has excellent weather resistance and anticorrosive properties.
The following examples are given to illustrate the present invention in greater detail.
EXAMPLE 1
An alloy of Co 0 .8 Ni 0 .2 was deposited on a polyethylene terephthalate film (thickness: 23 μm) to form a thin magnetic metal film 3 having a thickness of 1400 Å by the method of oblique vapor deposition having an angle of incidence of 60° under a vacuum condition of 5×10 -5 Torr. Further, a protective layer having a composition of Cr, Ni and Fe in a mixing ratio of 20 wt %, and 3 wt % and 77 wt %, respectively, was formed thereon by a method of vapor deposition which was carried out under a vacuum condition of 3×10 -5 Torr to have a thickness of 45 Å.
The evaluation of weather resistance and corrosion resistance properties was conducted with respect to the thus obtained magnetic recording medium. The evaluation was conducted by observing the degree of demagnetization and corrosion after the magnetic recording medium of the present invention was allowed to stand in a thermostatic room at 60° C. and 90% relative humidity for 2 weeks. As a result of the evaluation, it was found that the magnetic recording medium of the present invention had the degree of demagnetization of 3% and had no corrosion patches.
The relationship between the corrosion resistance (anti-corrosive properties) and the thickness of the protective layer when changed from 10 Å to 200 Å is shown in FIG. 4.
On the other hand, the magnetic recording medium having no protective layer of the present invention, which was evaluated for comparison, had the degree of demagnetization of 15% and a marked amount of corrosion was observed thereon.
EXAMPLE 2
An alloy of Co 0 .8 Ni 0 .2 was deposited by a method of an oblique vapor deposition with an angle of incidence of 45° and under the oxygen atmosphere of 2×10 -4 Torr on a polyethylene terephthalate film (thickness: 23 μm) to form a thin magnetic metal film 3 having a thickness of 1200 Å. A protective layer having a composition of Cr and Fe in a mixing ratio of 20% and 80%, respectively, was thereafter provided thereon under a vacuum condition of 1×10 -3 Torr by introducing argon gas using a sputtering method to have a thickness of 30 Å.
The evaluation of weather resistance and corrosion resistance properties was conducted with respect to the thus obtained magnetic recording medium in the same manner as in Example 1, and as a result, the degree of demagnetization was 5% and corrosion patches were not observed.
COMPARATIVE EXAMPLE 1
The magnetic recording mediums were prepared in the same manner as in Example 1 except that the composition of the protective layer was changed into 100% by weight of Cr, Ti, Sn or Ni alone, respectively, and the thickness of the protective layer was changed into the ranges of 10 Å to 200 Å.
The evaluation of corrosion resistance was conducted with respect to the thus obtained each magnetic recording medium in the same manner as in Example 1. The relationship between the corrosion resistance and the thickness of the protective layer when changed from 10 Å to 200 Å is shown in FIG. 4. In FIG. 4, evaluation "5" of corrosion resistance means that corrosion patches were not observed, and evaluation "1" of corrosion resistance means that corrosion patches were wholly observed. The results of the evaluation of corrosion resistance were further divided into five stages as shown in FIG. 4.
COMPARATIVE EXAMPLE 2
The magnetic recording mediums were prepared in the same manner as in Example 1 except that the composition of the protective layer was changed into the composition shown in Table 1, respectively, and the thickness of the protective layer was changed into 100 Å.
The evaluation of corrosion resistance were conducted with respect to the thus obtained each magnetic recording medium in the same manner as in Example 1. Further, the film-scraping was also observed. The results are shown in Table 1 below.
TABLE 1______________________________________ Composition of Protective LayerParticular of This Invention ComparisonEvaluation Fe.sub.77 Ni.sub.3 Cr.sub.20 Fe.sub.97 Ni.sub.3 Fe.sub.17 Ni.sub.3 Cr.sub.80 Cr.sub.100______________________________________Corrosion 5 2 5 5ResistanceScraping O O X XX______________________________________ Note: "Corrosion Resistance" was evaluated by five stages as in Comparative Example 1. In the scraping observation, "O" means no scraping, "X" means scraping partially caused, and "XX" means a scraping wholly caused.
From the results shown in Table 1, it can be seen that when Cr content is large, the scraping tends to be caused.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is in the field of crosslinkable compositions comprising hydroxy-functional epoxy resins and anhydride curing agents. More specifically, the present invention relates to crosslinkable coating compositions having low volatile organic content which are particularly useful in color-plus-clear coating applications.
2. Brief Description of the Prior Art
Color-plus-clear coating systems involving the application of a colored or pigmented base coat to a substrate followed by the application of a transparent or clear top coat to the base coat are becoming increasingly popular as original finishes for automobiles. The color-plus-clear systems have outstanding gloss and distinctness of image, and the clear coat is particularly important for these properties. Illustratively, two-pack clear coat compositions comprising polyols such as polyester polyols, polyurethane polyols and acrylic polyols, and polyisocyanate curing agents give outstanding gloss and distinctness of image.
It is an object of the present invention to provide for a novel crosslinkable composition which provides for coatings which can be used in a wide variety of coatings applications. It is particularly the object of the present invention to provide a crosslinkable coating composition which can be formulated into a high solids coating composition with excellent adhesion, gloss and distinctness of image enabling the coating composition to be used as clear coats in a color-plus-clear coating system, particularly for use as an original finish for automobiles to provide remarkable appearance. It is furthermore the object of this invention to provide such a high solids crosslinkable composition having low volatile organic content (VOC).
SUMMARY OF THE INVENTION
In accordance with the foregoing, the present invention encompasses an improved process of applying a composite coating to a substrate, said process comprising applying to the substrate a colored film-forming composition to form a base coat, and applying to said base coat a clear film-forming composition to form a transparent top coat over the base coat; followed by heating the composite coating to a temperature sufficient to provide effective cure; the improvement comprising the clear and/or base coat containing a high solids solvent-based thermosetting composition comprising:
(a) a low molecular weight hydroxy-functional polyepoxide,
(b) a curing agent consisting essentially of an acid-anhydride comprising a monoanhydride,
(c) a cure catalyst said composition is characterized in that it is curable in the absence of a melamine curing agent.
In the particularly preferred embodiment of this invention, the coating compositions typically contain cure catalysts which are tertiary amines or ammonium salts. The coating compositions of this embodiment have been found to be particularly suited to painting automobiles in the color-plus-clear mode to provide coatings having outstanding appearances and other desirable properties.
In this text, the terms molecular weight, solids content, volatile organic content (VOC) and appearance are defined as follows. The term "molecular weight" refers to a number average molecular weight as determined by gel permeation chromatography using a standard (such as polystyrene or glycol). Therefore, it is not the actual number average molecular weight which is measured but a number average molecular weight which is relative to the standard.
The solids (i.e., the non-volatile) content of a composition is determined by ASTM D-2369 testing modified as follows: 0.3 grams of the composition is mixed with 5 milliliters of 1:1 mixture of acetone and tetrahydrofuran and heated at 110° C. for 1 hour in a forced draft oven. The composition is then cooled in a desiccator, reweighed and the non-volatile content calculated. The percentage by weight of the composition remaining is the solids content.
The term "sprayability" means the maximum concentration of solids at which the coating composition can form a uniformly deposited coating, under normal spraying conditions of, say, temperature, pressure, and spray equipment design such as entails the use of an air suction gun operating at 60 psi with a No. 30 air cap. This maximum concentration is solvent dependent and usually occurs in a viscosity range of 20 to 80 and preferably at about 20 to 24 seconds with a No. 4 Ford cup at room temperature after thinning with a solvent such as a mixture of methyl amyl ketone and ethoxyethyl acetate. Above this maximum concentration, appearance of the coating as manifested by leveling and solvent popping typically becomes unacceptable.
The VOC is defined as the weight per volume of any compound of carbon which evaporates from a paint or related coating material under the specific conditions for the determination of the non-volatile content of that material. This does not include water which is volatile under the test conditions. Thus, the water content of the material undergoing analysis must be determined. To obtain the VOC of a sample, the non-volatile content, water content and the density of the material are determined. The VOC number is calculated by correcting the total organic volatile content for the water content and dividing by the volume of the paint corrected for the water content. The determination of the VOC is by ASTM D-3960 testing which entails heating the paint or related coating material at 110° C. for 1 hour.
Appearance is defined in terms of distinctness of image (DOI) which is measured by a Dori-Gon Meter D47-6 manufactured by Hunter Laboratories.
DETAILED DESCRIPTION OF THE INVENTION
The coating compositions of this invention are high solids types. They have a sprayable solids content of about 45 percent or higher and preferably about 80 percent or higher. Also, the coating compositions have VOC of less than 3.6 and preferably less than 3 pounds per gallon, and down to about 1.8 pounds per gallon. As described more fully below, the components of the composition are selected on the basis that would result in high solids coating compositions having properties as described herein.
The hydroxy-functional polyepoxides useful herein are of low molecular weight and have epoxide equivalent weights of about 50 to 1000 and preferably about 100 to 300; and a hydroxy equivalent weight of about 50 to 1000 and preferably 100 to 500. Typically, the hydroxy-functional polyepoxides contain more than 2 and preferably 3 or more epoxy groups per molecule, and at least one hydroxyl group per molecule. Typical but non-limiting examples of the hydroxy-functional polyepoxides are hydroxy-functional glycidyl ethers, hydroxy-functional glycidyl esters, hydroxy-functional glycidyl acrylic polymers, hydroxy-functional glycidyl isocyanates, hydroxy-functional epoxidized oils, hydroxy-functional cycloaliphatic epoxies or mixture thereof.
Illustrative examples of the preferred glycidyl ethers are glycerol polyglycidyl ether having 3 epoxy groups; trimethylolpropane polyglycidyl ether having 3 epoxy groups; and diglycerol polyglycidyl ether having 3 epoxy groups, such as is available from Nagase America Corporation under the tradename DENACOL.
Illustrative examples of the hydroxy-functional glycidyl acrylic polymers are copolymers of ethylenically unsaturated monomers, one of which contains a glycidyl group and another which contains a hydroxyl group. The copolymers are prepared by free radical polymerization of the ethylenically unsaturated monomers. Examples of the ethylenically unsaturated monomers containing a glycidyl group can be a glycidyl acrylate, a glycidyl methacrylate, and an allyl glycidyl ether. Examples of ethylenically unsaturated monomers containing hydroxyl groups are hydroxyethyl acrylate, hydroxyethyl methacrylate, hydroxypropyl acrylate, hydroxypropyl methacrylate, and the like. Other monomers that can be copolymerized with the above monomers can be alkyl esters of acrylic or methacrylic acid, e.g., ethyl acrylate, butyl acrylate or 2-ethylhexyl acrylate, ethyl methacrylate, butyl methacrylate and the like; vinyl monomers such as styrene, vinyl toluene and the like.
The anhydrides useful herein are of low molecular weight, and are typically polyacid anhydrides comprising monoanhydrides. The molecular weight of the anhydrides can be in the range of about 100 to 500 and preferably about 100 to 200. Examples of the preferred monoanhydrides are alkyl hexahydrophthalic anhydrides wherein the alkyl group has up to 7 carbon atoms. A particularly preferred monoanhydride is methyl hexahydrophthalic anhydride. Other anhydrides that can be used herein are succinic anhydride, methyl succinic anhydride, dodecenyl succinic anhydride, octadecenyl succinic anhydride, phthalic anhydride, tetrahydrophthalic anhydride, methyltetrahydrophthalic anhydride and the like. In the preferred embodiment of the invention, the polyacid anhydrides consisting essentially of monoanhydrides such as described herein above.
The catalyst useful herein can be selected from the group consisting of tertiary amines such as dimethydodecyl amine or dimethyethanol amine; onium compounds such as quaternary ammonium salt, e.g., tetrabutyl ammonium fluoride, tetrabutyl ammonium bromide, tetrabutyl ammonium hydroxide; phosphonium salts and the like.
The proportion in which the components are employed is such as leads to the formation of gellable compositions that can cure effectively. Hence, the equivalent ratio of the anhydride curing agent to the hydroxy-functional epoxy resins based on the anhydride to the hydroxyl group can be from about 0.5 to 20:1 and preferably 1 to 5:1. The equivalent ratio of the anhydride to the epoxy can be from about 0.3 to 5:1 and preferably about 0.5 to 2:1.
The aforedescribed components can be formulated into the claimed coating compositions which are typically solvent-based. The hydroxy-functional polyepoxide can be employed with only the anhydride as the curing agent to produce the claimed thermosetting coating compositions which can be heated to temperature sufficient to cure effectively. The cured coatings are hard and solvent resistant and can posses other desirable properties. Unlike the case of art-related coatings, other curing agents such as aminoplasts or isocyanates are not required to provide effective cure. Accordingly, the present invention can be said to encompass thermosetting high solids coating compositions consisting essentially of the hydroxy-functional polyepoxides, and anhydrides as curing agent therefor. It is, however, desired to point out that while the likes of aminoplasts are not required to effect cure, they can nonetheless be employed as coating additives in less than the art-required curing amounts.
It is a distinct feature of the invention that the claimed thermosetting coating compositions are free of, or substantially free of other curing agents, particularly melamine resins. This feature of the invention is all the more significant in the particularly preferred embodiment, wherein appearance is an important criterion. In this embodiment, the coating compositions typically contain cure catalysts such as tertiary amines or quaternary ammonium salts. Accordingly, in this embodiment the coating compositions consist essentially of the hydroxy-function polyepoxide, the anhydride and the cure catalyst.
In the coating formulation, additives such as ultraviolet light absorbers and/or stabilizers, flow control agents, antioxidants, plasticizers and the like can be employed. These additives can be employed in amounts up to about 25 percent by weight based on the total resin weight.
It is envisaged that the coating compositions of this invention can be practiced as multi-pack such as a two-pack coating compositions. For example, the hydroxy-functional polyepoxide and the cure catalyst can be employed in one pack and the anhydride in another.
The coating composition can be applied to a substrate by any of the conventional coating techniques such as brushing, spraying, dipping or flowing, but it is preferred that spray applications be used since this gives the best appearance. Any of the known spray techniques may be employed such as compressed air spraying, electrostatic spraying and either manual or automatic methods.
It is a distinct feature of the invention that the high solids thermosetting coating compositions of this invention display a surprisingly acceptable sag control at a film thickness of up to about 2 mils. Considering that coating compositions comprising low molecular weight components generally have sag control problems, it is indeed surprising that the instant coatings having low molecular weight components have the acceptable sag control. Thus, relatively lower amounts, if any at all, of sag control agents need to be added to the coating composition. Therefore, these coating compositions do not suffer a reduced solids content and poorer appearance, as is otherwise the case with art-related high solids compositions wherein sag control agents are added.
After application of the coating composition to the substrate, the coated substrate is heated to cure the coating. In the curing operation, solvents are driven off and the film-forming material of the top coat and/or of the base coat is crosslinked. The heating or curing operation is usually carried out at a temperature in the range of from 160°-350° F. (71°-177° C.) but if needed lower or higher temperatures may be used depending upon whether it is sufficient to activate any necessary crosslinking mechanisms. The thickness of the coating is usually from about 1 to 5, preferably 1.2 to 3 mils.
The preferred coating compositions of the present invention, particularly those prepared with the aliphatic polyepoxides, are used as clear coats for use in a color-plus-clear application. In a color-plus-clear application, a composite coating is applied to a substrate. The process comprises applying to the substrate a pigmented or colored film-forming composition to form a base coat and applying to the base coat a second film-forming composition to form a transparent top coat over the base coat.
The film-forming composition of the base coat can be any of the compositions useful in coating applications, particularly automotive applications in which the color-plus-clear coating applications are finding their most use. The film-forming composition conventionally comprises a resinous binder and is employed in combination with a pigment which acts as a colorant. Particularly useful resinous binders are acrylic polymers, polyesters including alkyds and polyurethanes. The resinous binder for the base coat can be an organic solvent-based material such as those described in U.S. Pat. No. 4,220,679, note column 2, line 24, continuing through column 4, line 40. Also, water-based coating compositions such as those described in U.S. Pat. Nos. 4,403,003 and 4,147,679 can also be used as the binder in the base coat composition. The resinous binder for the base coat can also be the same as those of the present invention.
As afore-stated, the base coat composition also contains pigments including metallic pigmentation to give it color. Examples of suitable pigmentations for the base coat are described in the aforementioned U.S. Pat. Nos. 4,220,679; 4,403,003 and 4,147,679.
Optional ingredients in the base coat composition are those which are well known in the art of formulating surface coatings and include surfactants, flow control agents, thixotropic agents, fillers, anti-gassing agents, organic co-solvents, catalysts and other customary auxiliaries. Examples of these materials and suitable amounts are described in the aforementioned U.S. Pat. Nos. 4,220,679; 4,403,003 and 4,147,679, but they are most often applied by spraying. The coating compositions can be applied by air spraying and electrostatic spraying in either manual or automatic methods which are preferred.
During application of the base coat to the substrate, a film of the base coat is formed on the substrate typically in a thickness of about 0.1 to 5 and preferably about 0.1 to 2 mils. After forming a film of the base coat on the substrate, solvent, that is, organic solvent and/or water, is driven out of the base coat film by heating or simply an air drying period before application of the clear coat. Preferably, the heating step will be for a short period of time sufficient to insure that the clear top coat composition can be applied to the base coat without the former dissolving the base coat composition, that is, "striking in". Suitable drying conditions will depend on the particular base coat composition, on the ambient humidity with certain water-based compositions, but in general a drying time of from about 1 to 5 minutes at a temperature of about 80°-175° F. (20°-79° C.) will be adequate to insure that mixing of the two coats is minimized. At the same time, the base coat film is adequately wetted by the clear top coat composition so that satisfactory intercoat adhesion can be obtained. Also, more than one base coat and more than one top coat may be applied to develop optimum appearance. Usually between coats, the previously applied base coat or top coat is flashed, that is, exposed to ambient conditions for about 1 to 20 minutes.
The clear top coat composition is applied to the base coat by any of the conventional coating techniques mentioned above, although spray applications are typical. As mentioned above, the clear top coat is applied to the base coat via a wet-on-wet technique before the base coat has been cured. The two coatings are then heated to a temperature sufficient to cure and to conjointly harden both coating layers. Curing conditions such as described above can be used. In the preferred embodiments of the invention, the cured coatings are hard, solvent-resistance and possess the remarkable appearance and other desirable film properties.
Appearance of the color-plus-clear systems of this invention is remarkable. DOI measurement of the coating can range MP to about 100. Overall, the combination of highly desirable properties of the claimed coatings, to wit, high solids, high sprayability, low VOC, acceptable sag control and excellent appearance, markedly distinguishes the claimed coating over art-related coatings.
The invention will be further defined by reference to the following examples. Unless otherwise indicated, all parts are by weight.
EXAMPLE A
This example illustrate a high solids thermosetting clear coating composition and the methods of preparing and using the same.
______________________________________Ingredients Parts by Weight (grams) Solids______________________________________Pack ATINUVIN 328.sup.1 3.0 3.0Methyl ethyl ketone 16.5TINUVIN 292.sup.2 1.0 1.0Silicone fluid.sup.3 1.0 0.1(10% solution in xylene)ARMEEN DM 12D.sup.4 2.0 2.0DENACOL 421.sup.5 48.0 48.0Cellulose acetate butyrate 4.0 1.0Pack B Methylhexahydrophthalic 52.0 52.0anhydride______________________________________ .sup.1 UV absorber available from Ciba Geigy Corp. .sup.2 UV stabilizer available from Ciba Geigy Corp. .sup.3 Available as DC 200 10CS from Dow Corning Co. .sup.4 Dimethyldodecylamine available from Akzo Chemical Co. .sup.5 Diglycerol polyglycidyl ether from Nagase America Corp.
The above ingredients were formulated into a clear coating composition by mixing them at a low shear with good agitation. The resultant composition had a solids content of 87.3 percent measured at 100° C. after 60 minutes, and a viscosity of 22 seconds measured with a number 4 Ford cup.
The clear coat was spray applied over a panel of steel substrates that had been electrocoated with UNI-PRIME® (which is a cationic electrodepositable composition available from PPG Industries, Inc.) and baked at 340° F. (171° C.) for 30 minutes. The electrocoated panels were spray painted with a base coat (available from ICI Limited as M-979) to a film thickness of 0.3 mil. The panels were then flashed for 3 minutes at 150° F. (66° C.), before the above clear coat was spray applied. The resultant color-plus-clear coat had a film thickness of 1.4 mils, DOI was 90, and Tukon hardness of 8.2.
EXAMPLE B
This example illustrates a high solids thermosetting clear coating composition and the methods of preparing and using the same.
______________________________________Ingredients Parts by Weight (grams) Solids______________________________________Pack ATINUVIN 1130.sup.2 3.0 3.0TINUVIN 292 1.0 1.0Silicone fluid 1.0 0.1(10% solution in xylene)Cellulose acetate butyrate 4.0 1.0ARMEEN DM 12D 3.0 3.0Epoxy/Hydroxy-functionalAcrylic Polymer.sup.2Polymeric acid.sup.3 4.3 3.0Methyl ethyl ketone 16.5Pack B Methylhexahydrophthalic 34.0 34.0anhydride______________________________________ .sup.1 UV absorber available from Ciba Geigy Corp. .sup.2 The acrylic polymer was derived from 40% glycidyl methacrylate/15% butyl acrylate/25% methylmeth acrylate/10% CARDUARA/Acrylic acid. (CARDUARA E which is an epoxy ester of Versatic acid, available from Shel Chemical Co. was herein reacted with acrylic acid). .sup.3 Polymeric acid derived from 2 moles of hexahydropthalic anhydride and 1 mole of 1,6hexanediol.
The above ingredients were formulated into a clear coating composition by mixing them at a low shear with good agitation. The resultant composition had a solids content of 65.6 percent measured at 110° C. after 60 minutes, and a viscosity of 22 seconds measured with a number 4 Ford cup.
The clear coating composition was spray applied over a panel of steel substrates that had been electrocoated with UNI-PRIME® (which is a cationic electrodepositable composition available from PPG Industries, Inc.) and baked at 340° F. (171° C.) for 30 minutes. The electrocoated panels were spray painted with a base coat (available from ICI Limited as M-979) to a film thickness of 0.3 mil. The panels were then flashed for 3 minutes at 150° F. (66° C.), before the above clear coat coating was composition spray applied. The resultant color-plus-clear coat had a film thickness of 1.4 mils, gloss (at 20 degree angle) was 86, DOI of 90, and Tukon hardness of 10.10.
EXAMPLE C
This example further illustrates the clear coating composition of this invention and the methods of making and using the same.
______________________________________Ingredients Parts by Weight (grams) Solids______________________________________Pack ATINUVIN 1130 3.0 3.0TINUVIN 292 3.0 3.0Silicone fluid 1.0 0.1ARMEEN DM 12D 3.0 3.0Cellulose acetate butyrate 4.0 1.0Polymeric acid.sup.1 4.3 3.0Hydroxy-functional glycidyl 104.0 60.3acrylic polymer.sup.2Pack B Methylhexahydrophthalic 31.2 31.2anhydride______________________________________ .sup.1 Same as in Example A. .sup.2 Same as in Example B.
The above ingredients were formulated by mixing them in the order indicated above at low shear with good agitation. The resultant composition had a determined solids content of about 70 percent (at 110° C. for 60 minutes) and viscosity of 31.5 seconds measured with a number 4 Ford cup.
The clear coating with spray applied wet-on-wet in a color-plus-clear mode as described in Example A. The resultant coating had a film thickness of 2 mils, DOI of 90 and Tukon hardness of 12.50. | 4y
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This is a division of application Ser. No. 431,600, filed Jan. 8, 1974.
BACKGROUND OF THE INVENTION
This invention relates to novel ester derivatives of prostaglandin A 1 (hereinafter identified as "PGA 1 "), 15-alkyl-PGA 1 , 15(R)-15-alkyl-PGA 1 , and their racemic forms, and to processes for producing them.
PGA 1 is represented by the formula: ##SPC1##
A systematic name for PGA 1 is 7-{2β-[(3S)-3-hydroxy-trans-1-octenyl]-5-oxo-1α-cyclo-3-pentenyl}heptanoic acid. PGA 1 is known to be useful for a variety of pharmacological and medical purposes, for example to reduce and control excessive gastric secretion, to increase the flow of blood in the mammalian kidney as in cases of renal dysfunction, to control spasm and facilitate breathing in asthmatic conditions, and as a hypotensive agent to reduce blood pressure in mammals, including humans. See Bergstrom et al., Pharmacol. Rev. 20, 1 (1968) and references cited therein. As to racemic PGA 1 , see for example P. W. Ramwell, Nature 221, 1251 (1969).
The 15-alkyl-PGA 1 analog and its 15(R) epimer are represented by the formula ##SPC2##
wherein Y' is ##EQU1## following the usual convention wherein broken line attachment of hydroxy to the side chain at carbon 15 indicates the natural or "S" configuration and solid line attachment of hydroxy indicates the epi or "R" configuration. See for example Nugteren et al., Nature 212, 38 (1966) and Cahn, J. Chem. Ed. 41, 116 (1964). The 15-alkyl- and 15(R)-15-alkyl-PGA 1 analogs in their optically active and racemic forms are known. See for example Belg. Pat. No. 772,584, Derwent Farmdoc No. 19694T. These analogs are also useful for the above-described pharmacological purposes.
Esters of the above compounds are known, wherein the hydrogen atom of the carboxyl group is replaced by a hydrocarbyl or substituted hydrocarbyl group. Among these is the methyl ester of PGA 1 (J. P. Lee et al., Biochem. J. 105, 1251 (1967)).
SUMMARY OF THE INVENTION
It is a purpose of this invention to provide novel ester derivatives of prostaglandin PGA 1 , 15-alkyl-PGA 1 , 15(R)-15-alkyl-PGA 1 , and their racemic forms. It is a further purpose to provide such esters derived from substituted phenols and naphthols. It is a further purpose to provide such esters in a free-flowing crystalline form. It is still a further purpose to provide novel processes for preparing these esters.
The presently described esters include compounds represented by the generic formula: ##SPC3##
wherein Z is the substituted phenyl or naphthyl group as defined immediately below, and Y is ##EQU2## i.e. esters of PGA 1 , 15-methyl-PGA 1 , 15(R)-15-methyl-PGA 1 , 15-ethyl-PGA 1 , and 15(R)-15-ethyl-PGA 1 ; and also the racemic compounds represented by each respective formula and the mirror image thereof; Z being represented by ##SPC4##
For example, PGA 1 , p-acetamidophenyl ester, is represented by formula III when Y is ##EQU3## and Z is A, i.e. ##SPC5##
and is conveniently identified herein as the PGA 1 ester of formula III-A. Racemic compounds are designated by the prefix "racemic" or "dl"; when that prefix is absent, the intent is to designate an optically active compound. Racemic 15-methyl-PGA 1 , p-benzamidophenyl ester, corresponds to formula III wherein Y is ##EQU4## and Z is B, i.e. ##SPC6##
including the course not only the optically active isomer represented by formula III but also its mirror image.
The novel formula-III compounds and corresponding racemic compounds of this invention are each useful for the same purposes as described above for PGA 1 and are used for those purposes in the same manner known in the art, including oral, sublingual, buccal, rectal, intravaginal, intrauterine, or topical administration.
For many applications these novel prostaglandin esters which I have obtained from certain specific phenols and naphthols have advantages over the corresponding known prostaglandin compounds. Thus, these substituted phenyl and naphthyl esters are surprisingly stable compounds having outstanding shelf-life and thermal stability. In contrast to the acid form of these prostaglandins, these esters are not subject to decomposition either by elimination of water, or epimerization, or isomerization. Thus these compounds have improved stability either in solid, liquid, or solution form. In oral administration these esters have shown surprisingly greater efficacy than the corresponding free acids or lower alkyl esters, whether because of longer duration of biological activity or because of improved lipophilicity and absorption is not certain. These esters offer a further advantage in that they have low solubility in water and the body fluids and are therefore retained longer at the site of administration.
A particularly outstanding advantage of many of these substituted phenyl and naphthyl esters is that they are obtained in free-flowing crystalline form, generally of moderately high melting point, in the range 90°-180°C. This form is especially desirable for ease of handling, administering, and purifying. These crystals are highly stable, for example showing practically no decomposition at accelerated storage tests at 65° C., in comparison with liquid alkyl esters or the free acids. This quality is advantageous because the compound does not lose its potency and does not become contaminated with decomposition products.
These crystalline esters also provide a means of purifying PGA 1 , 15-methyl-PGA 1 , 15(R)-15-methyl-PGA 1 , 15-ethyl-PGA 1 , or 15(R)-15-ethyl-PGA 1 , which are first converted to one of these esters, recrystallized until pure, and then recovered as the free acid. One method of recovering the free acid is by enzymatic hydrolysis of the ester, for example with a lipase. See German Pat. No. 2,242,792, Derwent Farmdoc No. 23047U.
To obtain the optimum combination of stability, duration of biological activity, lipophilicity, solubility, and crystallinity, certain compounds within the scope of formula III are preferred.
One preference is that Z is limited to either ##SPC7##
Another preference is that Z is further limited to ##SPC8##
Another preference is that Z is limited to ##SPC9##
Another preference is that Z is limited to ##SPC10##
Especially preferred are those compounds which are in free-flowing crystalline form, for example:
p-benzamidophenyl ester of PGA 1
p-ureidophenyl ester of PGA 1
2-naphthyl ester of PGA 1
The substituted phenyl and naphthyl esters of PGA 1 , 15-alkyl-PGA 1 and 15(R)-15-alkyl-PGA 1 , encompassed by formula III wherein Z is defined by ester groups A through Y are produced by the reactions and procedures described and exemplified hereinafter. For convenience, the above prostaglandin or prostaglandin analog is referred to as "the PG compound". The term "phenol" is used in a generic sense, including both phenols and naphthols.
Various methods are available for preparing these esters, differing as to yield and purity of product. Thus, by one method, the PG compound is converted to a tertiary amine salt, reacted with pivaloyl halide to give the mixed acid anhydride and then reacted with the phenol. Alternately, instead of pivaloyl halide, an alkyl or phenylsulfonyl halide is used, such as p-toluenesulfonyl chloride. See for example Belg. Pat. Nos. 775,106 and 776,294, Derwent Farmdoc Nos. 33705T and 39011T.
Still another method is by the use of the coupling reagent, dicyclohexylcarbodiimide. See Fieser et al., "Reagents for Organic Synthesis", pp. 231-236, John Wiley and Sons, Inc., New York (1967). The PG compound is contacted with 1 to 10 molar equivalents of the phenol in the presence of 2-10 molar equivalents of dicyclohexylcarbodiimide in pyridine as a solvent.
The preferred novel process for the preparation of these esters, however, comprises the steps (1) forming a mixed anhydride with the PG compound and isobutylchloroformate in the presence of a tertiary amine and (2) reacting the anhydride with an appropriate phenol or naphthol.
The mixed anhydride is represented by the formula: ##SPC11##
for the optically active PG compounds, Y having the same definition as above.
The anhydride is formed readily at temperatures in the range -40° to +60° C., preferably at -10° to +10° C. so that the rate is reasonably fast and yet side reactions are minimized. The isobutylchloroformate reagent is preferably used in excess, for example 1.2 molar equivalents up to 4.0 per mole of the PG compound. The reaction is preferably done in a solvent and for this purpose acetone is preferred, although other relatively non-polar solvents are used such as acetonitrile, dichloromethane, and chloroform. The reaction is run in the presence of a tertiary amine, for example triethylamine, and the co-formed amine hydrochloride usually crystallizes out, but need not be removed for the next step.
The anhydride is usually not isolated but is reacted directly in solution with the phenol, preferably in the presence of a tertiary amine such as pyridine.
The phenol is preferably used in equivalent amounts or in excess to insure that all of the mixed anhydride is converted to ester. Excess phenol is separated from the product by methods described herein or known in the art, for example by crystallization. The tertiary amine is not only a basic catalyst for the esterification but also a convenient solvent. Other examples of tertiary amines useful for this purpose include N-methylmorpholine, triethylamine, diisopropylethylamine, and dimethylaniline. Although they may be used, 2-methylpyridine and quinoline result in a slow reaction. A highly hindered amine such as 2,6-dimethyllutidine is not useful because of the slowness of the reaction.
The reaction with the anhydride proceeds smoothly at room temperature (about 20° to 30° C.) and can be followed in the conventional manner with thin layer chromatography (TLC), usually being found complete within 1-4 hours.
The reaction mixture is worked up to yield the ester following methods known in the art, and the product is purified, for example by silica gel chromatography.
Solid esters are converted to a free-flowing crystalline form on crystallization from a variety of solvents, including ethyl acetate, tetrahydrofuran, methanol, and acetone, by cooling or evaporating a saturated solution of the ester in the solvent or by adding a miscible non-solvent such as diethyl ether, hexane, or water. The crystals are then collected by conventional techniques, e.g. filtration or centrifugation, washed with a small amount of solvent, and dried under reduced pressure. They may also be dried in a current of warm nitrogen or argon, or by warming to about 75° C. Although the crystals are normally pure enough for many applications, they may be recrystallized by the same general techniques to achieve improved purity after each recrystallization.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention can be more fully understood by the following examples.
All temperatures are in degrees centigrade.
Silica gel chromatography, as used herein, is understood to include chromatography on a column packed with silica gel, elution, collection of fractions, and combination of those fractions shown by thin layer chromatography (TLC) to contain the desired product free of starting material and impurities.
"TLC", herein, refers to thin layer chromatography.
PREPARATION 1
p-Benzamidophenol
A solution of p-hydroxyaniline (20 g.) in 200 ml. pyridine is treated with benzoic anhydride (20 g.). After 4 hr. at about 25° C., the mixture is concentrated under reduced pressure and the residue is taken up in 200 ml. of hot methanol and reprecipitated with 300 ml. of water. The product is recrystallized from hot acetonitrile as white crystals, 8.5 g., m.p. 218.0°-218.5° C.
PREPARATION 2
p-(p-Acetamidobenzamido)phenol
A solution of p-acetamidobenzoic acid (12.5 g.) in 250 ml. of tetrahydrofuran is treated with triethylamine (11.1 l ml.). The mixture is then treated with isobutylchloroformate (10.4 ml.) and, after 5 min. at about 25° C., with p-aminophenol (13.3 g.) in 80 ml. of dry pyridine. After 40 min. the crude product is obtained by addition of 2 liters of water. The product is recrystallized from 500 ml. of hot methanol by dilution with 300 ml. of water as white crystals, 5.9 g., m.p. 275.0°-277.0° C.
EXAMPLE 1
PGA 1 , p-Acetamidophenyl Ester (Formula III-A)
A solution of PGA 1 (0.506 g.) and triethylamine (0.250 ml.) in 20 ml. of acetone is treated at -10° C. with isobutylchloroformate (0.236 ml) whereupon triethylamine hydrochloride is precipitated. After 5 min. the mixture is treated with p-acetamidophenol (0.453 g.) in 5 ml. of pyridine for 3 hr. at about 25° C. The solvent is removed under reduced pressure and the residue is dissolved in ethyl acetate and washed with aqueous citric acid (2%) and water. The organic phase is dried over sodium sulfate, concentrated, and subjected to silica gel chromatography, eluting with chloroform-acetonitrile (7:3) containing 1% water, followed by chloroform-acetonitrile (1:4). The residue obtained by concentration of selected fractions, an oil, is the title compound, 0.539 g., having R f 0.4 (TLC on silica gel in chloroform-acetonitrile (7:3)).
EXAMPLE 2
p-Benzamidophenyl Ester of PGA 1 (Formula III-B)
Following the procedure of Example 1 but using 0.510 g. of PGA 1 , 0.254 ml. of triethylamine, 0.238 ml. of isobutyl-chloroformate, and 0.484 g. of p-benzamidophenol (Preparation 1), there is obtained a crude residue. This residue is subjected to silica gel chromatography, eluting with chloroform-acetonitrile (85:15). The residue obtained by concentration of selected fractions, 0.505 g., is crystallized from ethyl acetate diluted with 2.5 volumes of hexane as the title compound, white free-flowing crystals, m.p. 96.8°-98.3° C., having R f 0.6 (TLC on silica gel in chloroformacetonitrile (4:1).
EXAMPLE 3
p-Hydroxyphenylurea Ester of PGA 1 , (Formula III-E)
Following the procedure of Example 1 but using 0.506 g. of PGA 1 , 0.250 ml. of triethylamine, 0.236 ml. of isobutyl-chloroformate, and 0.456 g. of p-hydroxyphenylurea, there is obtained a crude residue. This residue is subjected to silica gel chromatography, eluting with ethyl acetate-acetonitrile-water (94:5:1). The residue obtained by concentration of selected fractions, 0.646 g., is crystallized from ethyl acetate as the title compound, white free-flowing crystals, m.p. 96.3°-98.3° C., having R f 0.4 (TLC on silica gel in ethyl acetate-acetonitrile (95:5)).
EXAMPLE 4
p-Acetylphenyl Ester of PGA 1 (Formula III-L)
Following the procedure of Example 1 but using 0.508 g. of PGA 1 , 0.254 ml. of triethylamine, 0.238 ml. of isobutylchloroformate, and 0.309 g. of p-hydroxyacetophenone, there is obtained a crude residue. This residue is subjected to silica gel chromatography, eluting with ethyl acetate-hexane (2:3), followed by ethyl acetate-hexane (7:3). The residue obtained by concentration of selected fractions, 0.500 g., an oil, is the title compound, having R f 0.4 (TLC on silica gel in ethyl acetate-hexane (1:1)).
EXAMPLE 5
p-Carbamoylphenyl Ester of PGA 1 (Formula III-N).
Following the procedure of Example 1 but using 0.506 g. of PGA 1 0.250 ml. of triethylamine, 0.236 ml. of isobutylchloroformate, and 0.412 g. of p-hydroxybenzamide there is obtained a crude residue. This residue is subjected to silica gel chromatography, eluting with chloroform-acetonitrile (6:4). The residue obtained by concentration of selected fractions, 0.260 g., an oil, as the title compound, having R f 0.5 (TLC on silica gel in chloroform-acetonitrile (3:2)).
EXAMPLE 6
2-Naphthyl Ester of PGA 1 (Formula III-X)
Following the procedure of Example 1 but using 0.506 g. of PGA 1 , 0.254 ml. of triethylamine, 0.238 ml. of isobutylchloroformate, and 0.327 g. of β-naphthol, there is obtained a crude residue. This residue is subjected to silica gel chromatography, eluting with ethyl acetate-hexane (2:3) followed by ethyl acetate-hexane (7:3). The residue obtained by concentration of selected fractions, 0.45 g., is crystallized from ethyl acetate diluted with two volumes of hexane as the title compound, white free-flowing crystals, m.p. 49.0°-50.0° C., having R f 0.5 (TLC on silica gel in ethyl acetate-hexane (1:1)).
Following the procedures of Examples 1-6 but employing the racemic forms of the PG compounds, there are obtained the corresponding esters of racemic PG compounds.
EXAMPLES 7-76
The substituted phenyl and naphthyl esters of PGA 1 , 15-methyl-PGA 1 , and 15(R)-15-methyl-PGA 1 of Tables I-III below are obtained following the procedures of Example 1, wherein the prostaglandin compound is reacted in the presence of triethylamine and isobutylchloroformate with the appropriate hydroxy phenyl or naphthyl compound, listed in the Table. These phenols or naphthols are readily available or prepared by methods described herein or known in the art. The crude products, obtained by concentration under reduced pressure, are purified by means described herein or known in the art, including partitioning, solvent extraction, washing, silica gel chromatography, trituration, or crystallization.
Following the procedures of Examples 7-76 but employing the racemic forms of the PG compounds, there are obtained the corresponding esters of the racemic PG compounds.
TABLE I______________________________________Esters of PGA.sub.1Hydroxy Phenyl or Product PGA.sub.1Ex. Naphthyl Compound Ester of formula:______________________________________ 7 p-acetamidophenol III-A 8 p-(p-acetamidobenzamidophenol III-C 9 p-(p-benzamidobenzamidophenol III-D10 p-hydroxy-1,3-diphenylurea III-E11 p-phenylphenol III-G12 p-tritylphenol III-H13 N-acetyl-L-tyrosinamide III-I14 N-benzoyl-L-tyrosinamide III-J15 p-hydroxybenzaldehyde semicarbazone III-K16 p-hydroxybenzophenone III-M17 o-hydroxybenzamide III-O18 N-(p-tritylphenyl)-p-hydroxybenzamide III-P19 p-hydroxybenzoic acid, methyl ester III-Q20 hydroquinone benzoate III-R21 hydroquinone, p-acetamidobenzoicacid ester III-S22 2,4-diacetamidophenol III-T23 1-acetamido-4-hydroxynaphthalene III-U24 1-benzamido-4-hydroxynaphthalene III-V25 1-hydroxy-4-ureidonaphthalene III-W26 1-hydroxy-5-naphthalenesulfonamide III-Y______________________________________
TABLE II______________________________________Esters of 15-Methyl-PGA.sub.1 ProductHydroxy Phenyl or 15-Methyl-PGA.sub.1Ex. Naphthyl Compound Ester of formula:______________________________________27 p-acetamidophenol III-A28 p-benzamidophenol III-B29 p-(p-acetamidobenzamidophenol III-C30 p-(p-benzamidobenzamidophenol III-D31 p-hydroxyphenylurea III-E32 p-hydroxy-1,3-diphenylurea III-F33 p-phenylphenol III-G34 p-tritylphenol III-H35 N-acetyl-L-tyrosinamide III-I36 N-benzoyl-L-tyrosinamide III-J37 p-hydroxybenzaldehyde semicarbazone III-K38 p-hydroxyacetophenone III-L39 p-hydroxybenzophenone III-M40 p-hydroxybenzamide III-N41 o-hydroxybenzamide III-O42 N-(p-tritylphenyl)-p-hydroxybenzamide III-P43 p-hydroxybenzoic acid, methyl ester III-Q44 hydroquinone benzoate III-R45 hydroquinone, p-acetamidobenzoic III-Sacid ester46 2,4-diacetamidophenol III-T47 1-acetamido-4-hydroxynaphthalene III-U48 1-benzamido-4-hydroxynaphthalene III-V49 1-hydroxy-4-ureidonaphthalene III-W50 2-naphthol III-X51 1-hydroxy-5-naphthalenesulfonamide III-Y______________________________________
TABLE III______________________________________Esters of 15(R)-15-Methyl-PGA.sub.1 Product 15(R)-15-Hydroxy Phenyl or Methyl-PGA.sub.1Ex. Naphthyl Compound Ester of formula:______________________________________52 p-acetamidophenol III-A53 p-benzamidophenol III-B54 p-(p-acetamidobenzamidophenol III-C55 p-(p-benzamidobenzamidophenol III-D56 p-hydroxyphenylurea III-E57 p-hydroxy-1,3-diphenylurea III-F58 p-phenylphenol III-G59 p-tritylphenol III-H60 N-acetyl-L-tyrosinamide III-I61 N-benzoyl-L-tyrosinamide III-J62 p-hydroxybenzaldehyde semicarbazone III-K63 p-hydroxyacetophenone III-L64 p-hydroxybenzophenone III-M65 p-hydroxybenzamide III-N66 o-hydroxybenzamide III-O67 N-(p-tritylphenyl)-p-hydroxybenzamide III-P68 p-hydroxybenzoic acid, methyl ester III-Q69 hydroquinone benzoate III-R70 hydroquinone, p-acetamidobenzoic III-Sacid ester71 2,4-diacetamidophenol III-T72 1-acetamido-4-hydroxynaphthalene III-U73 1-benzamido-4-hydroxynaphthalene III-V74 1-hydroxy-4-ureidonaphthalene III-W75 2-naphthol III-X76 1-hydroxy-5-naphthalenesulfonamide III-Y______________________________________ | 4y
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FIELD OF THE INVENTION
The present invention relates to a direct gasoline injection type spark igniting internal combustion engine with turbocharger and the engine control method thereof, and more particularly to a control mechanism and a control method of an exhaust passage.
DESCRIPTION OF THE RELATED ART
Since a direct gasoline injection type spark igniting internal combustion engine directly injects fuel into a cylinder, stratified combustion of collecting and burning fuel near an ignition plug so as to set a lean air fuel ratio as a whole can be conducted. However, in the case of a natural air supply type engine, since an amount of air sucked within the cylinder is small, a range capable of executing a stratified operation is narrow and a sufficient specific fuel consumption improving effect can not be obtained. On the contrary, a system combining a turbocharger and a catalyst (a pre catalyst and a main catalyst) with a conventional direct gasoline injection type spark igniting internal combustion engine is known in Japanese Patent No. 3090536.
In order to increase purification performance at a time of starting an engine, it is general in view of an exhaust countermeasure to additionally provide the pre catalyst assisting the main catalyst near the engine, in addition to the main catalyst placed below a floor of a vehicle body. However, in the case of placing the turbocharger, there is a problem that the turbocharger interferes with the pre catalyst so as to reduce their performances therebetween. As a countermeasure therefor, as shown in Japanese Patent No. 3093536, there is a method of placing valves for switching respective exhaust passages, however, a structure and a control thereof are complex since a number of the valves is increased. Further, in the conventional direct gasoline injection type spark igniting internal combustion engine, there is a problem that an actuation area of the turbocharger does not correspond to the stratified combustion area.
SUMMARY OF THE INVENTION
The present invention simplifies a structure and a control by contriving an arrangement of a pre catalyst, a turbine of a turbocharger and a bypass exhaust passage bypassing the turbine so as to set a control valve to one.
Further, the present invention expands a stratified operation area by reducing a capacity of the turbocharger, and shifting the actuation area thereof to a low capacity side so as to coincide it with the stratified combustion area, thereby increasing an amount of air in the stratified area.
In the present invention, an air-fuel ratio (A/F) is shifted to a rich side in an area that the engine rotational speed increases over one half of the maximum rotational speed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a first embodiment in accordance with the present invention;
FIG. 2 is an operation view of a control valve in the first embodiment;
FIG. 3 is an operation flow chart of the control valve in the first embodiment;
FIG. 4 is a schematic view of a rotational number and an output torque of an engine according to the present invention;
FIG. 5 is a schematic view showing one example of an effect according to the present invention;
FIG. 6 is a schematic view of a second embodiment in accordance with the present invention;
FIG. 7 is an operation view of a control valve in accordance with the second embodiment;
FIG. 8 is a schematic view of an exhaust passage in accordance with the second embodiment;
FIG. 9 is a schematic view of the exhaust passage in accordance with the second embodiment;
FIG. 10 is a schematic view of a third embodiment in accordance with the present invention;
FIG. 11 is an operation view of a control valve in accordance with the third embodiment;
FIG. 12 is an operation flow chart of the control valve in accordance with the third embodiment;
FIG. 13 is an operation view of a waist gate valve in accordance with the third embodiment;
FIG. 14 is an operation flow chart of the waist gate valve in accordance with the third embodiment;
FIG. 15 is a schematic view of a fourth embodiment in accordance with the present invention;
FIG. 16 is an operation view of a control valve in accordance with the fourth embodiment;
FIG. 17 is an operation flow chart of the control valve in accordance with the fourth embodiment;
FIG. 18 is a schematic view of a fifth embodiment in accordance with the present invention;
FIG. 19 is an operation view of a control valve in accordance with the fifth embodiment;
FIG. 20 is a schematic view of a sixth embodiment in accordance with the present invention;
FIG. 21 is a schematic view of a fuel injection timing in the embodiments according to the present invention;
FIG. 22 is a schematic view showing a relation between an air/fuel (A/F) ratio and an exhaust gas temperature in an engine;
FIG. 23 is a schematic view of a control valve in a seventh embodiment according to the present invention; and
FIG. 24 is a schematic view of a control valve in an eighth embodiment according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a schematic view of a first embodiment in accordance with the present invention. A suction pipe 2 and a throttle valve 3 are provided in an engine 1 . A suction air enters into the throttle valve 3 via an air cleaner 6 , an air flow meter (AFM) 5 , a compressor 13 b of a turbocharger 13 and an intercooler 4 , and is supplied to the engine 1 from the suction pipe 2 . An exhaust gas from the engine 1 is discharged to a passage 22 through two passages 21 , 21 a branched from the exhaust pipe 10 and disposed in parallel to each other. A turbine 13 a is arranged on the passage 21 , and a pre catalyst 11 is arranged on the passage 21 a. In this case, the pre catalyst 11 is structured such as to assist a main catalyst 15 . Respective downstream sides of the pre catalyst 11 and the turbine 13 a communicate with a control valve 7 , are combined so as to enter to the passage 22 , and communicate with the main catalyst 15 . An angle signal of a crank angle sensor 19 in the engine and an air amount signal of the AFM 5 are input to an engine control unit (ECU) 14 , and an ignition signal and drive signals for fuel injection valves 18 a, 18 b, 18 c and 18 d are output via an ignition apparatus 20 . Further, a signal for controlling an actuator 7 a of the control valve 7 is output, and an exhaust gas pressure signal of the exhaust gas pressure sensor 8 and an idle switch (SW) signal for detecting a position of the throttle valve 3 are applied. Since an upstream pressure of the turbocharger is applied to the pre catalyst by placing the control valve 7 downstream the pre catalyst, it is possible to set a temperature of the pre catalyst higher than that in the case of attaching the control valve upstream the pre catalyst.
FIG. 2 shows an operation of the control valve 7 in accordance with the first embodiment shown in FIG. 1 . The control valve 7 is controlled to a closed position, a middle opening degree and an open position by the actuator 7 a. In the case of the closed position, a passage for the pre catalyst is closed (a turbo side passage is opened). In the case of the open position, a passage for the pre catalyst is opened (the turbo side passage is closed). In the case of the middle opening degree, the passages on both sides are opened, and the exhaust gas flows through both passages. A position in the case of the middle opening degree is changed on the basis of an exhaust gas amount and an exhaust gas pressure.
FIG. 3 is a control method of the control valve 7 in accordance with the first embodiment shown in FIG. 1 . At first, a judgement of a cooling water temperature Tw is executed. In the case that the relation Tw≧a is No, the engine is under warming up, and the process is finished by opening the control valve 7 (the exhaust gas is flowed only through the pre catalyst). In the case that the relation Tw≧a is Yes, a judgement of an idle SW is executed. In the case that a condition of the idle SW ON is Yes, a time t that the SW is ON is judged. In the case that the relation t≧t 1 is Yes, the process is finished by opening the control valve 7 . Immediately after the engine returns to the idle state from a traveling state (a load operation), the main catalyst maintain an activation due to the remaining heat, and it is not necessary to immediately use the pre catalyst. In the case that the relation t≧t 1 is No, the process is finished by closing the control valve 7 (the exhaust gas is flowed only through the turbocharger 13 ). When the idle period becomes certainly long, an effect of the remaining heat of the main catalyst is lost, and it is necessary to use the pre catalyst. Further, it is possible to reduce a frequency of use of the control valve 7 by using a timer in the manner mentioned above, and it is useful to improve a durability of the control valve. In the case that the condition of the idle SW ON is No, a judgement of an exhaust gas pressure Pe is executed. In the case that the relation Pe≧P 1 is No, the process is finished by closing the control valve 7 . In the case that the relation Pe≧P 1 is Yes, the process is finished by opening the control valve 7 at a middle opening degree so that Pe becomes P 1 so as to control the exhaust gas pressure.
FIG. 4 shows a relation between a rotational number of the engine and an output torque. In the conventional engine with the turbocharger, a supercharge is started from a point close to one half of a maximum rotational number, and an output torque becomes larger than that of a natural air supply engine in an area having a great engine rotational number. On the contrary, in the engine in accordance with the present invention, weight saving is achieved by making the turbocharger compact and shifting the actuation range of the turbocharger to a low rotational number side. As a result, in the engine in accordance with the present invention, the output torque is increased from the low rotational number range of the engine. However, since the turbocharger is made compact and light, the exhaust gas pressure becomes too high in a high rotational number side (near substantially one half of the maximum rotational number) in which the exhaust gas amount of the engine is increased. Accordingly, the passage (the conventional waist gate valve) for bypassing the turbocharger is opened earlier (at the lower rotational number) than the conventional engine with the turbocharger, and the output torque becomes smaller than that of the conventional apparatus on the high rotational number side.
FIG. 5 shows an effect of the present invention, and shows a relation between the engine rotational number and the output torque. An air amount in the low rotational number range is increased by additionally providing the turbocharger in accordance with the present invention, and it is possible to expand the stratified area of the conventional natural air supply to the large output torque. As a result, a fuel consumption is improved.
FIG. 6 shows a second embodiment in accordance with the present invention. The passage 21 is communicated with the exhaust pipe 10 , and the control valve 7 is placed there. The passage 21 is connected to the turbine 13 a of the turbocharger. On the other side, a passage 23 is branched from the control valve 7 and is communicated with the pre catalyst 11 . When the control valve 7 is attached to the upstream of the pre catalyst 11 in the manner mentioned above, a heat insulating effect of the pre catalyst 11 at a time when the control valve 7 is closed is reduced, however, the same effects as that in FIG. 1 are expected except the above effect.
FIG. 7 describes an operation of the control valve 7 in accordance with the second embodiment shown in FIG. 6 . In the case that the control valve 7 is at the closed position, the passage 23 corresponding to the passage for the pre catalyst 11 is closed. In the case that the control valve 7 is at the open position, the passage 23 is inversely opened and the passage 21 is closed. A control method of the control valve 7 is the same as that in FIG. 3 .
FIGS. 8 and 9 show an example of a passage structure of the control valve 7 . The passage is formed in a T-shaped pipe shape in FIGS. 1 and 6, however is formed in a Y-shaped pipe shape in the present embodiment. FIG. 8 shows a case of confluence of the flows and FIG. 9 shows a case of separation of the flows. In both cases, the rotational angle of the control valve 7 can be made smaller than that of the T-shaped pipe. Further, since a curve of an exhaust gas flow is the same in both passages, there is no difference between flow resistances caused by the passages.
FIG. 10 shows a third embodiment in accordance with the present invention, in which the control valve employs a control valve 17 having a two-position motion between “open” and “close”. Accordingly, a waist gate valve 12 is placed so as to bypass the turbine 13 a. The control valve can be simplified by employing the two-position motion valve to the control valve. Further, although the waist gate valve 12 is newly required, the similar structure has been conventionally provided in the turbocharger, so that a mechanical improvement is reduced.
FIG. 11 shows a motion of the control valve 17 in accordance with the third embodiment. The passage of the pre catalyst is opened (the turbine 13 a is closed) at the open position. The turbine 13 a side is opened (the pre catalyst 11 side is closed) at the closed position.
FIG. 12 shows a control flow chart of the control valve 17 in accordance with the third embodiment. At first, a cooling water temperature Tw is judged. In the case that the relation Tw≧a is No, the engine is under warming up, and the process is finished by opening the control valve 17 . In the case that the relation Tw≧a is Yes, a judgement of an idle SW is executed. In the case that a condition of the idle SW ON is Yes, a time t that the SW is ON is judged. In the case that the relation t≧t 1 is Yes, the process is finished by opening the control valve 17 . In the case that the relation t≧t 1 is No, the process is finished by closing the control valve 17 . In the case that the condition of the idle SW ON is No, the process is finished by closing the control valve 17 .
FIG. 13 shows a structure of the waist gate valve 12 in accordance with the third embodiment. When a valve opening signal is input to an actuator 12 a, a valve 24 is opened in correspondence to a magnitude thereof, and the exhaust gas flows so as to bypass the turbine 13 a, thereby controlling the exhaust gas pressure.
FIG. 14 shows a control method of the waist gate valve 12 in accordance with the third embodiment. The waist gate valve 12 in accordance with the present invention controls the exhaust gas pressure to a predetermined value. At first, a judgement of an exhaust gas pressure Pe is executed. In the case that the relation Pe≧P 1 is No, the process is finished by closing the waist gate valve 12 . In the case that the relation Pe≧P 1 is Yes, the process is finished by controlling the exhaust gas pressure (the middle opening degree) by the waist gate valve 12 .
FIG. 15 shows a fourth embodiment in accordance with the present invention. This embodiment corresponds to an embodiment in which the pre catalyst 11 is positioned on the upstream side of the turbine 13 a in the structure in which the pre catalyst and the turbine 13 a are arranged in series and a passage 25 bypassing the turbine 13 a is placed. The control valve 7 is placed in a branch portion between the passage 21 and the passage 25 .
FIG. 16 is an operation view of the control valve 7 in accordance with the fourth embodiment. When the control valve 7 is at the open position, the exhaust gas flows only through the passage 25 . When the control valve 7 is at the closed position, the exhaust gas flows to the turbine 13 a side. In the case of executing the exhaust gas pressure control, the valve is at the middle opening degree, and the exhaust gas flows through both of the passages 21 and 25 .
FIG. 17 is a control flow chart of the control valve 7 shown in FIG. 16 . At first, a judgement of a cooling water temperature Tw is executed. In the case that the relation Tw≧c °C. is No, the process is finished by opening the control valve 7 . In the case that the relation Tw≧c °C. is Yes, a judgement of an exhaust gas pressure Pe is executed. In the case that the relation Pe≧P 1 is No, the process is finished by closing the control valve 7 . In the case that the relation Pe≧P 1 is Yes, the exhaust gas pressure control is executed by the control valve 7 (the middle opening degree).
FIG. 18 shows a fifth embodiment in accordance with the present invention. This embodiment corresponds to an embodiment in which the pre catalyst 11 is positioned on the downstream side of the turbine 13 a in the structure in which the pre catalyst and the turbine 13 a are arranged in series and a passage 26 bypassing the turbine 13 a is placed. The control valve 7 makes the passage 26 and a passage 27 confluent.
FIG. 19 is an operation view of the control valve 7 in accordance with the fifth embodiment. The closed position of the control valve 7 corresponds to a state that the passage 26 is closed. The open position of the control valve 7 corresponds to a state that the turbine 13 a is closed. The middle opening degree corresponds to a state that the exhaust gas flows through both of the passages 27 and 26 and the exhaust gas pressure control is executed. The control flow is the same as that shown in FIG. 17 .
FIG. 20 shows a sixth embodiment in accordance with the present invention in which for omitting the conventional main catalyst, a so-called manifold catalyst 28 having one catalyst placed at a position close to the engine is combined with the pre catalyst of which the capacity is increased. The main catalyst conventionally placed in the passage 22 is omitted. The mounting and the operation of the control valve 7 are the same as those in FIG. 18 .
Further, in each of the embodiments shown in FIGS. 6, 15 , 18 and 20 , in the same manner as that of the third embodiment shown in FIG. 10, it is possible to place the waist gate valve 12 , and the control valve can be replaced by the two-position motion valve.
FIG. 21 shows a fuel injection method at a time of starting and warming up of the engine. In the timing after finishing the warming-up executed in the normal operation, there is executed a so-called compression stroke injection of injecting the fuel at a rear half of the compression stroke, forming the mixture in a stratified state and igniting the mixture. However, at a time of starting and warming up, an early warming-up of the exhaust gas system including the pre catalyst for a short time is important in view of an improvement of an exhaust performance. The fuel is injected at a specific injection timing for warming up, and an engine warm up condition of stratified combustion is executed. That is, a first time fuel injection is executed at a rear half of the compression stroke in the same manner as the normal operation, and an ignition is executed. Next, the engine proceeds on to an expansion stroke, however, a second time fuel injection which is substantially the same as the first time injection is executed at a rear half of the expansion stroke. Since the fuel injected at the second time is hardly converted into work and is exhausted, the exhaust gas temperature is raised, and the fuel contributes to the temperature up of the exhaust system. When the present invention is combined with the two-time injection in the compression and the expansion strokes, the engine warm up time can be further reduced, and an exhaust gas purification effect can be improved.
FIG. 22 shows a relation between the A/F and the exhaust gas temperature. There is known a characteristic that an exhaust gas temperature achieves a maximum temperature on a little rich side in comparison with a theoretical air fuel ratio, and the temperature is reduced on either of a lean side or a rich side in comparison thereof. In the case that the exhaust gas amount is increased, the exhaust gas pressure becomes high and the exhaust gas bypasses the turbine, as in the embodiments in accordance with the resent invention, there is a case that the pre catalyst is exposed to the high temperature exhaust gas and a durability of the catalyst is reduced. In the case mentioned above, there is employed a method of shifting the air fuel ratio of the mixture supplied to the engine to a rich side and reducing the exhaust gas temperature. In accordance with the present invention, these methods are also effective means.
FIG. 23 shows a seventh embodiment in accordance with the present invention in which a bypass passage 29 always bypassing a part of the exhaust gas is added to the control valve 7 . With the structure, the exhaust gas always flows through the pre catalyst, and an activation is kept. In the seventh embodiment shown in FIG. 23, there is shown a case that the control valve 7 is placed in a confluent portion downstream of the pre catalyst 11 and the turbine 13 a. In the case of placing the control valve 7 in the branch portion upstream of both of them, the present embodiment is also effective. It is effective for raising the temperature of the pre catalyst and keeping the activation to attach the bypass passage 29 to the pre catalyst side.
FIG. 24 is an eighth embodiment in accordance with the present invention in which a hole 30 is pierced to the control valve 7 and a part of the exhaust gas is always bypassed. When piercing the hole 30 in the control valve 7 , a part of the exhaust gas flows to the turbine 13 a even in the case of closing the turbine 13 a, so that the exhaust performance at a time of starting is reduced in some degree. However, since a preliminary rotation is previously given to the turbine, a response at a time of starting the turbine is improved. In this embodiment, the same effect can be obtained even when placing in the junction portion shown in FIG. 23 .
In accordance with the present invention, since it is possible to prevent the exhaust gas from being cooled by the turbocharger at a time of starting the engine, an early warm up of the main catalyst can be executed, the exhaust gas is purified and an amount of air in the stratified area is increased, so that the stratified area expands to the high output side and the fuel consumption is improved. | 4y
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TECHNICAL FIELD
[0001] The invention is based on a procedure for operating a reagent metering valve, which is metering a reagent into the exhaust gas area of a combustion engine, and on a device for implementing the procedure according to the category of independent claims. Subject of the present invention is also a computer program as well as a computer program product.
BACKGROUND
[0002] DE 199 03 439 A1 describes a procedure and device for operating a combustion engine, in whose exhaust gas area a SCR-catalyst (selective-catalytic-reduction) is arranged, which reduces the nitrous gases that are contained in the exhaust gas of the combustion engine with a reagent into nitrogen. The metering of the reagent or a preliminary stage of the reagent preferably takes place depending on parameters of the combustion engine, as for example the engine speed and the injected fuel quantity. Furthermore the metering preferably takes place depending on exhaust gas parameters, as for example the exhaust gas temperature or the operating temperature of the SCR-catalyst.
[0003] The reducing agent ammoniac, which can be won from a urea/water solution as a preliminary stage of the reagent, is for example provided as the reagent. The metering of the reagent or the preliminary stage has to be determined accurately. Too low metering causes nitrous gases in the catalyst not to be able to be completely reduced anymore. Too high metering causes a reagent slip, which can cause unnecessarily high reagent consumption on the one hand and depending on the consistency of the reagent an unpleasant odor nuisance on the other hand.
[0004] The determination of the reagent rate or the reagent dosage amount can take place according to EP 1 024 254 A2, based on an operating parameter of the combustion engine, as for example the fuel injection quantity and/or the engine speed and at least one parameter of the exhaust gas if necessary, as for example the exhaust gas temperature.
[0005] DE 196 36 507 A1 describes a procedure for controlling a combustion engine, at which at least one fuel after-injection is provided, which introduces oxidized exhaust components into the exhaust gas area of the combustion engine, which shall react exothermically in the exhaust gas area, in order to increase the exhaust gas temperature or at least to heat a component part. If only a small fuel amount shall be injected in the scope of the fuel after-injection, which cannot be shown anymore by the fuel injection valve, it is provided that only at each n-th fuel metering a fuel after-injection takes place.
[0006] DE 103 01 821 A1 describes a procedure for controlling an electromotor with a pulse-width modulated signal, which provides a default cycle duration and a certain duty cycle, which determines the performance or the engine speed of the engine. The cycle duration of the pulse-width modulated signal is modified depending on the duty cycle. Thereby it is ensured, that for each possible duty cycle the cycle duration is chosen in such a way that requirements regarding the power loss and requirements regarding the grid-bound failures are complied with.
[0007] EP 840 430 A1 describes a servo-drive, which is controlled by a three-phase pulse-width modulated signal. Provided are dead-times between the switch-on time and the switch-off time, whereby the dead times are variable, so that a modification of the switch-on time at a fixed cycle duration does not cause a corresponding modification of the switch-off time in all operating statuses. Thereby a more dissolved duty cycle can be achieved at a default cycle duration of the pulse-width modulated signal.
[0008] DE 37 10 467 A1 describes a fuel injection valve, which contains a core that is surrounded by an electromagnetic solenoid as well as a armature that interacts with the core and that is connected with a valve needle. When switching the electromagnet on it attracts the armature and enables thereby an opening for metering the fuel that is under pressure so long until the electromagnet is switched off.
[0009] DE 34 26 799 C2 describes a procedure for determining the opening point of time of a solenoid valve, from which on the solenoid valve is completely opened. The opening point of time is determined with the aid of the inductance change, which results from the attraction movement of the valve needle that is fixedly connected to the armature of the electromagnet, after switching on the electromagnet by changing the geometric proportions.
[0010] The invention is based on the task to provide a procedure for operating a metering valve, which is metering a reagent or a preliminary stage of a reagent into the exhaust gas area of a combustion engine, and a device for implementing the procedure, which enable a metering as exact as possible especially at lower dosage amounts or dosage rates.
SUMMARY
[0011] The approach of the invention with the characteristics of the independent claim provides the advantage that it is always ensured at each default dosage amount or dosage rate, which can be determined in a very big range, that a correct spray mist is produced. Thereby an exact metering of a reagent or the preliminary stage of the reagent is ensured, which a catalyst that is arranged in the exhaust gas area requires for converting the NOx that is in the exhaust gas either directly or after a conversion into a reagent that is directly applicable for the catalyst. By the approach of the invention a crystallizing of the reagent is especially avoided, which can cause a clogging of a metering valve, especially when the preliminary stage of the reagent is a urea/water solution.
[0012] Advantageous improvements and embodiments of the invention accrue from dependent claims.
[0013] Advantageous embodiments concern the consideration of parameters, depending on which the minimum opening duration of the metering valve is determined. The minimum opening duration can be determined depending on the pressure of the reagent and/or the exhaust gas temperature. Furthermore it can be provided that the minimum opening duration is determined depending on the operating voltage of the electromagnet of the metering valve. Moreover is can be additionally or alternatively provided that the minimum opening duration is determined depending on a measure for the exhaust gas temperature and/or a measure for the exhaust gas mass flow and/or a measure for the operating temperature of the metering valve and/or the reagent.
[0014] Another embodiment provides that the status, in which the metering valve is opened, is determined with the aid of an inductance-modification during the opening process of the metering valve that is actuated by an electromagnet. Thereby the minimum opening duration can be determined exactly. The inductance-modification can be simply determined from the measured current, which flows through the electromagnet.
[0015] The device according to the invention for implementing the procedure concerns initially a control unit, which is customized for implementing the procedure.
[0016] An extremely advantageous embodiment of the invention provides that a gasoline injection valve, which is known from the state of the art and which is very inexpensive due to the mass production, is used as the metering valve.
[0017] Another embodiment provides that for metering a urea/water solution is used as preliminary stage of the reagent.
[0018] The control unit preferably contains at least one electrical memory, in which the steps of the procedure are saved as a computer program.
[0019] The computer program according to the invention provides, that all steps of the procedure are carried out, when it runs on a computer.
[0020] The computer program product according to the invention with a program code, which is saved on a machine readable medium, carries out the procedure, when it runs on a computer or in the control unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Further advantageous improvements and embodiments of the procedure according to the invention arise from further dependent claims. One embodiment of the invention is illustrated in the drawing and further explained in the following description.
[0022] FIG. 1 is a technical environment, in which a procedure according to the invention is carried out; and
[0023] FIG. 2 is a metering valve-opening duration and a pulse-width modulated metering signal.
DETAILED DESCRIPTION
[0024] FIG. 1 shows a combustion engine 10 , in whose suction area 11 an air sensor 12 and in whose exhaust gas area 13 , in which a NOx-mass flow ms_NOx, an exhaust gas mass flow ms_Abg and an exhaust gas temperature te_Abg occur, a metering device 14 , an exhaust gas temperature sensor 15 as well as a catalyst 16 are arranged.
[0025] The air sensor 12 provides an air signal ms_ 1 to a control unit 20 , the combustion engine 10 an engine speed n and the exhaust gas temperature sensor 15 a measured exhaust gas temperature te_Abg_Mes. The control unit 20 supplies the fuel metering device 21 with a fuel signal m_K.
[0026] A metering valve 22 that is actuated by an electromagnet 23 is assigned to the metering device 14 . The metering valve 22 is impinged with a metering signal s_DV, which is provided by the control unit 20 and which actuates the electromagnet 23 . The current i that flows through the electromagnet 23 is detected by a current sensor 24 and supplied to the control unit 20 as measured current i_Mes. The reagent or the preliminary stage of the reagent that has to be metered provides an operating pressure p.
[0027] The control unit 20 contains a NOx-mass-flow-detection 30 , which provides the air signal ms_L as well as a measure Md for the load of the combustion engine 10 and which provides a calculated NOx-mass flow ms_NOx_Sim.
[0028] The control unit 20 furthermore contains a valve needle position detection 31 , which determines the metering valve opening point of time ti_BIP as well as the metering valve closing point of time ti_EIP for m the measured current i_Mes. A metering valve opening duration ti_D exists between the metering valve opening time ti_BIP and the metering valve closing point of time ti_EIP.
[0029] The valve needle position detection 31 provides the metering valve opening point of time ti_BIP to a metering signal determining 35 . The metering signal determination 35 is then supplied with the calculated NOX-mass flow ms_NOx_Sim, the metering valve operating temperature te_DV, the electromagnet operating voltage u, the exhaust gas temperature te_Abg as well as a default minimum metering valve opening duration ti_D_min. By doing so the metering signal s_DV is determined.
[0030] The metering signal determination 35 provides the metering signal s_DV as a pulse-width modulated signal, which is further explained in the scope of the following description of the functions with the aid of FIG. 2 .
[0031] When operating the combustion engine 10 a NOx-mass flow ms_NOx can occur in the exhaust gas area 13 , especially depending on the measure Md for the load of the combustion engine 10 , which is not allowed to exceed a default measure due to statutory provisions. Equivalent to a NOx-mass flow ms_NOx is the integral of the NOx-mass flow ms_NOx, which reflects the NOx-mass related to the time or especially to a route, as long as the combustion engine 10 is used as drive motor in a motor vehicle.
[0032] The measure Md for the load of the combustion engine 10 can for example be won from a position of a not further shown accelerator pedal. The measure Md for the load of a combustion engine 10 is for example also reflected in the fuel signal m_K, which determines at least one fuel injection point of time during a cycle of the combustion engine 10 as well as the quantity of the fuel metering device 21 that has to be dosed. Ii is assumed in the shown embodiment that the NOx-mass flow ms_NOx of the NOx-mass-flow-determination 30 provides the calculated NOx-mass flow ms_NOx_Sim with the aid of the air signal ms_L that is supplied by the air sensor 12 and the measure Md for the load of the combustion engine 10 .
[0033] The NOx that is contained in the exhaust gas shall be converted as much as possible in the catalyst 16 . It is assumed in the shown embodiment that a SCR-catalyst is used as the catalyst 16 , which requires the reagent or the preliminary stage of the reagent that has to be introduced into the exhaust gas area 13 with the metering device 14 of the reagent that efficiently works in the SCR-catalyst for carrying out the NOx-conversion.
[0034] It is assumed in the embodiment that a urea/water solution that is used as the preliminary stage of the reagent is directly sprayed into the exhaust gas area 13 , whereby ammoniac is created there by a thermolysis, which the SCR_catalyst 16 can use as a reagent.
[0035] The reagent can be spayed directly into the exhaust gas area 13 by the metering valve 22 . In that case the metering device 14 is identical to the metering valve 14 except for example for an assembly flange. Alternatively it can be provided that the metering device 14 contains a spraying pipe and that the metering valve 22 is not directly attached to an exhaust gas pipe or near to it.
[0036] The metering valve 22 is actuated by the electromagnet 23 . A realization of the metering valve 22 that is as inexpensive as possible provides, that a usual gasoline injection valve that is very inexpensive due to its mass production is used as the metering valve 22 .
[0037] A simple realization of the metering valve 22 provides, that being in switched-on state the electromagnet 23 attracts an armature, which is fixedly connected with a valve needle, which enables one or several openings in attracted state of the armature, from which the reagent that is under operating pressure p is sprayed out.
[0038] The electromagnet 23 is controlled with the pulse-width modulated metering signal s_DV, which is shown in the lower part of FIG. 2 . A pulse-width modulated signal is provided, which initially supplies preferably a default cycle duration ti_PR_con, which begins at the first point of time ti 1 and ends at the fifth point of time ti 5 . The variable switch-on duration ti_E_var, which lies between the first point of time ti 1 and the fourth point of time ti 4 , determines the switch-on duration ti_E_var of the electromagnet 23 . The variable switch-on duration ti_E_var begins again at the fifth point of time ti 5 and ends at the ninth point of time ti 9 .
[0039] At least during a part of the switch-on duration ti_E_var the opening duration ti_D of the metering valve 22 occurs. In the subsequent switch-off duration ti_A_var, which lies between the forth point of time ti 4 and the fifth point of time ti 5 , the electromagnet 23 is switched off and the metering valve 22 closed. The next opening duration ti_D occurs at the sixth point of time ti 6 and ends at the ninth point of time ti 9 . It is assumed in the following that the switch-off point of time ti_EIP of the electromagnet 23 coincides at least approximately with the closing point of time of the metering valve 22 .
[0040] In contrast to a usual gasoline injection the metering valve 22 in this approach that is preferably realized as a gasoline injection valve doses a significantly lower liquid quantity related to the time or the route. While a quantity of for example 5-15 liters/100 km is assumed at the gasoline injection, a consumption of for example almost 0 to 2 liters/1000 km can be assumed at a reagent metering.
[0041] The duty cycle of the pulse-width signal, which can be defined as switch-on duration ti_E_var/switch-off duration ti_A_var, varies thereby in a correspondingly wide range.
[0042] It has been proven by experiments that the reagent, for example the preliminary stage the urea/water solution, is not sprayed off as spray mist anymore below a certain opening duration ti_D of the metering valve 22 . Instead driblets occur, which partially remain in the metering valve 22 or which get as an incomplete spray mist or especially driblets into the exhaust gas area 13 .
[0043] Due to these driblets a loss of reagent occurs on the one hand and on the hand it was determined, that for example and urea/water solution is crystallized. The crystallization influences the geometric proportions at the metering valve 22 and can impair the ability for producing a spray mist. In the extreme case the crystallization can cause a clogging of the metering valve 22 .
[0044] It has been proven by experiments that it can be ensured with a limitation of the opening duration ti_D of the metering valve 22 onto the minimum opening duration ti_D_min that at each metering process during the opening duration ti_D a correct spray mist is produced. By doing so the minimum opening duration ti_D_min has to be determined experimentally preferably depending on the valve type and/or on the conditions in the exhaust gas area 13 . The default minimum opening duration ti_D_min is usually longer than the technically qualified minimum opening duration of the metering valve 22 . The minimum opening duration ti_D_min is for example determined to 5 milliseconds, while the technically qualified minimum opening duration of a fuel injection valve, for example of a regular gasoline injection valve, can lie around 1 millisecond for example.
[0045] According to a simple embodiment the minimum default opening duration ti_D_min is equally determined with the minimum switch-on duration ti_D_min of the electromagnet 23 . The metering valve cut-in time ti_ans lies between the beginning of the switch-on duration i_E_var of the electromagnet 23 at the first point of time ti 1 and the complete opening of the metering valve at the second point of time ti 2 . Because the cut-in time ti_Ans can already have a significant percentage of the opening duration ti_D at the minimum default opening duration ti_D_min, the metering valve cut-in time ti_Ans is preferably considered. The approach for determining the cut-in time ti_Ans is known from the above stated state of the art according to DE 34 26 799 C2. The default minimum opening duration ti_D_min is counted in that case from the second point of time yi 2 and ends at the third point of time ti 3 . The next default minimum opening duration ti_D_min begins at the eighth point of time ti 8 and ends at the tenth point of time ti 10 .
[0046] By the default of the minimum opening duration ti_D_min the constant cycle duration ti_PR_con cannot be maintained anymore at a very low duty cycle, for example below 5%. In order to be able to adjust the duty cycle to lower values, it is therefore provided to arrange the cycle duration of the pulse-width modulated signal as a variable cycle duration ti_PR_var. by doing so the variable switch-of duration ti_A_var occurs then, which begins at the first point of time ti 1 terminates at the seventh point of time ti 7 .
[0047] It has been proven by experiments that the production of spray mist depends on the operating pressure p of the reagent. According to an advantageous embodiment it is therefore provided to determine the minimum opening duration ti_D_min depending on the operating pressure p of the reagent,
[0048] The operating voltage u, with which the electromagnet 23 of the metering valve 22 is operated, has influence on the cut-in time ti_Ans in relation to inner resistance of the electromagnet 23 . According to an advantageous embodiment it is therefore provided that the operating voltage u is considered at the determination of the minimum opening duration ti_D_min.
[0049] Furthermore it has been proven with experiments that the production of spray mist depends on the exhaust gas mass flow ms_Abg, on the exhaust gas temperature te_Abg, on the exhaust gas pressure and on the operating temperature of the metering valve.
[0050] Advantageously the exhaust gas mass flow ms_Abg, the exhaust gas temperature te_Abg, the exhaust gas pressure and the operating temperature of the metering valve are therefore considered at the determination of the minimum opening duration ti_D_min.
[0051] The exhaust gas mass flow ms_Abg can be calculated by a not further shown exhaust gas ass flow determination with the aid of at least the air signal ms_L and if necessary the engine speed n and if necessary the measure Md for the load. The exhaust gas temperature te_Abg can also be at least approximately calculated from the air signal ms_L and the measure Md for the load of the combustion engine 10 . In the shown embodiment the exhaust gas temperature sensor 15 provides the exhaust gas temperature te_Abg_Mes. The operating temperature of the metering valve 22 can be at least approximately calculated for example from the inner resistance of the electromagnet 23 .
[0052] Therefore it is possible with these measures to consider the different influences on to the metering valve cut-in time ti_Ans, in order to specify the minimum opening time ti_D_min as correct as possible. | 4y
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BACKGROUND OF THE INVENTION
[0001] Motors, particularly gas powered motors or automobile engines, create a significant amount of vibration. For example, the action of the cam shaft creates torsional vibration. Torsional vibration can be reduced by using a vibration dampener. Typically the dampener mounts to the drive shaft and includes an annular weight fixed to a hub by an elastomeric member. A pulley may ride on the exterior surface of annular weight. Regardless, it is important that the weight not slip relative to the hub.
[0002] The elastomeric member or ring can be formed in a number of different ways. The elastomer can be injection molded between the annular weight and the hub and cured in place. This is by far the strongest bond that can be achieved in the torsional vibration dampener. Alternately a pre-formed or pre-cured elastomeric ring can be forced between the annular weight and the hub. Adhesive can be pre-applied to either surface to improve the bond between the metal weight and the metal hub.
[0003] The least expensive torsional vibration dampener simply uses a pre-cured elastomeric member which is compressed and force-fitted between the annular ring and hub. The resulting compression provides a strong bond between the annular ring and hub and prevents relative slippage. However, as this heats, the elastomeric member softens and slipping is a more significant problem.
[0004] The concern with relative movement between a elastomeric member and a metal member can be found in other applications such as the rubber bushing on a shock absorber.
SUMMARY OF THE INVENTION
[0005] The present invention is premised on the realization that the bond between a previously cured elastomeric member and a metal surface can be significantly enhanced by phosphating the metal surface prior to compression fitting the elastomeric member to the metal member.
[0006] Further with certain elastomeric members the bond strength between the metal surface and the elastomeric member can increase as the composite structure is heat aged as might occur during use. The phosphated surface actually promotes a bond between the metal surface and the elastomeric member particularly with respect to pre-cured EPDM and pre-cured ethylene acrylates.
[0007] The objects and advantages of the present invention will be further appreciated in light of the following detailed description and drawings in which:
BRIEF DESCRIPTION OF DRAWINGS
[0008] [0008]FIG. 1 is a front view of a vibration dampener;
[0009] [0009]FIG. 2 is a cross-sectional view taken at lines 2 - 2 of FIG. 1.
DETAILED DESCRIPTION
[0010] According to the present invention, the bond strength between a metal surface and a compression fitted rubber surface is improved by phosphating the metal surface prior to compression fitting the rubber member against the metal surface. As described below, the present invention is particularly useful in the formation of torsional vibration dampeners. The same invention can also be used in other applications such a rubber bushings attached to shock absorbers and the like. However, the invention will be particularly described with respect to a torsional vibration dampener.
[0011] There are a vast number of different designs of torsional vibration dampeners. Exemplary vibration dampeners are disclosed in U.S. Pat. No. 4,710,152 and U.S. Pat. No. 5,231,893. The vibration dampener 10 shown in FIG. 1 is itself merely exemplary as shown as with all torsional vibration dampeners, there is a hub portion 11 which attaches to a rotating shaft 12 of an internal combustion engine (not shown). The hub 11 in turn is attached to an annular weight or inertia ring 14 by an elastomeric ring 15 compression fitted between the annular weight 14 and an outer annular surface 16 of the hub 11 . The annular weight 14 may include an outer surface 17 which is a belt driving surface designed to drive an engine belt (not shown) which is in turn used to drive the alternator, power steering compressor, air conditioner compressor or the like. The elastomeric 15 member is held in compression between an inner surface 18 of the annular weight and an outer surface 16 of the hub 11 .
[0012] The elastomeric member can be a wide variety of different elastomers and is cured prior to assembly. The elastomeric member can be for example natural rubber or synthetic elastomer. Suitable elastomers include EPDM, styrene butadiene rubber, isoprene rubber, nitrile rubber, ethylene propylene copolymer and ethylene acrylic copolymer. The selection of the particular elastomeric member simply depends on the particular application. With respect to torsional vibration dampeners, the elastomer and its formulation are dictated by customer demand and performance requirements. An exemplary EPDM formula is shown below.
INGREDIENT DESCRIPTION/DETAILS PARTS EPDM BASE POLYMER 100 Mw/Mn = 3.0-7.0 % Unsaturation = 3-10% Ethylene % - wt. = 50-75% CARBON BLACK Filler 20-70 PLASTICIZER Paraffinic oil 5-30 ZINC OXIDE Curing agent 2-10 CO-AGENT Trifunctional methacrylate 1-7 ANTIOXIDANT Ozone Inhibitor .5-5.0 PEROXIDE Curing agent 1-7
[0013] One skilled in the art can vary this widely or use different elastomer formulations to achieve the desired result.
[0014] The hub itself and the weight are both metal. Generally these will be formed from automotive ductile cast iron, automotive gray cast iron, steel or aluminum. The hub preferably will use automotive ductile cast iron whereas the weight is preferably automotive gray cast iron although this is not essential for use in the present invention.
[0015] Both the annular weight, particularly its inner surface, and the hub, particularly its outer annular surface, are subjected to a phosphatizing treatment. In such a treatment the surfaces are first subjected to an alkaline wash by immersing or spraying the metal with an aqueous alkaline solution having a pH of 9-13. The pH is established by a sodium hydroxide solution. This can be heated if necessary depending upon how dirty the metal surface is. Generally this would take a matter of a few seconds to several minutes to accomplish. The metal is then rinsed with tap water.
[0016] The phosphatizing agent is an acidic aqueous solution of phosphate ion. The phosphate may be any soluble phosphate including zinc phosphate, iron phosphate, calcium phosphate and mixed calcium zinc phosphate. Iron phosphate is preferred. The concentration of the phosphate ion should be 1 to 4% and the pH of the bath should be 2 to 6.
[0017] Some phosphatizing baths include certain accelerators. These are all well known in the art. Accelerators that are acceptable for use in the present invention include sodium chlorate, sodium molybdate, sodium nitrobenzene sulfonate, sodium nitrate, sodium nitrite, hydroxyl amine sulphate, sodium borate, plus other metal or amine salts of the above. Particular phosphatizing agents can be purchased from Parker, DuBois Chemical and Betz Dearborn. These are used per the manufacturer's instructions.
[0018] Preferably the parts are simply immersed in the phosphatizing bath at a temperature of 110 to about 150° F. for a period of about 50 to about 150 seconds. The parts are then removed and dried.
[0019] The torsional vibration dampener is assembled by holding the hub and the annular weight in a jig or fixture leaving an annular space between the two. The elastomeric member is then placed in an appropriate fixture or annular space and hydraulic or pneumatic pressure is applied to force the elastomeric member into the annular space. Adhesive is not applied to either surface of the annular weight or the hub.
[0020] For use in the present invention, two preferred elastomeric members are ethylene propylene diene monomer rubber and ethylene acrylate polymers. The present invention improves the grip strength between any elastomeric member and the inner surface of the annular weight or the outer surface of the hub. When EPDM or ethylene acrylate copolymer are used, the bond strength between the elastomeric member and the phosphated metal surfaces actually increases as surfaces are heated overtime. This heating typically occurs during use. For example an automobile's torsional vibration dampener is subject to elevated temperatures (in excess of 100° C.) for extended periods of time. This heat aging increases bond strength.
[0021] This has been a description of the present invention along with the preferred method of practicing the invention. | 4y
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This is a continuation-in-part of U.S. application Ser. No. 08/295,081, filed Aug. 24, 1994, pending, which is a continuation of U.S. application Ser. No. 07/962,357, filed Oct. 16, 1992, abandoned.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for the culture of microorganisms of the genera Helicobacter, Campylobacter and Arcobacter, wherein culture media are employed which comprise cyclodextrins.
BACKGROUND OF THE INVENTION
The culture on industrial scale of microorganisms of the genera Helicobacter, Campylobacter and Arcobacter is getting more and more important both for the production of relevant amounts of the same microorganisms and because of the importance of the products which can be produced during the fermentation culture or still for the manufacture of cheap media suitable for the primary isolation of microorganisms belonging to the aforementioned genera. With regard to the importance attained by the above cited microorganisms, it should be considered, for instance, that the Helicobacter pylori is recognized as the aetiological agent of type B gastritis, likely the second most disseminated chronic infection in the world after dental caries, and as co-agent of peptic ulcer. Infection with Helicobacter pylori has also been associated with increased risk for gastric carcinoma, a disease which may be responsible for one million deaths annually. Forman, et al., Br. Med. J., 302: 1302-1305, 1991. The microbial etiology of these diseases indicates that they might be prevented through vaccination. It is therefore evident that a more developed knowledge of the physiological and pathological properties of said microorganism, knowledge that at present is still very poor due to the difficulty involved in the cultivation, and the large scale cultivation of such microorganism, should be of extreme importance.
The cultures of H. pylori are usually carried out by adding to the culture media blood or derivatives thereof (serum, red cells etc.), yolk in concentration ranging between 5% and 20%. Said additives, obviously, cannot be employed on industrial scale because of the drawbacks deriving therefrom for the purification of the culture products, drawbacks which moreover involve high costs for the industry. It is therefore extremely interesting to avail a culture media wherein blood and derivatives thereof are replaced, entirely or partially, by products which do not bring about the above cited disadvantages, without compromising the culture yield though.
SUMMARY OF THE INVENTION
It has been surprisingly discovered, and it makes the object of the present invention, that culture media wherein blood and its derivatives are, at least partially, replaced by cyclodextrins, enable the microorganisms of the genera Helicobacter, Campylobacter and Arcobacter to be cultivated in a similar way and with yield even improved over those obtained with the traditional media.
The present invention therefore relates to a method for the culture of microorganisms of the genera Helicobacter, Campylobacter and Arcobacter with the object of preparing the cell layer of the same microorganisms and/or the specific proteins of pharmaceutical interest produced by the same or still for manufacturing cheap culture media suitable for the primary isolation of microorganisms belonging to the aforementioned genera.
According to a specific embodiment of the present invention said culture method relates to the culture of microorganisms selected from the group consisting of Camplylobacter jejuni, Campylobacter coli, Campylobacter laridis, Campylobacter jejuni subspecies doylei, Campylobacter upsaliensis, Campylobacter hyointestinalis, Campylobacter fetus subspecies fetus, Campylobacter fetus subspecies venerealis, Campylobacter fennelliae, Campylobacter sputorum subspecies bubulus, Campylobacter sputorum subspecies fecalis, and Campylobacter concisus, Arcobacter nitrofigilis, Arcobacter cryaerophilus, and Arcobacter butzleri. More specifically the invention relates to a method for the culture of Helicobacter pylori, and to the production of the about 130 kD (128 kD) protein associated to the cytotoxic activity, the protein exhibiting ureasic activity synthesized by the same microorganism, and the about 90 kD protein associated to vacuolating activity (VacA). The about 130 kD protein is the immunodominant surface exposed antigen of H. pylori.
According to a still more specific embodiment of the present invention, blood and/or derivatives thereof are entirely absent from the culture media. The culture is carried out on media, either solid or liquid, comprising cyclodextrins.
In particular cyclodextrins selected from the group consisting of α-cyclodextrin and β-cyclodextrin, optionally methylated, are employed.
According to a specific embodiment of the invention dimethyl-O-β-cyclodextrin is used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the amount of about 130 kD protein cytoxicity-associated protein isolated from Helicobacter pylori cultures.
FIG. 2 depicts the amount of urease isolated from Helicobacter pylori cultures.
FIGS. 3a and b depict the growth densities of Helicobacter pylori cultured with various cyclodextrins in liquid medium.
FIGS. 4a and b depict the VacA production from Helicobacter pylori cultured with various cyclodextrins.
DETAILED DESCRIPTION
As discussed below, H. pylori is able to grow for many generations in BB containing several different cyclodextrins (CDs), with the exception of γCD, yielding bacterial growth densities higher than, or comparable to, growth obtained with 1% fetal calf serum, a media supplement traditionally used for H. pylori liquid culture.
It is possible that the improved growth of H. pylori in media containing cyclodextrins may be due to the capacity of CDs to clathrate certain molecules present in the culture medium. Thus, the CDs may function through complexation of inhibitory factors which are present in the medium, or produced by the metabolism of the microorganism itself, creating a more favorable environment.
The CDs used were composed of 6, 7, or 8 D-glucose units linked 1-4 to form α, β, or γ CD respectively, some being methylated. Each of these cyclic molecules has a hydrophilic shell and a hydrophobic cavity, and can thus form inclusion complexes in which a variety of suitable guest molecules can be accommodated. Differences in culture growth densities permitted by the various CDs tested were observed. These differences may be due to the specific chemical-physical characteristics of each CD, such as the size of the cavity and substitution of the hydroxyl groups. These properties may thus affect the efficiency of complexation of toxic compound(s) in the H. pylori medium. Indirect evidence for the existence of inhibitory factors clathrated by CDs is provided by the concentration-dependent effect of dMeβCd. In this case, the plateau of bacterial growth density at dMeβCD concentrations of 2 g 1 -1 and above may indicate a saturable effect on the sequestration of a putative inhibitor.
Recently it has been shown that the growth of H. pylori is inhibited by certain polyunsaturated fatty acids (Thompson et al., Gut, 35: 1557-1561, 1994). Additionally, it has been demonstrated that BSA added to the culture medium resulted in the enhanced growth of the bacteria, possibly through the adsorption of unsaturated fatty acids (Hazell and Graham, J. Clin. Microbiol., 28: 1060-1061, 1990). Cyclodextrins may act through a similar mechanism.
The about 130 kD cytotoxicity-associated protein may be extracted from the biomass collected upon centrifugation of the culture media according to the procedure disclosed hereinafter. After washing with phosphate buffer pH 7.4 (PBS) the cell layer is treated with a 6M guanidine HCl in PBS solution at room temperature under stirring. After centrifugation the supernatant is dialysed versus PBS and represents a fraction enriched in 130 kD cytotoxin.
Urease may be purified from the same biomass according to the procedure reported hereinafter. The pellet of bacterial cells is resuspended in 0.25M glycine HCl, pH3, 5 mM EDTA and incubated at 37° C. for 16 hours. The supernatant obtained upon centrifugation at 12,000 rpm, at 5° C. for 30 minutes in a centrifuge Beckman fitted with a JA 20 rotor, is added with two volumes absolute acetone and cooled at -20° C. After keeping for 5 hours at said temperature, the proteic pellet is collected by centrifugation as already described and finally resuspended and dialysed in PBS.
It has now also been found that the method according to the invention can be used for the production of VacA, recently identified as having a key role in the pathology of gastric diseases. (WO 93/18150, incorporated herein by reference.) The production of VacA was quantitatively analyzed in flask cultures grown in the presence of each of the CDs tested, and results indicate that VacA expression was maintained over multiple subcultures in all cases except γCD. Furthermore, a general trend observed is in that the quantity of VacA produced correlated with optical density of the culture achieved.
The culture temperature may vary from 30° to 42° C., and is preferably maintained at 37° C. The culture media is maintained under stirring and in microaerophylic conditions in presence of CO 2 and optionally H 2 .
The method according to the invention has not only simplified, as already said, the culture of the aforementioned microorganisms at issue and the recovery of the proteins produced by them, but it has also allowed the study of the biochemical and physiological (motility) features as well as the chemosensitivity and the pathogenicity of the H. pylori to be improved by simplifying it. Given the need for a simplified liquid medium for industrial purposes of H. pylori fermentation and antigen recovery, the application of CDs represents a significant improvement over previous supplements commonly employed.
EXAMPLE 1
The strain of H. pylori was cultured on Petri dishes containing 20 ml of the agarized culture media Columbia Difco, modified with the addition of 2 g/l dimethyl-O-β-cyclodextrin. The dishes, once inoculated, were incubated in microaerophylic atmosphere at high humidity level (about 95%) at a temperature of 37° C. for 72-96 hours. When the cell layer was clearly apparent on the dishes, the method was prosecuted with the suspension, by means of a wad of sterile cotton wool, of the bacteria in Brucella media until an optical density equivalent to 9 McFarland was achieved. Five millilitres of this suspension were inoculated in a 2000 ml conical flask containing 500 ml Brucella Difco media modified by adding 2 g/l dimethyl-O-β-cyclodextrin, 2.5 mg/l FeCl 2 , 2.5 mg/l amphotericin B, 10 mg/l trimethoprin, 5 mg/l vancomycin, and 5 U/ml polymixin B. another 5 millilitres were inoculated in a conic flask of the same size as the previous and containing the same medium, where however cyclodextrin is replaced by 10 g/1 fetal serum. The conic flasks were incubated for 72 hours in a rotating incubator at 200 rpm at a temperature of 37° C. in microaerophylic atmosphere having the following composition: N 2 75%, CO 2 10%, H 2 10% and O 2 5%.
After said period the optic density was monitored at 590 nm and a subculture on Columbia agar/blood and a Gram staining were performed in order to verify the purity of the culture. The optic density obtained was equivalent to 2.8 in the conic flask with cyclodextrin and 1.8 in that with fetal serum.
Two samples, 5 g layer each, collected from cultures carried out, as reported above, with either cyclodextrin (CD) or fetal serum (FS) respectively, were treated as follows: after washing with 100 ml PBS, they were centrifuged with a Beckman centrifuge fitted with a JA 20 rotor at 5000 rpm for 30 min at 4° C. The layer was treated with 25 ml 6M guanidine HCl in PBS solution and maintained under agitation for 60 minutes at room temperature. Then the suspensions were centrifuged, as disclosed above, and the supernatants, 20 ml for each sample, were dialysed versus PBS for 16 hours at 40° C. After dialysis a further centrifugation was carried out to remove the insoluble material; the obtained supernatants represent the fractions enriched in the protein of about 130 kD associated to the cytotoxic activity.
As shown in FIG. 1 the amount of the protein of about 130 kD obtained from the two cell layers was comparable, however, with an excess from the culture obtained by using cyclodextrin from which a larger amount of cell layer has been recovered.
EXAMPLE 2
The liquid cultures of H. pylori obtained as reported in Example 1 were collected by centrifugation and resuspended in 25 ml, 0.25M glycine HCl , 5 mM EDTA, pH 3 and incubated at 37° C. for 16 hours without agitation.
The obtained bacteria suspension was added with 10N NaOH to a pH value of 7.4 and subsequently centrifuged at 12,000 rpm for 30 min at 5° C. The obtained supernatants were quickly cooled in ice/water added with two volumes acetone precooled at -20° C. The suspensions so obtained were maintained at -20° C. for 5 hours and subsequently centrifuged at 12,000 rpm. The recovered pellets were resuspended in 5 ml PBS and dialysed against PBS at 4° C. for 16 hours. Thus obtained samples represent fractions enriched in urease and they are shown in FIG. 2. The comparison of the bands puts in evidence that the bands relative to the two major urease subunits, i.e. 66 and 29 kD, are nearly equivalent in the two samples.
In FIGS. 1 and 2 there are reported the results obtained from the electrophoresis of the cellular layer obtained in Examples 1 and 2 respectively (lane CD in each figure) compared with the cellular layer obtained with the traditional media (lanes SF). Lane C in both figures indicates the standards for the determination of the molecular weight. The electrophoresis was performed in 7% SDS-PAGE on minigel according to the method of Laemmli U.K., employing an electrophoretic cell Mini-Protean 2 Biorad® at 200 V for 45 min. The protein bands were stained with Coomassie® R-250.
EXAMPLE 3
Eight strains of H. pylori, namely the strain CCUG 17874 and sever further strains isolated from gastric biopsies, were evaluated for their ability to grow on Columbia agar and on Muller-Hinton agar containing either dimethyl-O-β-cyclodextrin (2 g/l) or, in the alternative, 50 g/l defibrinated horse blood. The aforementioned culture media were assayed in their selective form obtained upon addition of one of the two chemotherapeutic mixtures reported hereinafter: Mixture A: 5 mg/l vancomycin, 10 mg/l trimethoprin, 5 mg/l amphotericin B, 5 U/ml polymixin; Mixture B: same as mixture A, but replacing Polymixin by 6 mg/l cefsulodin.
The strains, maintained in Wilkins-Chalgren media with 20% glycerol at -80° C., were thawed, inoculated on dishes of Columbia agar containing 5% defibrinated horse blood, and incubated at 37° C. for 72 hours in microaerophylic conditions. Then the bacterial layer from each strain was suspended in Brucella media up to an optic density of about 6 McFarland. Ten μl of the bacterial suspension were inoculated on each of the aforementioned dishes and smeared with the technique of the isolation. The dishes were incubated as reported above and monitored after 5-7 days.
The colonies which developed on the media containing cyclodextrin, with or without antibiotics, were about 2 mm in size, were in relief, opaque, regularly cut, and with buttery consistence. The features of said colonies did not differ from those of colonies developed on media comprising blood.
The colonies developed on media either with cyclodextrin or with blood showed the same results, peculiar of the species, by the following tests: Gram negative staining; oxidase, catalase and urease positive; nitrate to nitrite reduction; hippurate hydrolysis negative; leucine-aryl-amidase, gamma-glutamyl transpeptidase, acid phosphatase and indoxyl acetate positive.
EXAMPLE 4
Sensitivity assays of H. pylori to chemotherapeutics were carried out using Columbia agar comprising dimethyl-O-β-cyclodextrin. The eight strains reported in Example 3 were examined.
The chemotherapeutics tested according to the Kirby-Bauer method were the following: ampicillin (10 μg flat tablet), erythromycin (15 μg flat tablet), clindamycin (2 μg flat tablet), metronidazole (100 μg tablets), and colloidal bismuth subcitrate (De Nol) (100 μg flat tablets). The metronidazole was also tested according to the method designated E-test (AB Biodisk, Solna, Sweden). The tests were carried out either on Columbia agar comprising 0.1-0.2% cyclodextrin or on Columbia agar comprising 5% defibrinated horse blood. Eighty ml of the above cited solid culture media were put in Petri dishes of 150 mm.
The strains were suspended in Brucella media up to an optic density of 4 McFarland and subsequently dispensed on the dishes with a sterile cotton wad. After placement of diskettes and strips, the dishes were maintained for 3-5 days in microaerophylic atmosphere at high level of humidity, at 37° C. After said period of time, the inhibition halos of the different chemotherapeutics and the minimum inhibiting concentrations (MIC) of metronidazole were compared on the dishes containing the media with cyclodextrin and those with defibrinated horse blood. The halos proved to be overlapping.
EXAMPLE 5
Assays of motility on soft agar were performed using the eight strains disclosed in Example 3. The soft agar was prepared by adding, before the sterilization, 5 g DIFCO agar per litre Brucella media. The compared media were those comprising either 0.1-0.2% cyclodextrin or 10% heat inactivated fetal bovine serum.
The inoculation was effected by dipping, about 2 mm, the ring containing the bacterial layer picked up from a dish of agar comprising 0.1-0.2% cyclodextrin. Once inoculated, the dishes were incubated at the same conditions referred to in Example 4 and observed after 5 days. Among the eight tested strains, six showed diffusion within the depth of the agar of both media, which indicates motility, whereas the remaining two did not evidence any diffusion in both media.
EXAMPLE 6
Specimens from 10 patients subjected to diagnostic gastroscopy for dyspepsy were examined. From each patient 5 biopsy specimens were collected from the stomach cavity: one for the histological test; one for the culture on Columbia agar comprising 0.1-0.2% dimethyl-O-β-cyclodextrin, 5 mg/l vancomycin, 10 mg/l trimethoprim, 6 mg/l cefsulodin, 5000U/l polymixin and 5 mg/l amphotericin B; one for the culture on Columbia agar comprising 5% defibrinated blood plus the chemotherapeutic mixture cited above; one for the bacterioscopic examination upon staining of the smears of biopsies on slide with acridine orange; and one for the determination of the urease activity.
The dishes were incubated in microaerophylia at 37° C. and examined after 48 hours and daily during 7 days. The suspected colonies were identified as H. pylori by following the procedure disclosed in Example 3.
H. pylori was isolated in 5 cases: in three cases on both media, in a fourth case on cyclodextrin medium only, and in a fifth case on blood medium only. The H. Pylori colonies on Columbia agar with cyclodextrin were already well visible after 48 hours; by the fifth day the colony sizes were similar to those developed on Columbia agar comprising blood. The selectivity of the two media in relation to the bacteria accompanying H. pylori in the same specimen from the biopsy proved to be identical. This experimentation confirms the suitability of cyclodextrin comprising media for the primary isolation of H. pylori from gastric biopsies.
EXAMPLE 7
Helicobacter Pylori CCUG 17874 (type strain, Culture Collection of the University of G oteborg, Sweden) was used in this and the following examples to determine the effect of CDs over many bacterial generations, we performed five sequential subcultures.
Columbia blood agar (CBA) (Difco, Detroit, Mich., USA), supplemented with the following antibiotics (Sigma, St. Louis, Mo., USA) cefsulodin 6 mg/l, vancomycin 5 mg/l, trimethoprim 10 mg/l, amphotericin B 8 mg/l, was used as solid medium. Brucella broth (BB) (Difco) supplemented with cyclodextrins (Cyclolab, Pusztaszeri U., H 1025 Budapest, Hungary) at the indicated concentrations, or 1% fetal calf serum (FCS) (GIBCO Laboratories, Grand Island, N. Y., USA) and the antibiotics mentioned above, was used as liquid medium. The cyclodextrins used were: α cyclodextrin (αCD), β cyclodextrin (βCD), γ cyclodextrin (γCD), (2, 6-di-o-methyl)-β-cyclodextrin (dMeβCD) and (2, 3, 6-tri-o-methyl)-0-cyclodextrin (tMeβCD).
Frozen aliquots for inocula were prepared from flask cultures of 2×10 8 CFU/ml diluted 1:2 with a solution composed of 40% glycerol, 20% fetal calf serum and 0.4% dMeβCD. The suspension obtained was distributed in 1.5 ml vials and frozen at -80° C.
One aliquot of frozen bacterial suspension was spread on agar plates (CBA) and incubated at 36° C. for 72 hours. The plates were placed inside anaerobic jars and BBL Campy Pak envelopes (Becton Dickinson, Le Pont de Claix, France) were used to generate the proper microoxic conditions. Liquid cultures were performed in 130 ml Erlenmeyer flasks containing 30 ml of liquid medium. Bacteria were harvested from plates and resuspended in BB. This solution was used to inoculate flasks at an initial OD 590 =0.1. The flasks were incubated at 36° C. with shaking (100 rpm, 2.5 cm throw) in microaerobic conditions as above. Subcultures were performed by diluting aliquots of the 48 hour culture into fresh medium to an initial OD 590 =0.1.
Growth was monitored by optical density at 590 nm (Perkin Elmer 35 spectrophotometer). Purity checks of the samples were made by Gram staining and by subculturing samples on CBA plates which were incubated in a normal atmosphere at 37° C. for 24 hours.
Each subculture was grown for 72 hours in the presence of various CDs at a concentration of 2 grams/liter -1 . Control subcultures were performed using Brucella broth containing 1% fetal calf serum, according to previously published methods (Morgan et al., J. Clin. Microbiol., 25: 2123-2123, 1987, incorporated herein by reference), or Brucella broth alone. At various time points, samples were collected and bacterial growth was measured as the optical density at 590 nm.
The growth data of the bacteria at 24, 48, and 72 hours in the initial and fifth subcultures are presented in FIGS. 3a and b, respectively. Data analysis reveals that αCD and dMeβCD yielded growth at approximately 2 OD units in each subculture. βCD and tMeβCD also permitted robust growth, resulting in slightly lower culture densities than aCD or dMeβCD. Brucella broth supplemented with 1% FCS yielded growth to approximately 1.2 OD, a level comparable to that obtained with βCD or tMeβCD. βCD or BB alone did not sustain a significant growth after five subcultures.
EXAMPLE 8
For the purpose of production of industrial quantities of antigen for vaccine research, the use of CDs in growth medium should preferably result in consistent expression of VacA over the course of several generations. Therefore, VacA production was analyzed in parallel with culture density from both the initial and fifth subcultures.
After 48 hours, culture samples were normalized to an OD 590 of 1 and were centrifuged at 8300×g for 10 minutes. The pellets were separated from supernatants and both were frozen at -20° C. Pellet fractions were resuspended appropriately to yield an OD 590 =1 in SDS-PAGE loading buffer containing 3β mercaptoethanol. Both fractions were analyzed by 9% SDS-PAGE using a BioRad Mini Prot II apparatus according to Laemmli. Proteins were transferred to nitrocellulose filters (Schleicher & Schuell, Dassel, Germany) and incubated overnight with polyclonal antisera raised against the VacA protein (Telford et al., J. Exp. Med., 179:1653-1658, 1994). Immunoreactive bands were visualized after incubation with a horseradish-peroxidase conjugated secondary antibody (Sigma), followed by a 4-chloro-napthol staining. For each immunoblot, the amount of cytotoxin in culture supernatant was estimated using a calibration curve obtained with known quantities of purified VacA protein. Quantitative estimation was made by ultrascanner densitometry using an Image Master Desk Top Scanner (Pharmacia LKB, Uppsala, Sweden) in 1D reflectance mode.
The results are depicted in FIGS. 4a and b. The results from the first (4a) and fifth (4b) subculture are shown. "N.D." represents not detectable. The fraction of VacA present in the supernatant (out) and VacA associated with bacterial cells (in) was calculated using a standard curve. With the exception of γcyclodextrin, VacA production was comparable to the fetal calf serum-containing medium with the CDs tested. The addition of dMeβCD to growth medium resulted in a significantly higher yield of VacA as compared to the other CDs, or medium supplemented with 1% fetal calf serum.
EXAMPLE 9
From our previous analysis, dMeβCD was chosen for a detailed study utilizing CD concentrations from 0.25 g 1 -1 to 6 g 1 -1 . Culture conditions were as in the previous examples. After 48 hours of growth, optical density was measured and bacteria were harvested and separated into supernatant and pellet fractions. These fractions were analyzed by quantitative Western blot, and the results are summarized in Table 1.
TABLE 1______________________________________ VacA totaldMeβCD VacA.sub.pellet /OD VacA.sub.supernatant /OD production(gl.sup.-1) OD.sub.590nm (mgl.sup.-1 OD.sup.-1) (mgl.sup.-1 OD.sup.-1) (mgl.sup.-1)______________________________________0.25 1.10 1.80 2.60 4.800.50 1.30 1.90 2.80 6.101.00 1.56 3.60 3.80 11.502.00 1.85 6.50 4.00 19.504.00 1.90 7.80 4.20 22.806.00 1.80 8.10 4.00 21.80______________________________________
VacA production was measured as total immunoreactive material recovered. VacA protein associated with supernatant and pellet fractions was normalized for culture optical density, in order to analyze growth-independent effects of dMeβCD. Both the optical density of H. pylori cultures and VacA production increased in a linear fashion with dMeβCD concentration reaching a plateau at 2 g -1 .
The foregoing examples are meant to illustrate the invention and not to limit it in any way. Those skilled in the art will recognize that changes can be made which are within the spirit and scope of the invention as set forth in the appended claims. | 4y
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BACKGROUND OF THE INVENTION
This invention pertains to a method and coating composition useful for coating glass so as to provide lubricity and abrasion resistance to the surface of the glass. More particularly, it pertains to such a method and composition suitable for application as a bare, freshly formed glass surface without pretreatment and particularly without a prior "hot-end" coating or treatment.
Due to the nature of raw glass surfaces, abrasion occurs whenever two such surfaces come in contact with each other or in contact with equipment used for handling a glass product. Any scratches or flaws in a glass surface may cause a decrease in strength of the glass to as little as one-fourth of its original value. Generally, glass articles of commerce, such as jars, fibers, tubes, pipes, bottles, tumblers, and the like are strongest when freshly formed. This strength decreases as the glass articles come into contact with each other and with other surfaces in the course of manufacturing, packaging, filling, and shipment.
It is, therefore, desirable for a glass surface to be coated with a composition having good lubricity and scratch or abrasion resistance properties. This decreases the likelihood of breakage, permitting more bottles, for example, to be handled by high-speed filling and packaging apparatus even though the glass surfaces will be subject to more contact with each other and with other surfaces, such as in glass to glass shrink wrapped bulk palletizing.
In the past, numerous types of such protective coatings have been developed. The compositions of such coatings include polyethylene waxes, acrylic-ethylene copolymers, complex stearates, fatty acids, and its derivatives, polyurethanes, vinyl copolymers, and silicones. Such coatings are generally applied after the glass is annealed and close to room temperature; therefore, these coatings are called "cold-end" coatings. One feature of all of these known "cold-end" coatings is that they are only effective in providing abrasion protection on glass surfaces that have been pretreated with a "hot-end" coating. Typically, hot-end coatings are formed by depositing a pyrolyzable titanium or tin compound, which chemically decomposes upon heating to form corresponding oxides of the metal, onto the glass surface while the surface is at a temperture above the pyrolyzing temperature of the compound (usually between 700°-1300° F.).
Such hot end coatings are applied soon after the article leaves the glass-forming machine and before it is cooled in the annealing lehr, after which one of the above-mentioned prior art types of "cold-end" coatings is applied. The "hot-end" surface treatment does not offer increased protection or lubricity when used by itself but merely alters the composition of the bonding surface and allows the prior art "cold-end" coatings to form a uniform durable film. Such pairs of "hot-end" and "cold-end" coatings have been in use for many years in the glass container industry. However, the use of "hot-end" surface treatment is an added expense and requires expensive exhaust systems with special stacks and scrubbers to remove the toxic and corrosive vapors produced from the decomposition products of "hot-end" coating compositions. In addition, these "hot-end" surface treatments have to be applied to bottles and containers in a manner such that the "finish" (i.e., the neck) of the bottle is untreated to avoid screw cap removal problems. Another problem commonly encountered in industry is an undesirable silvery appearance on "hot-end" treated ware due to an excess of the metal oxide deposit on the surface.
Certain of the prior art glass treating compositions have specific objectionable characteristics. For example, polyethylene waxes and silicones form a continuous hydrophobic surface on the glassware which is not receptive to conventional label adhesives and decorative inks and hence have to be removed prior to labelling, printing, or decorating. While the stearate soap type coatings are satisfactory from a lubrication and protection standpoint when immediately applied over "hot-end" treated bottles, such coatings are soluble in water and are removed when the ware is subjected to long term storage in humid atmospheres or prior to filling, autoclaving for sterilization, or retort processing or pasteurizing of filled ware.
It is apparent, therefore, that there is a significant need for a commercially practical method and composition by which a glass surface can be treated with a "cold-end" coating composition (i.e. without prior "hot-end" treatment), which provides desirable properties of durability, lubricity, clarity, and abrasion protection to glass and glassware. To the extent specific "cold-end" coatings have been proposed, significant problems, such as lack of clarity, are encountered with all such known coatings.
For example, oleic acid "cold-end" coating, deposited in vapor form may contaminate the glassware interior. (Internal contamination results when, during the application of the coating to the exterior surface of the glassware, a small amount of the coating enters the mouth of the glassware. Where the possibility of such contamination exists, it is essential that the coating ingredients be selected from materials in compliance with FDA regulations.) Poor label adhesion may also be experienced when an excess of the oleic acid is deposited on the glassware surface.
A mixture of polyvinylalcohol and polyoxyethylene stearate has apparently been used (proposed in U.S. Pat. No. 3,712,829) for coating ware without prior hot end coating. But this coating is suitable only where high abrasion resistance and permanent coating is not required.
A carboxyl functional polyamino acrylate ester resin crosslinked with a water soluble crosslinking agent such as epoxy or formaldehyde condensation resins and blended with carnuba wax and a silane coupling agent is claimed to provide abrasion protection to glassware with no hot-end pretreatment (in U.S. Pat. No. 4,224,365). However, this type of treatment requires a heavy coating thickness of about 10 to 25 microns and abrasion protection is minimal. Also the coating composition requires high temperature cure for several minutes which is not practical in many high speed glassware production lines.
In view of these problems, it is the object of this invention to provide a method and composition for applying an aqueous coating solution to glassware, which requires no prior "hot-end" pretreatment, and which produces a coating having desirable properties, at very low coating thickness, including clarity, lubricity, abrasion protection, permanency, resistance to hot water washing, autoclavibility, FDA compliance, and receptiveness to conventional label adhesives and decorating or printing inks.
It is also an object of this invention to provide a method and composition for applying an aqueous coating solution to glassware, with or without hot-end pre-treatment which is useful on glassware adapted to be sterilized by dry-heat techniques (elevated temperatures without the presence of high humidity) at temperatures of up to 400° F. for 4 hours with no discoloration.
Another object of this invention is to provide an aqueous coating composition that can also provide abrasion protection to glassware subjected to an automatic dishwasher detergent wash.
A further object of this invention is to provide an aqueous coating composition that can be applied to glassware by conventional coating application methods such as spraying, roller or brush coating, and dipping.
BRIEF DESCRIPTION OF THE INVENTION
The foregoing objectives are met, in brief, by a method and coating composition, wherein the composition comprises a low molecular weight polymeric resin having functional carboxylic groups, a chemical crosslinking agent for the resin and a lubricious additive, all in solution, preferably aqueous solution, at a solids concentration of below 10% solids (gram solids per 100 cc solution). Preferred carboxylic functional resins include styrene-maleic anhydride copolymers (of the types sold by Arco Chemical Company, of Philadelphia, Pa., as "SMA" resins and by the Monsanto Company as Scriptset resins) and acrylic copolymeric resins or emulsions (of the type sold by the B. F. Goodrich Company, of Akron, Ohio, as "Carboset" resins and similar types commercially available from Rohm and Haas, Sybron, Polyvinyl Chemicals, Union Chemicals and the Johnson Wax Company). Combinations of the foregoing resins may also be used.
Preferably also, these resins are solublized in aqueous ammonia and combined with a crosslinking agent from the group consisting of polyvalent metal ions, such as zinc or zirconium ions, epoxy, polyethyleneimine, polyfunctional aziridines or formaldehyde condensation resins.
As lubricious additives, an agent selected from the group consisting of emulsified paraffinic wax, particularly polyethylene wax and/or fatty acid derivatives, such as stearates and oleates, are preferred. The lubricious additives may also serve as resin plasticizing agents.
For FDA compliance, the oxidized polyethylene lubricious additives should be used with acid values of less than 20. In all cases, dispersing agents used in these compositions are preferably volatile typical examples being aqueous ammonia and fugitive emulsifiers such as dimethylaminomethylpropanol for dispersing the lubricious additives.
In accordance with the method of the invention, coating compositions as described above, are applied in a dilute solution, preferably aqueous, by spraying, rolling, or dipping, and the water is then permitted to escape by volatilization from the coating with subsequent or contemporaneous crosslinking of the resin by the crosslinking agent included in the composition. The carboxylic functionality in the starting resin permits its aqueous dispersion and even after crosslinking provides a relatively hydrophilic surface for receptivity to decorating inks and labels.
The thickness of the resulting coating is generally less than 1/1000 inch and more commonly on the order of 500-5000 angstroms.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, a freshly formed glass article, such as a bottle, is removed from an annealing lehr and cooled below the annealing range to a temperature on the order of room temperature to 200° F. The outside surface of the glass article, while still bare and untreated, is then coated by means of a curtain overflow coating process, spraying, dipping, or roller coating. If the coated article is a bottle, for example, special care is taken to avoid the invasion of the interior thereof by the coating solution. This solution consists generally of a dilute aqueous solution of resin, including a crosslinking agent for the resin and a lubricious additive, the resin being selected so that in its crosslinked form, it retains some carboxylic functionality.
A particularly desirable binder resin for use in this invention is a low molecular weight, styrene maleic anhydride adduct copolymer available from Arco Chemical Company, under the trade name "SMA Resins". Such copolymers are available in styrene-maleic anhydride ratios of 1:1, 2:1, and 3:1, all of which are useful in the present invention. Scripset styrene-maleic anhydride resins sold by Monsanto may also be used. These resins are available with their carboxylic functionality in esterified or partially esterified form, including the disodium salt and the amide and ammonium salt forms. The average molecular weight of these resins varies from 10,000 to 50,000. All of these resins may be used in the present invention.
These resins may be neutralized by either strong or weak bases to form water soluble salts. Such solubilization occurs when the resin is dispersed in an ammonium hydroxide solution. While sodium hydroxide may also be used, ammonium hydroxide is preferred so that the film formed on application and drying is free of the neutralizing base due to evaporation of ammonia. Note that because of the carboxylic functionality of the resin, it is readily disperible as an aqueous solution. The remaining carboxylic functionality in the crosslinked form of the resin in the coating is also effective to render the coating relatively hydrophilic so that it is receptive to decorating inks and label adhesives.
Such resins are crosslinkable by zinc ions, for example, through the formation of an intermediate zinc ammonium complex producing a zinc salt of the resin as ammonia escapes. The proportion of crosslinking agent present will determine the degree to which the resin is crosslinked which will in turn determine the resistance of the coating to deterioration in water and to loss of clarity.
Permanent coatings which cure rapidly at low temperatures and which have excellent water resistance can be achieved with polyfunctional aziridines as a crosslinking agent. Good permanent coatings can also be achieved by crosslinking agents, such as epoxies and formaldehyde condensation resins. The latter, while they require a higher temperature cure, perhaps even above room temperature to the 200° F. range, provide good chemical resistance.
Other binder resins which may be used are the ionomers described in U.S. Pat. Nos. 3,264,272 and 3,836,386, as well as acrylic acid copolymers, styrene butadiene resins, styrene acrylic copolymers, such as those commercially available from the B. F. Goodrich Co. as Carboset resins. Still further, polyacrylamide vinyl/acrylic copolymers, and polyesters, all having some carboxylic functionality may also be used. Resins having some hydroxyl functionality may also be crosslinked and utilized in accordance with the present invention.
Where better alkali resistance is required, vinyl homopolymer and copolymer resins may be used as binder resins or blended with styrene, maleic anhydride, or other polymers.
Combinations of the foregoing resins may also be used.
The lubricious additives included in the composition of the present invention may be comprised of oxidized polyethylene (with an acid number of less than 20 to comply with FDA specifications for certain applications), and the oxidized polyethylene may be emulsified by conventional emulsifying techniques known in the art. It is preferable to use fugitive emulsifiers so that after application, the water sensitivity of the film is reduced. High melting polyethylenes are also preferable for high water resistance and autoclavibility. Polyethylene emulsions using non-oxidized polyethylenes may also be prepared by emulsion polymerization of ethylene. Fatty acid derivatives, such as ethylene bis-steramide, are difficult to emulsify by themselves. However, these may be more easily coemulsified with polyethylene. Other lubricating agents which may be solubilized in an aqueous base or water may also be blended directly with the binder resin without pre-emulsifying.
It is preferable to blend the binder resin with the lubricating agent, such as polyethylene or ethylene bis-oleamide, in a solids ratio of 80/20 to 70/30 respectively, although in some applications, lower lubricant ratios of 90/10 or higher lubricant ratios up to 40/60 may be desired. Still higher lubricant ratios may also be employed but the hot water resistance of the coating decreases significantly when the lubricant concentration in the coating exceeds 60%. If hot water resistance is not important in a specific application, coatings with good abrasion resistance may be formulated with higher lubricant concentrations.
Following are four examples in which bottles have been coated in accordance with the present invention:
EXAMPLE 1
Styrene-maleic anhydride copolymer--SMA 3000 (Arco Chemical Co.) powder was dissolved in aqueous ammonia using deionized water and 28% concentrated ammonium hydroxide at 2% solids. The pH was adjusted to 8.0-9.0. The solution was warmed to about 70° C. and stirred for about 1 to 2 hours until all the powder dissolved. A non-ionic emulsion of high density polyethylene wax with a softening point of 138° C. and acid value of 16 (Allied Chemical's AC 316), emulsified with ethoxylated nonyl phenol and other emulsifying agents, at 30% solids (available from Chemical Corporation of America, CHEMCOR, East Rutherford, N.J.) was diluted with deionized water to 2% solids solution. 70 parts by volume of the 2% SMA 3000 solution was mixed with 30 parts by volume of 2% emulsion 316 solution. 0.8 ml. of a solution of zinc ammonium carbonate containing 20% zinc oxide solids (available from Sherwin Williams Co.) was mixed with every 100 mls. of the blend prepared as above. All ingredients in this formulation are in compliance with applicable FDA food contact regulations.
EXAMPLE 2
A 1% solution of partially esterified styrenemaleic anhydride copolymer, SMA 2625 (Arco Chemical Co.), was dissolved in aqueous ammonia as described in Example 1. An anionic coemulsion prepared by emulsifying a high density polyethylene wax P.E.D. 121 (commercially available from American Hoechst) and ethylene bis-oleamide in the solids ratio of 9/1, respectively, using diethyl ethanolamine stearate as emulsifier, with total solids 25% (available from the Chemical Corporation of America under the trade name, Emulsion 267A) was diluted to 1% solids by adding deionized water. Seventy (70) parts by volume of the 1% SMA 2625 solution was mixed with twenty-five (25) parts by volume of 1% Emulsion 267A. 0.2 mils of a solution of ammonium zirconium carbonate containing 20% zirconium oxide solids (from Magnesium Elektron, Inc., Flemington, N.J. under the trade name of Bacote-20) was mixed in with every 100 mls. of this blend.
EXAMPLE 3
(For Better Detergent Resistance)
A 3% solids solution of SMA 3000 was prepared by dissolving SMA 3000 powder in aqueous ammonia as described in Example 1. A 3% solution of AC316 emulsion and a 3% solution of Emulsion 267A were also prepared as described in Example 1. Seventy (70) parts by volume of 3% SMA 3000 was mixed with fifteen (15) parts by volume of 3% Emulsion 316 and ten (10) parts by volume of 3% Emulsion 267A. Three (3) mls. of CX-100 polyfunctional aziridine crosslinking agent (Polyvinyl Chemicals, Inc.) was added per 100 mls. of blend. This composition includes minor amounts of a constituent (CX 100) not aproved by the FDA. If all FDA-approved constituents are required, the CX-100 in this example may be replaced by Beetle 65, a urea resin available from American Cyanamid and the applied coating cured at 400° F. for 5 minutes. These coatings provide good abrasion protection after an automatic detergent wash cycle.
EXAMPLE 4
A 40% dispersion of carboxylate acrylic copolymer neutralized with a volatile neutralizing agent such as ammonium hydroxide (Carboset 514H from B. F. Goodrich Co.) was diluted with ammonia water to 2% solids. Seventy-five (75) parts by volume of 2% 514H solution was mixed with twenty-five (25) parts by volume of 2% Emulsion 316 (as described in Example 1). 0.2 ml. of zirconium ammonium carbonate solution (BaCote-20 as described in Example 2) was added per 100 mls. of the blend.
Freshly-made pristine, borosilicate flint bottles with no pretreatment were coated with the coating compositions described in Examples 1 to 4. Coating was applied to the exterior surfaces of glass bottles by spraying, roller coating, and dip coating. The temperature of the surface of the bottles was about 100° F. The coated bottles were air dried at room temperature. For comparison, glass bottles with and without a titanium oxide "hot-end" pretreatment were coated with three commonly used prior art "cold-end" coatings:
(1) AP-4 (Ball Packaging) polyethylene based;
(2) Myrj 52S (ICI) stearate type;
(3) AP-5 (Ball Packaging) oleic acid.
Except for oleic acid which is applied by vapor deposition, the other bottles were roller coated and compared with no pretreatment bottles roller coated with the new inventive coating compositions.
Bottles treated as described above were tested with a scratch test machine to evaluate the effectiveness of the respective coatings. The scratch test machine (Ball Packaging--Glass Container Manufacturers Institute (GCMI)--bulletin 64) is designed to abrade the surface of one glass against the surface of a similar bottle. One bottle is fastened securely in a stationary lower set of chucks. The other bottle is fastened in the upper set of chucks which are positioned so that the axis of the bottles will be at 90° to each other. The test load is applied to the upper bottle which is driven at a constant speed in a direction 45° to the axis of each bottle. By this design, a fresh surface on one bottle is always contacted with a fresh surface of the other. After each pass, the bottles are examined for scratches and the force or load in pounds required to scratch the bottle is noted. The maximum load that could be applied to this unit was 75 lbs. The scratch protection was measured on coated bottles after: (1) autoclaving at 121° C. for sixty minutes at 15 psi; (2) washing in an automatic dishwasher without detergent; (3) washing in a an automatic dishwasher with "Cascade" detergent; and (4) dry heat sterilization at 400° F. for 4 hours.
Since this scratch test simulated relatively mild abuse of glassware, another abrasion test was also devised to simulate more severe abuse. A bottle was placed on its side on a scale, and another bottle held in hand by its mouth and base was placed over the bottle lying on the scale so that the axis of the bottles were at 90° to each other and rubbed by sliding back and forth. The force exerted by hand was increased until a scratch was observed and the force noted on the scale. This type of abrasion testing produces scratches at a lower force than indicated by the Ball Scratch tester since the surface of one bottle is not always abrading with a fresh surface of the other bottle. The abrasion test results are shown in Table 1.
Another property that was measured was lubricity. Lubricity is measured by determining the angle at which the top bottle in a pyramid of three bottles, on their sides, will start to slide when the support is tilted. Untreated bottles will reach an angle of 35° to 40° before sliding. A good lubricious surface will permit a dry bottle to slide at about 8° to 16°. Lubricity measured on bottles with no pretreatment and coated with the new inventive coating compositions described herein were found to be within the range of 8° to 14°.
TABLE 1__________________________________________________________________________Number of Pounds to Produce Scratch Dishwasher Dishwasher Wash - No Wash - With AfterInitial Detergent Detergent AutoclaveBall Hand Ball Hand Ball Hand Ball HandScratch Scratch Scratch Scratch Scratch Scratch Scratch ScratchTester Test Tester Test Tester Test Tester Tester__________________________________________________________________________Untreated 5 2 5 2 5 2 5 2BottlesTitanium/AP-5 75+ 40 75 10 45 2 65 10AP-5 10 2 10 5 5 1 5 1Titanium/AP-4 75+ 30 40 10 40 5 75+ 15AP-4 25 5 5 1 5 1 10 1Titanium/MYRJ-52S 75+ 30 75 8 45 6 75+ 10MYRJ-52S 35 10 5 1 5 1 10 2Example 1 75+ 55 75+ 65 10 2 75+ 35Example 2 75+ 60 75+ 65 20 2 75+ 40Example 3 75+ 70+ 75+ 65 75 35 75+ 60Example 4 75+ 40 75+ 35 75+ 35__________________________________________________________________________ The above results demonstrate the superior abrasion protection and durability of the new inventive coating compositions applied over untreated bottles as compared to prior art "coldend" coatings applied ove treated and untreated bottles. Dry heat sterilized bottles exposed to 400° F. for 4 hours using Example 1 coating showed a hand abrasion of 60 lbs. as compared to titanium/AP5, titanium/AP4 and titanium/MYRJ52S coated bottles varying from 5-15 lbs.
The hydrophilic nature of the carboxylic functionality of the resin in the coatings of the present invention, which represents a substantial portion of the coating composition, provides a surface that is compatible with conventional label adhesives and printing inks used on glassware. Label adhesion tests conducted with pressure sensitive labels with adhesives based on rubbers and acrylics and on bottles with no coating and bottles coated with the inventive coating composition described herein were tested at 120° F. and high humidity conditions. No differences in adhesion was noted between uncoated and coated bottles. Slight improvement in adhesion was noted for coated bottles under high humidity conditions as compared to uncoated bottles.
The crosslinking reaction of the carboxylated resins with polyvalent metal ions as described herein is ionic in nature and is not temperature dependent. Therefore, no heat is specifically required to cure these coatings. The crosslinking reaction proceeds as the volatile neutralizing agent, such as ammonia, escapes from the thin coating applied on the bottle surface. Crosslinking with CX-100 polyfunctional aziridine also proceeds rapidly at ambient temperatures.
It is preferable to use resin concentrations of 1-5% solids in the coating compositions of the present invention, although higher total solids concentration can also be used. The coating thickness on bottles coated in accordance with the present invention, at 1-5% SMA resin solid concentration was estimated by microscopy and by a thickness measurement instrument with a sensitivity of 50 angstroms based on a mechanical stylus (Alfa Step Profiler from Tencor Instruments, Mountain View, Calif.). The coating thickness thus measured varied from 500 to 5,000 angstroms.
While this invention has been described with reference to specific embodiments thereof, it is not limited thereto, and the appended claims are intended to be construed to encompass the present invention in all of its forms and embodiments as may be devised by those skilled in the art. | 4y
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BACKGROUND AND SUMMARY
[0001] The present invention relates to a method of composite casting of a one-piece cast tool which comprises at least a first portion which comprises the working component of the tool and which is manufactured from steel, and a second portion which comprises the body component of the tool and which consists of or comprises grey iron, there being formed an interconnection zone between the steel and the grey iron.
[0002] In the production of tools for sheet metal working, for example cutting, hole making, bending or other shaping, previous practice has generally been to separately produce a tool body by casting of grey iron. The cast tool body has often required heat treatment and thereafter machining in order to create the requisite seats, holes for guide stub shafts, bolt holes etc., so that securing is made possible of working components, for example steel cutters, for carrying out the working operations proper for which the tool is intended. These working components have been manufactured from steel and the point of departure has often been bar material, the working components having been machined to the correct configuration, provided with apertures for guide stub shafts, fixing bolts and the like. This has been often followed by heat treatment, whereafter additional machining, for example grinding, has been carried out.
[0003] To produce a tool in the above-outlined manner is extremely time-consuming and expensive, and is often therefore determinative of the time consumption that is required for the new production of different sheet metal products.
[0004] WO 03/041895 discloses a one-piece cast composite tool which consists of two different material qualities, as well as a method of manufacturing such a tool.
[0005] According to the prior art technology, two different material qualities are cast in one and the same mould, steel being cast for forming working components in the tool, while grey iron has been cast for producing the tool body proper. Between the two material qualities, an interconnection zone is formed where, to some degree, mixing of the two material qualities may take place. The prior art technology suffers from numerous problems since it does not offer any possibility of positioning the interconnection zone in the tool in such a manner that the mechanical strength of the interconnection zone can be optimised.
[0006] In order for the interconnection zone to achieve the requisite quality, careful and accurate control is required of the temperature of the material which is cast first, before casting can take place of the material which is cast last. The prior art technology offers no such possibilities.
[0007] Finally, the prior art technology otters no possibility of orienting, in a suitable manner, the interconnection zone in a mould for producing the tool.
[0008] It is desirable to design the method intimated by way of introduction so that it obviates the drawbacks inherent in the prior art technology. In particular, it is desirable to design the method according to the invention so that the position of the interconnection zone may be optimised in view of mechanical strength aspects. It is also desirable to design the method according to the invention so that a superior control of the temperature conditions in and at the interconnection zone is created on casting of the last cast material. It is also desirable to design the method according to the invention in such a manner that the orientation of the interconnection zone in a mould may readily be controlled.
[0009] According to an aspect of the present invention, a method is characterised in that the casting process is carried out in a single mould which is kept unchanged and closed throughout the entire casting process, that the steel is cast first and in a direction from beneath and upwards, that after the casting of the steel a pause is made, and that the casting of the grey iron is carried out only when the temperature of the steel in the intended interconnection zone has fallen to a first temperature corresponding to the liquidus temperature of the steel minus approx. 30° to 150° C.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0010] The present invention will now be described in greater detail hereinbelow, with reference to the accompanying Drawings. In the accompanying Drawings:
[0011] FIG. 1 is a schematic cross section through a mould for reducing the method according to the present invention into practice;
[0012] FIG. 2 is a schematic cross section of a modified embodiment of a mould for reducing the method according to the present invention into practice;
[0013] FIG. 3 is a detailed section through a mould for applying the method according to the present invention;
[0014] FIG. 4 shows a tool cast according to the method according to the present invention, seen in perspective obliquely from beneath, compared with the position during the casting process;
[0015] FIG. 5 is an alternative view corresponding to that of FIG. 4 ; and
[0016] FIG. 6 is a top plan view of a tool cast according to the present invention.
DETAILED DESCRIPTION
[0017] Referring to the Drawings, in FIG. 1 , reference numeral 1 relates to a substrate on which rests a mould 2 for reducing the present invention into practice. The substrate 1 is preferably a horizontal floor. If no such floor is available, some equalisation platform or the like must be placed on the substrate so that its upper surface will be horizontal and the mould thus rests on a horizontal substrate.
[0018] The moulding consists of or comprises a moulding box or flask 3 , which encloses in itself a first model section 4 and a second model section 5 . In such instance, the first model section 4 is designed for casting of the working component of the tool by casting of steel. It should be emphasised already at this stage that the tool may very well have more than one working component and thus the mould may have several first model sections 4 .
[0019] Above the first model section 4 , there is disposed a second model section 5 which is intended for the casting of grey iron, so that a tool body is formed. The second model section may, in the conventional manner, be provided with mould cores so that cavities 6 are formed in the tool body cast from grey iron. In addition, the mould box 3 is, in the conventional manner, filled with foundry or moulding sand 7 which has tamped, packed and set.
[0020] Both of the model sections 4 and 5 have a planar contact surface where they are in contact with one another, or where they are united. This contact surface 8 is the desired position of the interconnection zone which is formed in the interface region between the steel which is cast in the first model section 4 and the grey iron which is cast in the second model section 5 . The contact surface 8 is parallel with the lower edge 9 of the moulding box 3 so that the contact surface 8 will be horizontal when the moulding box rests on a horizontal substrate.
[0021] In the production of the mould according to FIG. 1 , an upper portion 12 of the moulding box is first removed and the moulding box 3 is placed on a planar, horizontal substrate with its upper edge turned to face downwards. Thereafter, the total model, which hence consists of or comprises two or more first sections 4 and one second section 5 is placed on a substrate 1 on which the upper edge of the moulding box 3 rests. This presupposes however that the contact plane 8 is parallel with the upper surface of the second model section 5 . The important feature is that the contact plane 8 will be horizontal in the casting position of the mould, in the mould illustrated in FIG. 1 , parallel with the lower edge 9 of the moulding box.
[0022] It may be appropriate to join together the second model section 5 with the first model section or sections 4 , so that they together form a manageable unit.
[0023] Thereafter, the moulding box 3 is filled with foundry or moulding sand of suitable quality, and it should here be emphasised that this moulding sand need not be of the same quality around the second model section 5 and around the first model section or sections 4 . When the moulding box 3 has been filled in this manner with moulding sand and the sand has been tamped, packed and permitted to set, the moulding box 3 is inverted to the moulding position, it being ensured that the contact plane 8 is horizontal in that the substrate on which the moulding box is placed is also horizontal. Thereafter, the upper portion 12 is placed on the moulding box 3 and the mould is completed with the ingates 10 and 11 .
[0024] If the second section 5 of the model were not to have its upper side 5 (according to FIG. 1 ) parallel with the contact plane 8 , the second model section 5 must be chocked up to a correct inclination which compensates for the non-parallelism between the contact plane 8 and the upper surface, so that thereby, in the finished mould 2 , the contact plane 8 will always be horizontal when the moulding box 3 is on a horizontal substrate.
[0025] In FIG. 1 , reference numeral 10 relates, as was intimated above, to an ingate for the steel which is to be cast in the first model section 4 . While not being apparent from FIG. 1 , the ingate system that is employed for casting of the steel is formed in such a manner that it at least partly extends in under the first model section 4 and connects to it in order to give a casting direction for the steel from beneath and upwards towards the contact surface 8 , which represents the desired position of the interconnection zone which is to be formed between the two different material qualities.
[0026] The design of the ingate system for the grey iron may be made in a conventional manner. In order to close the mould box 3 upwardly and accommodate parts of the ingate systems, there is provided an upper portion 12 above the moulding box 3 which includes moulding or foundry sand 7 .
[0027] Both of the model sections 4 and 5 , which are included in the total mould model in FIG. 1 , are destructible models on casting, for example produced from expanded polystyrene. In a conventional manner they are also provided with blacking to improve the surface finish on the cast material.
[0028] FIG. 2 shows an alternative embodiment of a mould 2 for reducing the present invention into practice. The reference numerals in this Figure correspond to the reference numerals in FIG. 1 , but it will be clearly apparent that both of the model sections 4 and 5 have completely different appearances. Also in the embodiment according to FIG. 2 , there may occur a plurality of first model sections 4 , which are connected either directly to the ingate system 10 or indirectly via communications between the different first model sections.
[0029] It will be apparent from both FIG. 1 and FIG. 2 that, on casting of the steel in the first model section or sections 4 , these will be destroyed by the steel melt, since the model sections are produced from expanded polystyrene. However, this also applies to a part of the second model section 5 , at least in the area straight above the first model section 4 . This implies that, after the casting of the steel, those portions of the foundry sand that are exposed downwards towards the first model section or sections 4 will be exposed to an extremely powerful thermal radiation which possibly could break down the binder in the foundry sand. For this reason, the second model section 5 , at least on those parts which are exposed to this thermal radiation, are provided with extra protection in the form or one or more extra layers of blacking.
[0030] Regardless of whether the mould 2 has the appearance as illustrated in FIG. 1 or FIG. 2 , the steel is always cast first at a temperature of the order of magnitude or 1550° C. Once the steel casting has been completed and the upper surface of the steel has reached the level of the contact surface 8 , a pause is made in the casting process, so that the cast steel is permitted to cool. In such instance, it has been ensured that the steel cools last in the region of the contact surface or plane 8 in that the first model section has been given a form which entails that, to some degree, it tapers downwards (according to FIGS. 1 and 2 ) in a direction away from the contact surface or plane 8 . As a result, a directed cooling will be obtained, where the cooling first takes place in the lower parts of the first model section 4 and last in the region at the contact surface or plane 8 .
[0031] At the contact surface 8 , parts of the first and the second model sections 4 and 5 , respectively, have been given uniform thickness throughout their entire length (the length in the direction from left to right in FIGS. 1 and 2 ). The uniform thickness implies that the temperature distribution throughout the entire contact surface 8 where the model sections meet one another, will relatively uniform, which is an important precondition for good quality in the interconnection zone. In actual fact, it is the case that, by computer simulation, the parts 16 , 17 of the two model sections, lying in the proximity of the contact surface, are formed in such a manner that the steel cast in the lower model section will have as uniform a temperature distribution at the contact surface 8 as is humanly possible to achieve. In the same manner, by means of a computer simulation, a calculation is made of the time that is needed for achieving a temperature in the steel cast in the first model section 4 at the contact surface 8 , a first temperature corresponding to the liquidus temperature of the selected steel quality minus approx. 30° to 150° C., often in the region of 1440° to 1320° C.
[0032] This pause or stay time in the casting process may amount to one or a few minutes, but it may also be as long as between 15 and 20 minutes, depending overall on the size of the first model section or sections 4 .
[0033] The casting of the grey iron is carried out when the computed pause or stay time has elapsed at a second temperature, which corresponds to the liquidus temperature of the grey iron plus approx. 100° to 150° C., often approx. 1320° C.
[0034] At the interconnection zone, if the casting of the grey iron takes place at an elevated first temperature, i.e. at or above the upper end of the exemplified temperature range of approx. 1440° to 1320° C., a certain intermixing of the two materials may occur at the same time as a diffusion process occurs, where parts of the one material migrate into the other and vice versa. If, on the other hand, the casting takes place at a low first temperature, i.e. at or below the lower end of the exemplified temperature range, a diffusion process still occurs, which implies that the interconnection zone will also have a certain intermixing of the two materials, and still a thickness of at least a millimetre or so, but preferably slightly more, possibly up to 2.5-3.0 mm.
[0035] In practical strength trials which have been conducted, no breakage, either in tensile or bending tests, has occurred in the interconnection zone proper, but always occurred in the grey iron.
[0036] As was mentioned above, the contact surface 8 , i.e. the theoretical position of the interconnection zone in the vertical direction, is horizontal. Since the interconnection zone is defined by the upper, free surface of the steel melt, it will readily be perceived that this will planar and also horizontal.
[0037] There are certain problems in accurately computing the quantity of steel melt which is to be cast in the mould 2 . For this reason, the mould has been provided with one or more accommodation spaces 13 to which any possible surplus of steel will be permitted to run so that, thereby, the level of the cast steel will always be at the contact surface 8 . FIG. 3 shows in cross section a detail through a mould, where such an accommodation space 13 is provided. The accommodation space 13 is connected via a duct 14 to the mould cavity of the mould in the region of the contact surface 8 . The duct 14 has a lower wall 15 which, in the mould cavity, discharges on the level of the contact surface 8 . The cross-sectional area of the duct 14 is so large that it exceeds the total cross sectional area of the ingate system for steel, preferably by at least a factor of 1.5. It will also be apparent from FIG. 3 that the lower duct wall 15 slants from the contact surface 8 in a downward direction towards the accommodation space 13 .
[0038] Depending on the form, size and the number of the first model sections 4 , a plurality of different accommodation spaces 13 may be employed. In such instance, one accommodation space may directly or indirectly, via ducts, serve two or more first model sections 4 , but the reverse is also possible.
[0039] In order to give the interconnection zone the correct formation, i.e. uniform width throughout its entire extent, the first model section 4 has an upper region 16 which forms a uniformly thick wall or projection, which is directed in the vertical direction in the mould 2 and which extends up towards the second model section 5 . Correspondingly, the second model section 5 has a uniformly thick wall 17 or projection which extends downwards in a direction towards the first model section 4 . The interconnection zone is placed between both of these wall portions 16 and 17 displaying substantially constant cross-sectional area in the region of the interconnection zone, i.e. the contact surface 8 . Further, the lower end surface (in FIGS. 1 and 2 ) of the upper wall 17 abuts against the upper end surface of the lower wall 16 and further these end surfaces coincide substantially as regards size and configuration.
[0040] FIG. 4 shows (in a position inverted in relation to the position during casting) in perspective a tool cast according to the invention, and it will be apparent that this has a steel portion 18 which is cast in the first model section 4 , and a grey iron portion 19 which is cast in the second model section 5 . The Figure also shows an accommodation space 13 and two ducts 14 , by means of which it is connected to the first model section 4 (the steel portion 18 ).
[0041] That steel which may possibly arrive in the accommodation space or spaces 13 disposed in the mould is removed gradually, according as the casting of the complete tool proceeds.
[0042] FIG. 5 shows (in a position inverted in relation to the position during casting) in perspective a tool cast according to the present invention. It will be clearly apparent that the grey iron portion 19 has a wall 17 upwardly directed towards the steel portion 18 , the wall being of uniform thickness throughout its entire extent. Correspondingly, it will be apparent that the steel portion 18 has a wall 16 directed towards the grey iron portion 19 and having the same size and extent as the wall 17 .
[0043] FIG. 6 shows a further embodiment of a composite tool cast according to the present invention, which is shown in the same position as it has on casting in the mould. It will be apparent that the contact surface 8 , i.e. the interconnection zone in the finished tool, is horizontal. It will further be clearly apparent from the Figure that the grey iron portion 19 of the tool has a downwardly directed wall 17 which has its counterpart in an upwardly directed wall 16 on the steel portion 18 of the tool. Also in this embodiment, there is a number of cutting edges 20 on the steel portion.
[0044] As was mentioned above, the steel is cast from beneath and upwards as first component before the grey iron is cast. Since the model 4 , 5 is produced from expanded polystyrene, this will be destroyed, be vaporised and combust already during the casting of the steel. This implies quite a voluminous development of gas which would have as a consequence an uncontrolled and rapid gas outflow and combustion of the gases in the ingate 11 to the grey iron portion. In order to realise a better controlled casting process for the steel, but above all for reasons of working environment health, the ingate 11 to the grey iron is kept blocked while the steel is cast, so that the gases thus generated are forced to depart via other routes, for example via a ventilation system or quite simply through the foundry sand in the moulding box. | 4y
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FIELD OF THE INVENTION
This invention relates to the field of computer graphics. More specifically, the invention relates to the representation of clustered multi-resolution polygonal models in compressed form for progressive transmission and compact storage.
BACKGROUND OF THE INVENTION
Although modeling systems in Mechanical Computer Aided Design and in animation are expanding their geometric domain to free form surfaces, polygonal models remain the primary 3D representation used in the manufacturing, architectural, Geographic Information Systems, geoscience, and entertainment industries. Polygonal models are particularly effective for hardware assisted rendering, which is important for video-games, virtual reality, fly-through, and electronic mock-up applications involving complex Computer Aided Design models.
A polygonal model is defined by the position of its vertices (geometry), which are n-dimensional vectors, by the association between each face and its sustaining vertices (connectivity), and/or by colors, normals, and texture coordinates (properties), which do not affect the 3D geometry, but influences the way it is shaded.
In the present disclosure we will also refer to a polygonal model as a "single-resolution polygonal model".
Single-resolution polygonal models are described in detail in U.S. Pat. No. 5,825,369 "Compression of Simple Geometric Models Using Spanning Trees", Ser. No. 08/688,572 filed Jul. 30, 1996, by J. Rossignac and G. Taubin, and in U.S. patent application "Compression of Geometric Models Using Spanning Trees", Ser. No. 08/685,422 filed Jul. 30, 1996, by J. Rossignac and G. Taubin, which are here incorporated by reference in its entirety.
When the number of vertices and faces of a polygonal model is very large, the graphics rendering hardware may not be able to achieve frame rates high enough for interactive applications. Multi-resolution polygonal models are used in the prior art to solve this problem.
A multi-resolution polygonal model is a sequence of polygonal models, where each element of the sequence, called a "level of detail", or just a "level", has more vertices and faces than the previous level. The first element of the sequence is called the "lowest resolution level", and the last element of the sequence is called the "highest resolution level".
Multi-resolution polygonal models solve the problem of interacting with very large polygonal models by trading image quality for speed. Since the time required to render a frame is proportional to the complexity of the scene, rendering lower resolution levels yield higher frame rates. When there is relative motion of the object with respect to the camera, or a large distance between the object and the camera in the scene, a lower level of detail is rendered instead of the highest resolution level, which is the original polygonal model. When the scene becomes static, lower frame rates may be acceptable, and a higher resolution level can be rendered yielding higher image quality.
Prior art methods for generating multi-resolution polygonal models from single-resolution polygonal models are described in "Multi-resolution Surface Modeling", Course Notes for Siggraph'97, edited by Paul Heckbert, which is here incorporated by reference in its entirety. In all such methods the input single-resolution model becomes the highest level of detail of the generated multi-resolution model.
Many prior art methods to generate multi-resolution polygonal models are based on "vertex clustering algorithms", and the multi-resolution polygonal models produced by such methods are called "clustered multi-resolution polygonal models". In a clustered multi-resolution polygonal model the vertices of each level of detail are partitioned into disjoint subsets of vertices called "clusters", and all the vertices in each cluster are collapsed into a single vertex of the previous (lower resolution) level of detail.
Collapsing vertices may produce duplicate faces, faces with fewer comers, collapsing of faces into edges, or total collapsing of faces into single vertices. Faces which do not collapse, as well as those which collapse into faces with fewer comers, are preserved in the previous level of detail. Duplicate faces, as well as those which collapse into single vertices, are discarded in the previous level of detail. Faces which collapse into edges are optionally preserved in some methods.
One such method to generate clustered multi-resolution polygonal models is described in U.S. Pat. No. 5,448,686 "Multi-Resolution Graphic Representation Employing at Least One Simplified Model for Interactive Visualization Applications", by P. Borrel and J. Rossignac, which is here incorporated by reference in its entirety. In this method vertices of one level of detail are partitioned into clusters based on geometric proximity.
In other prior art methods to generate clustered multi-resolution polygonal models, the clustering of vertices is described as a sequence of "edge collapse" operations. An edge collapse operation identifies the two endpoints of an edge of a level, reducing the number of vertices of the level by one, and the number of triangles of the level by two. One such method is described in U.S. patent application "Surface Simplification Preserving a Solid Volume and Respecting Distance Tolerances", Ser. No. 08/742,641 filed Nov. 1, 1996, by A. Gueziec, which is here incorporated by reference in its entirety.
Switching between consecutive levels of detail may produce visual artifacts. The correspondence between vertices in one level of detail and vertices in the previous level of a clustered multi-resolution polygonal model is used in the prior art to mitigate this problem, by smoothly transitioning, or "morphing", from one level to the next interpolating the position of vertex coordinates as a function of time.
Single-resolution polygonal models and multi-resolution polygonal models are increasingly stored in file servers and exchanged over computer networks. In both cases it is desirable to compress the models to reduce the total amount of data stored and transmitted.
When transmitting a multi-resolution polygonal model it is desirable to send the information necessary to reconstruct the levels in increasing order of level of detail, i.e., from low to high resolution, so that the receiver could render a level as soon as it has all the information associated with such level, and let the user interact with it before it has all the information necessary to render the next level. This is called progressive representation and transmission.
Methods for efficiently representing single-resolution polygonal models in compressed form are known in the prior art. Methods for representing clustered multi-resolution polygonal models in progressive, but not compressed, form are also known in the prior art.
Since methods are known in the prior art for easily and efficiently triangulating arbitrary polygonal faces, many prior art methods only consider polygonal models defined by triangular meshes. A "triangular mesh" is a polygonal model in which all the faces are triangles.
One method to compress single resolution triangular meshes is described by Michael Deering in "Geometric Compression", Proceedings of ACM Siggraph'95, pp 13-20, August 1995, which is here incorporated by reference in its entirety; and in European Patent Applications "Method and apparatus for geometric compression of three-dimensional graphis", Ser. No. EP0 757 333, filed May 8, 1996, by Michael Deering, which is here incorporated by reference in its entirety. In this method a stack-buffer is used to store 16 of the previously used vertices instead of having random access to all the vertices of the model. The triangles of the mesh are partitioned into "generalized triangle meshes". Triangles which belong to the same generalized triangle mesh may share vertices, which are transmitted only once using the stack-buffer. But vertices common to triangles which belong to different generalized triangle meshes must be duplicated. In this method the connectivity of the triangular mesh is lost. The vertex positions and properties are quantized and entropy encoded.
Another such method to compress single resolution triangular meshes is described in U.S. Pat. No. 5,825,369 "Compression of Simple Geometric Models Using Spanning Trees", Ser. No. 08/688,572 filed Jul. 30, 1996, by J. Rossignac and G. Taubin, and in U.S. patent application "Compression of Geometric Models Using Spanning Trees", Ser. No. 08/685,422 filed Jul. 30, 1996, by J. Rossignac and G. Taubin, which are here incorporated by reference in its entirety. In this method the connectivity of the triangular mesh is preserved without loss of information. In this scheme the vertices of the triangular mesh are organized into a "vertex spanning tree", and the triangles into a "triangle spanning tree". The vertex spanning tree is a sub-graph of the "graph of the triangular mesh", which the graph defined by the vertices and edges of the triangular mesh. And the triangle spanning tree is a sub-graph of the "dual graph of the triangular mesh", which is the graph defined by the triangles and edges of the triangular mesh. The order of traversal of both trees define an "order for the edges of triangular mesh". The vertex positions and properties are quantized and entropy encoded. The prior art on graphs and trees is described by R. E. Tarjan in "Data Structures and Network Algorithms", SIAM, 1983; which is here incorporated by reference in its entirety.
One method for progressive transmission of triangular meshes is described by Hoppe in "Progressive Meshes", Proceedings of ACM SIGGRAPH'96, pp. 99-108; which is here incorporated by reference in its entirety. This scheme does not apply to general clustered multi-resolution polygonal models. It is restricted to clustered multi-resolution polygonal models generated by edge collapses with no change of connectivity. Another such scheme is described by Popovic et. al. in "Progressive Simplicial Complexes", Proceedings of ACM Siggraph'97, pp. 217-224, which is here incorporated by reference in its entirety. This scheme overcomes some of the limitations of Hoppe's method and allows some changes in connectivity.
The methods of Hoppe's and Popovic's build a progressive mesh representation that consists of a description of the transition from a simplified mesh to the original mesh. Hoppe represents this transition as a sequence of "vertex splits". Each of these vertex splits is specified by the index of a vertex of the mesh plus two edges incident to the given vertex. The edge split operation consists in cutting the mesh through the specified edges, resulting in the given vertex being split into two new vertices joined by an edge, and inserting two new triangles in the resulting whole. In addition, the displacements of the two new vertices with respect to the split vertex position in the previous level must be specified.
The method of Popovic et. al. is a generalization of Hoppe's scheme to lines, surfaces and volumes. A vertex split is replaced with a "generalized vertex split". With respect to the vertex split, additional information is necessary to encode whether the added vertex will add a point, a line segment, a triangle or a tetrahedron to the complex.
While Hoppe and Popovic claim that their methods can be used to compress clustered multi-resolution polygonal models generated by edge collapsing or generalized edge collapsing, these are not efficient compression schemes. They require in the order of N(log(N)) total bits of data to represent a triangular mesh of N vertices in progressive form. The other main problem with Hoppe's and Popovic's methods is that they do not apply to general clustered multi-resolution polygonal models.
On the other hand, Rossignac and Taubin method require in the order of N total bits of data to represent a single resolution mesh in compressed form, but do not apply to any multi-resolution model.
There is thus a long felt need to overcome these and other problems of the prior art. To date there is no method to efficiently represent in compressed form and progressively transmit clustered multi-resolution polygonal models.
OBJECTS OF THE INVENTION
An object of this invention is an improved system and method for compressing, storing, progressively transmitting, and progressively decompressing any clustered multi-resolution polygonal model.
Another object of this invention is an improved system and method for decomposing a clustering operation of a polygonal model as a connectivity preserving clustering operation and a anti-connectivity clustering operation, and for representing the clustering operation in compressed form.
SUMMARY OF THE INVENTION
This invention is a computer system and method that progressively stores and transmits compressed clustered multi-resolution polygonal models. The computer uses a data structure that represents a clustered multi-resolution polygonal model in n-dimensional space. The data structure has a connectivity record which encodes the connectivity information of the highest level of detail. The data structure also has a clustering record which encodes how the vertices of each level of detail are clustered to obtain the vertices of the next lower level of detail. The clustering record is organized in decreasing order of level of detail. The data structure also has a data record with information describing the vertex positions of the levels of detail, and optionally the corresponding properties. The fields of the data record are organized in increasing order of level of detail. The system also includes ways for creating this data structure from a clustered multi-resolution polygonal model, transmitting this information between computers, and compressing and decompressing this transmitted information.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is prior art example of polygonal model.
FIG. 2, comprising FIG. 2A, and FIG. 2B, is a prior art example of a clustered multi-resolution polygonal model.
FIG. 3, comprising FIG. 3A and FIG. 3B, is a block diagram of a data structure for representing a clustered multi-resolution polygonal model.
FIG. 4 is a flow chart of a method for compressing a clustered multi-resolution polygonal model.
FIG. 5 is a flow chart of a method for decompressing a clustered multi-resolution polygonal model.
FIG. 6 illustrates the representation of clustering operations.
FIG. 7 is a flow chart of a method for decomposing a clustering operation into a connectivity-preserving partition and an anti-connectivity partition, and to encode such partitions
FIG. 8 is a flow chart of a preferred implementation of a method to encode the connectivity-preserving partition as a sequence of connect bits.
FIG. 9 is a flow chart of a preferred implementation of a method to encode the anti-connectivity partition.
FIG. 10 is a flow chart of a method for decoding the connectivity-preserving and anti-connectivity partitions and to compose them to recover the a clustering operation.
FIG. 11 is a flow chart of a preferred implementation of a method to decode the connectivity preserving partition from a sequence of connect bits, and to reconstruct the corresponding connectivity preserving cluster array.
FIG. 12 is a flow chart of a preferred implementation of a method to decode the anti-connectivity partition from a lists of connectivity preserving cluster indices, and to reconstruct the corresponding anti-connectivity cluster array.
FIG. 13 is a block diagram showing an example computer system on which a preferred embodiment of the present invention operates.
FIG. 14 is a diagram that shows a first computer connected to a second computer through a communications link.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is prior art example of polygonal model. The prior art on polygonal models is described by Foley et.al. in "Computer Graphics: Principles and Practice", Addison-Wesley, 1990; which is here incorporated by reference in its entirety. A polygonal model 100 is composed of vertices 110, edges 120, and faces 130.
A polygonal model with V vertices and F faces is usually represented in the prior art by a "vertex positions array" and a "face array". The position of each vertex of the polygonal model is represented in the vertex positions array by N floating point coordinates. The location of this N-dimensional vector in the vertex positions array is referred to as the "vertex index" of the vertex. Each face of the polygonal mesh mesh is represented in the face array by a "face number of vertices" plus one or more "face vertex indices". The location of the face number of vertices in the face array is referred to as the "face index" of the vertex.
An "edge" of a polygonal model is a pair of consecutive vertices of a face, without taking into account the order of the two vertices within the edge. The two vertices of an edge are called "endpoints" of the edge.
From the vertex indices and the face indices, an "edge array" can be constructed to represent the edges explicitly. The edge array lists pairs of edge endpoints; preferably, the edges appear sorted lexicographically in the edge array, which smaller indices coming first; this provides a convention for enumerating the edges; each edge of the manifold triangular mesh has a corresponding "edge index" preferably defined as the position of the edge in the edge array; this convention is not a limitation upon the practice of the present invention; other conventions for enumerating the edges can be adopted;
FIG. 2, comprising FIG. 2A, and FIG. 2B, is a prior art example of a clustered multi-resolution polygonal model. A clustered multi-resolution polygonal model 2000, composed of levels of detail 2100, 2200, and 2300, is usually represented in the prior art by specifying the highest resolution level of detail 2300, and a sequence of recursive vertex clustering operations 2500, and 2400. Each vertex clustering operation describes how to construct the previous level of detail from the current level, and can be specified, without loss of generality, as a partition of the vertices of the corresponding level of detail into disjoint subsets, the subsets of vertices 2600, 2700, being in one-to-one correspondence with the vertices of the previous level of detail 2201, 2101. Each partition 2400, 2500, is usually represented in the prior art by a "cluster array" 2450, 2550, with the number of elements of each cluster array 2450, 2550, equal to the number of vertices of the corresponding level of detail 2200, 2300. Each "cluster array element" 2605, 2606, 2607 of the cluster array 2550 corresponds to one vertex 2305, 2306, 2307 of the current level, and the value of the cluster array element 2601 is the index 2201 of the corresponding vertex in the previous level of detail. Vertices of the current level 2305, 2306, 2307, whose corresponding cluster array elements have the same value collapsed into a "cluster representative" vertex 2201 in the previous level of detail.
FIG. 3, comprising FIG. 3A and FIG. 3B, is a block diagram of data structure 3000 disclosed in this invention for representing a clustered multi-resolution polygonal model. The data structure is composed of a "connectivity record" 3100, a "clustering record" 3200, and a "data record" 3300. The connectivity record 3100 contains the information necessary to reconstruct the connectivity of the highest level of detail. The clustering record 3200 is composed of one or more "partition fields" 3250, 3260, each partition field 3250 with information about how to partition the vertices of one level of detail 2200 into one or more clusters 2700, 2800, each cluster 2700 composed of one or more vertices 2210, 2220, 2230 of the level of detail 2200, and associated with one vertex 2900 of the previous level of detail 2100. The partition fields 3250, 3260 ordered in the clustering record 3200 in decreasing order of level of detail. The data record 3300 is composed of one "first data field" 3340, and one or more "data fields" 3350, 3360, the first data field 3340 with information necessary to reconstruct the vertex positions and properties of the first level of detail 2100. Each data field 3350 with information necessary to reconstruct the vertex positions and (optionally) the properties of one level of detail 2200. The data fields 3350, 3340 ordered in the data record 3300 in increasing order of level of detail.
FIG. 4 is a flow chart of a method 4000 for compressing a clustered multi-resolution polygonal model. In step 4100 the connectivity of the highest resolution level is encoded, and the resulting data is placed in the connectivity record 3100 of data structure 3000. In steps 4200, 4300, and 4400 the clustering operations are encoded, and the resulting data is placed in the partition fields 3260, 3250 of the clustering record 3200 of data structure 3000. In step 4300 a clustering operation corresponding to one level of detail is encoded, and the resulting data is placed in the corresponding partition field of the clustering record. In step 4400 the level counter is decremented, and in step 4200 the lowest resolution level is detected, signaling the end of the connectivity encoding phase. The clustering operations are encoded, and the resulting data is placed in the clustering record 3200, in decreasing order of level of detail, i.e., from highest level to lowest level. In step 4500 the geometric and (optionally) property data corresponding to the lowest level of detail is compressed and the resulting data is placed in the first data field 3340 of the data record 3300, in the data structure 3000. In steps 4600, 4700, and 4800, the geometry and (optionally) property data corresponding to the subsequent levels of detail is compressed, and placed in the data fields 3350, 3360 of the data record 3300. The geometry and (optionally) property data corresponding to the different levels of detail are compressed, and the resulting data is placed in the data record 3300, in increasing order of level of detail, i.e., from lowest resolution to highest resolution. In step 4700 the geometry and (optionally) property data corresponding to one level of detail is compressed, and the resulting data is placed in the corresponding data field of the data record. In step 4800 the level counter is incremented, and in step 4600 the highest level of detail is detected, producing the method to stop.
FIG. 5 is a flow chart of a method 5000 for decompressing a clustered multi-resolution polygonal model. In step 5100 the connectivity of the highest resolution level is decoded using the data present in the connectivity record 3100 of data structure 3000, and populating the face array of the highest resolution level of detail. In steps 5200, 5300, and 5400 the clustering operations are decoded, using the data present in the partition fields 3260, 3250 of the clustering record 3200 of data structure 3000, and populating the cluster arrays 2550, 2450. In step 5300 a clustering operation corresponding to one level of detail is decoded, and the resulting data is placed in the cluster array of the multi-resolution polygonal model. In step 5400 the level counter is decremented, and in step 5200 the lowest resolution level is detected, signaling the end of the connectivity decoding phase. The clustering operations are decoded, and the resulting data is placed in the cluster arrays 2550, 2450, in decreasing order of level of detail, i.e., from highest level to lowest level. In step 5500 the geometric and (optionally) property data present in data field 3340 of the data record 3300 corresponding to the lowest level of detail is decompressed, and the resulting data is placed in the vertex positions array and in the properties arrays. In steps 5600, 5700, and 5800, the geometry and (optionally) property data corresponding to the subsequent levels of detail is decompressed, from the data present in the data fields 3350, 3360 of the data record 3300. The geometry and (optionally) property data corresponding to the different levels of detail are decompressed, and the resulting data is placed in the vertex positions and (optionally) property arrays, in increasing order of level of detail, i.e., from lowest resolution to highest resolution. In step 5700 the geometry and (optionally) property data corresponding to one level of detail is decompressed, and the resulting data is placed in the corresponding vertex positions and (optionally) property arrays. In step 5800 the level counter is incremented, and in step 5600 the highest level of detail is detected, producing the method to stop.
In a preferred implementation the connectivity record 3100 is composed of a "triangle record", the triangle record composed of one or more "triangle fields", each triangle field composed of three "triangle vertex index" sub-fields.
In another preferred implementation the connectivity record 3100 is composed of a "face record", the face record composed of one or more "face fields", each face field composed of a "number of vertices" sub-field, and one or more "face vertex index" sub-fields.
In another more preferred implementation the connectivity of the highest level of detail is represented in compressed form in the connectivity record 3100 using the method described in commonly assigned U.S. Pat. No. 5,825,369 entitled "Compression of Simple Geometric Models Using Spanning Trees", Ser. No. 08/688,572 filed Jul. 30, 1996, by J. Rossignac and G. Taubin.
In another more preferred implementation the connectivity of the highest level of detail is represented in compressed form in the connectivity record 3100 using the method described in commonly assigned U.S. patent application entitled "Compression of Geometric Models Using Spanning Trees", Ser. No. 08/685,422 filed Jul. 30, 1996, by J. Rossignac and G. Taubin.
In a preferred implementation each partition field 3250 of the clustering record 3200 is composed of one or more "cluster lists", each cluster list corresponding to one cluster 2700 containing two or more vertices, and composed of two or more "cluster list elements", each cluster list element corresponding to one vertex belonging to the cluster. No cluster list is associated with clusters composed of exactly one vertex.
In a more preferred implementation each cluster list element is a vertex index 2210, 2220, 2230, of a vertex belonging to the cluster.
FIG. 6 illustrates the representation of clustering operations. Each clustering operation partitions the vertices of a "current level of detail" 6100 into one or more clusters of vertices 6105, 6110, 6115, each cluster associated with one vertex 6205, 6210, 6215 of a "previous level of detail" 6200. The edges of the current level of detail can be used to further partition each cluster into one or more "connected clusters" 6105, 6120, 6125, 6115. Two vertices joined by an edge of the current level of detail belong to the same connected cluster if the two vertices belong to the same cluster. The set of all connected clusters defines a new "connectivity-preserving" partition of the vertices of the current level of detail, which is finer that the partition determined by the clustering operation. The partition determined by the clustering operation can be described as further applying an "anti-connectivity" partition to the set of connected clusters. The anti-connectivity partition is defined by the association of connected clusters to clusters.
In a preferred implementation each partition field 3250 of the clustering record 3200 is composed of a "connectivity-preserving" sub-field 3252, and an "anti-connectivity" sub-field 3254. The connectivity preserving subfield describing the connectivity preserving partition, and the anti-connectivity sub-field describing the anti-connectivity partition.
In a preferred implementation the connectivity-preserving partition is encoded in subfield 3252 of the partition field 3250 as a "sequence of connect bits", composed of one or more "connect bits", each connect bit corresponding to one edge 2205 of the corresponding level of detail 2200, and where the value of the connect bit describes whether the two vertices joined by the edge belong to the same connected cluster or not.
In a more preferred implementation the sequence of connect bits is compressed.
In another more preferred implementation the sequence of connect bits is entropy encoded.
In another more preferred implementation the sequence of connect bits is run-length encoded.
In another more preferred implementation the sequence of connect bits is run-length and entropy encoded.
In a preferred implementation the anti-connectivity sub-field 3254 of the partition field 3250 is composed of one or more "anti cluster lists", each anti cluster list corresponding to one cluster 2700 containing two or more connected clusters, and composed of one or more "anti cluster list elements", each anti cluster list element corresponding to one connected cluster belonging to the cluster. No cluster list is associated with clusters composed of exactly one connected clusters.
FIG. 7 is a flow chart of a method 7000 for decomposing a clustering operation into a connectivity-preserving partition and an anti-connectivity partition, and to encode such partitions in the subfields 3252 and 3254 of the partition field 3250 of the clustering record 3200. Method 7000 is a preferred implementation of step 4300 of method 4000. In step 7050 the number of vertices N of the current level is determined. The clustering operation clusters the vertices of the current level, with each resulting cluster corresponding to one vertex of the previous level. In step 7100, the cluster array CL representing the clustering operation determined. In step 7150 the connectivity preserving partition clusters are initialized as sets with a single element, one per vertex of the current level. In the loop defined by steps 7200, 7250, 7300, and 7350, some of these sets are joined together. In step 7250 one edge of the current level is chosen. In step 7300 it is determined if the endpoints of the edge belong to the same cluster of the clustering operation by comparing the corresponding values of the clustering array CL. If the endpoint of the edge do belong to the same cluster of the clustering operation, in step 7350 the connectivity preserving partition clusters that the two endpoints belong to are joined together. Note that these two connectivity preserving partition clusters may have been the same even before the join operation as a result of a previous join operation, in which case step 7350 will produce no change. In step 7200 it is determined if all the edges of the current mesh have been considered. If no more edges remain to be considered, the method proceeds to step 7400. In step 7400 consecutive indices are assigned to different connectivity preserving clusters, starting with index 1. In step 7500, the connectivity preserving cluster array is constructed with the value assigned to a vertex of the current level being equal to the index of the connectivity preserving cluster the vertex belongs to. Finally, in step 7550 anti-connectivity cluster array is constructed. The length of this array is equal to the number of different connectivity preserving cluster arrays, and its values are such that the application of the anti-connectivity partition to the set of connectivity-preserving clusters produces the same result as the application of the clustering operation to the vertices of the current level. In step 7600 the connectivity-preserving partition is encoded in the subfield 3252 of the partition field 3250 of the data structure 3000. In step 7700 the anti-connectivity partition is encoded in the subfield 3254 of the partition field 3250 of the data structure 3000.
FIG. 8 is a flow chart of a preferred implementation of step 7600 of method 7000 to encode the connectivity-preserving partition as a sequence of connect bits in the subfield 3252 of the partition field 3250. In the loop defined by steps 8100, 8200, 8300, 8400, and 8500, the connect bit values are determined for all the edges of the current level of detail from the values stored in the connectivity preserving cluster array constructed by method 7000. In step 8100 it is determined whether all the connect bits have been determined or not. In step 8200 the next edge in the order defined by the edge array is chosen. In step 8300 it is determined whether the values of the connectivity-preserving cluster array at the endpoints of the edge are the same or not. In step 8400 the connect bit corresponding to the edge is set equalto 0 if the values of the connectivity-preserving cluster array at the endpoints of the edge are not the same. In step 8500 the connect bit corresponding to the edge is set equalto 1 if the values of the connectivity-preserving cluster array at the endpoints of the edge are the same. Once all the connect bits are determined, the sequence of connect bits is optionally compressed in step 8600. Finally, in step 8700, the resulting data is stored in the subfield 3252 of the partition field 3250.
FIG. 9 is a flow chart of a preferred implementation of step 7700 of method 7000 to encode the anti-connectivity partition into the subfield 3254 of the partition field 3250. In steps 9050, 9100, 9150, 9200, and 9250 the anti-connectivity clusters are first constructed as sets of anti-connectivity cluster indices, with one anti-connectivity cluster corresponding to each vertex of the previous level of detail. The anti-connectivity cluster indices are the indices of the anti-connectivity array constructed in step 7550 of method 7000. In step 9050 the number of vertices of the previous level of detail is determined. In step 9100 all the anti-connectivity clusters are initialize as empty sets. In step 9200 the next anti-connectivity cluster index is chosen, and in step 9250 it is added to the anti-connectivity cluster determined by the corresponding entry of the anti-connectivity array. In step 9150 it is determined whether all the anti-connectivity indices have been considered or not. Once all the anti-connectivity indices have been considered the method proceeds to step 9300. In the loop defined by steps 9300, 9350, 9400, and 9450, the anti-connectivity clusters with two or more elements are determined and saved as lists of anti-connectivity cluster indices in the subfield 3254 of the partition field 3250. In step 9300 it is determined whether all the anti-connectivity clusters have been considered or not. In step 9350 the next anti-connectivity cluster is chosen. In step 9400 it is determined whether the chosen anti-connectivity cluster has two or more elements or not. If it has two or more elements, in step 9450 it is saved as a list of anti-connectivity cluster indices in the subfield 3254 of the partition field 3250.
FIG. 10 is a flow chart of a method 10000 for decoding the connectivity-preserving and anti-connectivity partitions encoded in the subfields 3252 and 3254 of the partition field 3250, and to compose them to recover the a clustering operation. Method 10000 is a preferred implementation of step 5300 of method 5000. In step 10100 the number of vertices of the current level of detail is determined. In step 10200 the connectivity-preserving partition is decoded from the data stored in subfield 3252 of the partition field 3250 of the data structure 3000, and the connectivity-preserving cluster array is reconstructed. In step 10300 the anti-connectivity partition is decoded from the data stored in subfield 3254 of the partition field 3250 of the data structure 3000, and the anti-connectivity preserving cluster array is reconstructed. In step 10400 the connectivity-preserving and anti-connectivity cluster arrays are composed producing the cluster array of the clustering operation.
FIG. 11 is a flow chart of a preferred implementation of step 10200 of method 10000 to decode the connectivity preserving partition from the sequence of connect bits stored in the subfield 3252 of the partition field 3250, and to reconstruct the corresponding connectivity preserving cluster array. In step 11100 the number of vertices N of the current level is determined. In step 11150 the connectivity preserving partition clusters are initialized as sets with a single element, one per vertex of the current level. In the loop defined by steps 11200, 11250, 11300, 11350, and 11400, some of these sets are joined together. In step 11250 the next connect bit in the sequence of connect bits is chosen. In step 11300 the corresponding edge of the current level of detail is determined, as well as its endpoint. In step 11350 it is determined if the value of the connect bit is equal to one or not. If the value of the connect bit is equal to 1, in step 11400 the connectivity preserving partition clusters that the two endpoints belong to are joined together. Note that these two connectivity preserving partition clusters may have been the same even before the join operation as a result of a previous join operation, in which case step 11400 will produce no change. In step 11200 it is determined if all the connect bits of the sequence of connect bits have been considered. If no more connect bits remain to be considered, the method proceeds to step 11450. In step 11450 consecutive indices are assigned to different connectivity preserving clusters, starting with index 1. And in step 11500, the connectivity preserving cluster array is constructed with the value assigned to a vertex of the current level being equal to the index of the connectivity preserving cluster the vertex belongs to.
FIG. 12 is a flow chart of a preferred implementation of step 10300 of method 10000 to decode the anti-connectivity partition from the lists of connectivity preserving cluster indices stored in the subfield 3254 of the partition field 3250, and to reconstruct the corresponding anti-connectivity cluster array. In step 12100 the number of connectivity clusters N of the current level is determined. In step 12150 the anti-connectivity partition clusters are initialized as sets with a single element, one per connectivity preserving cluster of the current level. In the loop defined by steps 12200, 12210, 12220, 12230, 12240, 12250, and 12260, some of these sets are joined together. In step 12210 the next list of connectivity preserving cluster indices stored in subfield 3254 is chosen. In step 12220 the first element of the list is determined. In step 12240 the element following the previously determined element of the list is determined. In step 12250 the anti-connectivity partition clusters that the last two previously determined elements of the list belong to are joined together. Note that these two anti-connectivity partition clusters may have been the same even before the join operation as a result of a previous join operation, in which case step 12250 will produce no change. In step 12260 the pointer to the last determined element of the list is advanced. In step 12230 it is determined whether the last determined element of the list is the last element of the list or not. If the last determined element of the list is the last element of the list, the method proceeds to step 12450. In step 12450 consecutive indices are assigned to different anti-connectivity clusters, starting with index 1. And in step 12500, the anti-connectivity cluster array is constructed with the value assigned to a vertex of the current level being equal to the index of the anti-connectivity cluster the vertex belongs to.
In another more preferred implementation, the sequence of connect bits is described by a "parameterized bit pattern", the parameterized bit pattern composed of one or more "bit parameters", describing how to reconstruct the sequence of connect bits.
In a yet more preferred implementation, the connectivity record contains information to organize the vertices of the last level of detail as a "rooted spanning tree". The bit parameters determine a "vertex tree value" for each vertex as function of the bit parameters and the depth of the vertex in the rooted spanning tree. The value of the connect bit corresponding to an edge of the rooted spanning tree is determined by whether the vertex tree values of the two vertices joined by the edge are the same or not. All the connect bits associated with edges of the triangle mesh not belonging to the rooted spanning tree have value zero.
In a preferred implementation the first data field 3340 contains the values of the vertex coordinates and (optionally) the properties of the lowest resolution level of detail, and each data field 3350, 3360, contains the values of the vertex coordinates and (optionally) the properties of each subsequent level of detail.
In a more preferred implementation the vertex coordinates, and (optionally) the properties of the lowest resolution level of detail are computed by evaluating an "first prediction function" and then adding a "first correction vector". The first predictor function being a function of zero or more "first predictor parameters" and zero or more elements of the lowest resolution level of detail previously computed, the values of the first predictor parameters, and the first correction vectors, stored in the first data field 3340.
In another more preferred implementation the correspondence between the vertices and triangles of each subsequent level of detail and the vertices and triangles of the previous level of detail defined by the cluster array 2450, 2550 is used to represent the coordinates of each vertex of each subsequent level of detail as the sum of the coordinates of the corresponding vertex of the previous level of detail plus a "vertex displacement", and (optionally) the coordinates of each property vector of each subsequent level of detail as the sum of the coordinates of the corresponding property vector of the previous level of detail plus a property vector displacement. Instead of the vertex coordinates and (optionally) the properties, each data field 3350, 3360, contains the displacements.
In another more preferred implementation the vertices and (optionally) the properties of each subsequent level of detail are computed by evaluating a "predictor function" and then adding a "correction vector". The predictor function being a function of zero or more "predictor parameters" and zero or more elements of the previous level of detail, the values of the predictor parameters, and the correction vectors, stored in the data fields 3350, 3360.
In a yet more preferred implementation each correction vector is further computed by evaluating an "intra-level prediction function" and then adding a "second correction vector". The intra-level predictor function being a function of zero or more "intra-level predictor parameters" and zero or more elements of the current level of detail previously computed, the values of the predictor parameters, the intra-level predictor parameters, and the second correction vectors, stored in the data fields 3350, 3360.
FIG. 13 is a block diagram showing an example computer system 13300 on which a preferred embodiment of the present invention operates. The preferred embodiment includes one or more application programs 13302. One type of application program 13302 is a compiler 13305 which includes an optimizer 13306. The compiler 13305 and optimizer 13306 are configured to transform a source (like other application programs 13302) program into optimized executable code. More generally, the source program is transformed to an optimized form and then into executable code. The compiler 13305 and optimizer 13306 operate on a computer platform 13304 that includes a hardware unit 13312. Some application programs 13302 that run on the system 13300 include the compression 4000 and decompression 5000 processes describe above.
The hardware unit 13312 includes one or more central processing units (CPU) 13316, a random access memory (RAM) 13314, and an input/output interface 13318. Micro-instruction code 13310, for instance a reduced instruction set, may also be included on the platform 13304. Various peripheral components may be connected to the computer platform 10304 including a graphical interface or terminal 13326, a data storage device 13330, and a printing device 13334. An operating system 13308 coordinates the operation of the various components of the computer system 13300. An example of computer system 13300 like this is the IBM RISC System/6000 (RISC System/6000 is a trademark of the IBM Corporation.) It is readily understood that those skilled in the computer arts will be familiar with many equivalent computer systems 17300.
FIG. 14 is a diagram that shows a first computer 14200 connected to a second computer 14210 through a communications link 14220. Examples of communications links are serial links (RS-232), parallel links, radio frequency links, and infra red links. Networks (LAN, WAN) are also prior art examples of communication links. Networks are commonly known. One example of network is the Internet. See U.S. Pat. No. 5,371,852 to Attanasio et. al. filed on Oct. 14, 1992, which is herein incorporated by reference in its entirety. Computer 14200 compresses a triangular mesh by running a geometric compression process 4000 and sends the resulting data structure 3000 trough the communication link 14220. Computer 14210 receives the data structure 3000 and decompresses the triangular mesh by running a geometric decompression process 5000.
Given this disclosure alternative equivalent embodiments will become apparent to those skilled in the art. These embodiments are also within the contemplation of the inventors. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a device for the compressing of a gaseous medium and systems that apply such compressing devices, such as energy generating systems, gas separators, compressors and compressor systems for natural gas, air, and chemicals—such as ammoniac.
2. Brief Description of the Prior Art
Compressing a gaseous medium requires compression work, which work is directly proportional to the absolute temperature of the medium to be compressed. This means that compression work may be reduced by cooling the medium before and during the compression, and in the event of recycling, also after compression. This applies also if the medium is compressed successively in various stages. The main objective is a virtually ideal or quasi-isothermal compression.
The medium is cooled by introducing a liquid evaporation agent (usually water). The evaporation agent is introduced in the form of droplets that evaporate. The heat required for evaporation is provided by the medium, which consequently cools.
In principle, it is not necessary that the sprayed droplets of the evaporation agent evaporate completely. Incomplete evaporation of the droplets, however, may result in droplets of the evaporation agent coming into contact with the interior of the compressor unit, which may lead to erosion and corrosion of parts of the compressor unit.
The objective, therefore, is to introduce as tiny droplets as possible (1-10 μm). The smaller the droplets, the likelier the possibility that they will evaporate completely, but also the less likely that they will come into contact with the structure of the compressor unit. However, if the medium has a high velocity and/or the air residence time in the compressor unit is short, there usually is insufficient time for full evaporation.
DE-A-41 14 678 relates to a method for the atomisation of a fluid for a gas turbine. The atomisation of the fluid has to take place over the entire length of the compressor at a spraying pressure of 5-20 bar above the compressor pressure. The maximum quantity of fluid to be atomised—water in particular—lies between 0 to 0.2 kilogram per kilogram air and may not be exceeded. Finally, it is indicated that the manner wherein the fluid is atomised in the compressor has not yet been constructively solved.
U.S. Pat. No. 4,478,553 relates to the isothermal compression in the compressor of a gas turbine. Atomising means are strategically positioned in the rotor structure. The water to be dispersed is not pre-heated and the size of the droplets of the atomised evaporation agent is preferably maintained at between 2 and 10 μm.
U.S. Pat. No. 5,388,397 relates to a method for operating a turbocompressor, whereby air is compressed in two stages and cooled in between in an intercooler. The warm water of the intercooler is cooled in subsequent evaporating vessels and the resulting steam is transferred very compactly to the environment by spontaneous evaporation according to a flash method. The evaporated amount is made up to by a corresponding amount of fresh water.
EP-A 0 821 137 describes a system for generating energy, whereby the gas to be compressed is cooled by atomising water droplets with a drop size of 1-5 μm. Under certain conditions, however, the required flow rate of atomised water droplets is too small.
SUMMARY OF THE INVENTION
The present invention aims to provide a compressor device in which a gaseous medium may be compressed at relatively low temperatures by applying very small droplets of evaporation agent (the median is smaller than 5 μm, generally smaller than 3 μm, preferably smaller than 2 μm, e.g. 1.2 μm) whereas sufficient flow rate of this type of atomised droplets may be generated in dependency of the flow rate of the medium to be compressed.
Simultaneously, the present invention aims to provide a very adequate manner of cooling a gaseous medium, so that the cooling capacity of existing or required gas coolers (intercoolers) may be reduced or that they may be replaced.
This is achieved according to the invention by a device for compressing a gaseous medium, generally including a compressor unit provided with a medium inlet, an outlet for the compressed medium and of means for atomising a liquid evaporation agent in the medium, wherein the atomising means have at least one flash atomisation unit, mounted and arranged such, that the atomised evaporation agent fragmentises by the formation of gas in the atomised evaporation agent.
The atomising means of this compressor unit includes an inlet for evaporation agent and an outlet for evaporation agent into the gaseous medium line. It is possible that this gaseous medium still has to be compressed, is in the process of being compressed or has already been compressed. In the latter instance, the compressed medium may still be added to a subsequent compressing unit or may in part be recirculated. The atomising means usually also contain a very large number of atomisers via which the evaporation agent is sprayed into the gaseous medium.
In principle, any known type of atomiser may be used in the flash atomisation unit. Suitable ones are, for example, swirl atomisers, slot atomisers, orifice atomisers, rotating bowl atomisers and, if necessary, pen atomisers. Of importance is only that the atomiser gives off droplets or a film of evaporation agent to the gaseous medium, under circumstances changed to such extent that flash atomisation takes place subsequently. Flash atomisation means that the liquid evaporation agent arrives in the gaseous medium under such conditions that as a result of the pressure drop over the atomiser, boiling bubbles or gas bubbles are generated in the droplets or film of the evaporation agent, i.e. gas or vapour is formed in the evaporation agent. This so-called flashing or precipitation results in the explosion or fragmentation of the droplets or film of the evaporation agent as a result of the sudden partial boiling or gas precipitation. Such fragmentation results in the generation of very tiny droplets of evaporation agent in the gaseous medium. After fragmentation, the median size of the evaporation agent is less than 5 μm, in general smaller than 3 μm, preferably smaller than 2 μm, e.g. 1.2 μm.
This means that atomisers may be employed in the atomising means insofar as they result in droplets of the said median size after fragmentation. Of importance in this respect is that the atomising means, the flash atomisation units in particular, are mounted and arranged such that the atomised evaporation agent fragments by the generation of gas in the atomised evaporation agent.
Preferably, a flash atomisation unit is used that is provided with swirl atomisers. In such a known swirl atomiser, the evaporation agent is put in swirling motion in a swirl chamber. The swirling evaporation agent exits via an outlet. It has appeared that the thickness of the exiting layer of evaporation agent is only a fraction (e.g. 10%) of the diameter of the outlet passage. The subsequent flash fragmentation results in droplets having (dependent on the pressure drop, temperature and diameter of the outlet passage) a median size of 5 μm or less. Because of the reduced size of the droplets of evaporation agent, there will be less risk of contact with the interior of the compressor unit, which means that the entire length of the compressor unit can be cooled.
It will be clear that in order to realise this fragmentation, it is important that the conditions (in particular the changing of conditions) under which the evaporation agent is atomised in the gaseous medium must be optimal for fragmentation. Important conditions for flash fragmentation are the temperature of the evaporation agent, the atomisation pressure under which the evaporation agent is atomised in the gaseous medium, and the outlet passage diameter. Therefore, the flash atomisation unit preferably, has means for adjusting the temperature of the evaporation agent and/or the atomisation pressure.
As indicated above, known atomisers may, in principle, be used in the compressor device according to the invention. These atomisers may release the evaporation agent in the gaseous medium in a direction which is either traverse or parallel to the flow of the gaseous medium. The atomised evaporation agent may possess a radial or axial component vis-a-vis the gaseous medium. A radial component is important in order to avoid coalescence of the fragmentised droplets of evaporation agent and may be realised e.g. by applying a swirl atomiser. An axial component is important in order to transfer the energy of the evaporation agent as much as possible to the gaseous medium, such that the pressure drop is low or even negative. In the event the existing compressors or compressor systems for instance energy installations are retrofit, pre-position is provided for a spraying rack with swirl atomisers. This spraying rack should preferably be positioned close to the medium inlet of the compressor so that there is hardly any opportunity for droplet coalescence or heating of the medium. Under similar conditions it is also possible to include the atomisers in the blades of the compressor and to atomise from the stator or rotating compressor blade. The swirl atomiser and the slot atomiser or orifice atomiser in particular are preferred here because they are of a very simple construction and are quite easy to miniaturise. Accordingly, very large numbers of atomisers may be implemented in advance without requiring too extensive changes in the existing compressor device, thus enabling an optional but also large flow rate of fragmentised evaporation agent. A retrofit set up in this manner effectively reduces both the compression discharge temperature and the compression work.
If, furthermore, the means for adjusting the temperature adjusts the temperature of the evaporation agent preferably to or near the critical temperature, the evaporation agent attains a surface tension which is virtually or precisely 0 N/m 2 . This means that little or no further energy is required to atomise the liquid, so that the droplet size will be extremely small (a median droplet size of up to 0.1 μm is possible) and the use of other means for reducing the surface tension may be dispensed with. Depending on the amount of liquid evaporation agent that is atomised in the medium and the distance to the medium inlet of the compressor, the temperature of the medium/evaporation agent to be compressed may increase, e.g. from 15° C. to 23° C. and 30° C. at a final water content in the medium that leaves the compressor unit of 10 and 18 mol % respectively. Therefore, it is advantageous if the temperature of the evaporation agent to be atomised—water in particular—before atomisation is as low as possible. Finally, because of the extremely small size of the droplets, an optimal and maximum evaporation and consequently cooling will occur, as a result of which the compression work is minimal and therefore the forming of NO x as well.
Besides the aforementioned physical conditions for fragmentation it is also possible to promote fragmentation by adding chemical or physical additives to the evaporation agent. It is therefore preferable to add agents to the evaporation agent which reduce its surface tension, thereby reducing the energy required for the fragmentation. Agents that can be used to reduce the surface tension are detergents and the like. Preferred surface tension reducing agents are those that do not only reside at the interface of the evaporation agent and medium but that are also virtually homogeneously distributed throughout the evaporation agent (droplet or film). Thus, a reduced reduction of the surface tension is not required after atomisation and prior to fragmentation as a consequence of diffusion. Under such conditions the use of fatty acids, shortened fatty acids in particular, is preferred or, possibly, alcohol, e.g. methanol or ethanol. Use of the latter substances is especially preferred in the event they are to be added to gaseous mediums that are subsequently used in a combustion process. Thus, the risk of these additives negatively influencing the combustion process is avoided.
According to another preferred embodiment, the evaporation agent, generally includes a number of evaporation substances that each feature different boiling points. In particular, as the result of a pressure drop when the flash atomisation unit is passed, the vaporisable substances with the lowest boiling points will be the first to evaporate in a flash, forming boiling bubbles, as a result of which the remaining (liquid) evaporation agent will explode or fragment into small droplets. The mixture may e.g. be a mixture of water and carbon dioxide or a mixture of water and carbon monoxide.
The addition of a vaporisable substance having a lower boiling point also results in a further reduction of temperature in the atomised droplets. The atomisation of water, which is saturated with carbon dioxide (approx. 7% by wt at 150 bar) at 150 bar and 15° C. results, when it is suddenly expanded to 1 bar, in a lowering of the temperature to 12.5° C.
In principle, the compression device according to the invention may be applied under all kinds of conditions, in particular under conditions requiring isothermal or quasi-isothermal compression for reasons of efficiency, and such under conditions that leave little time for evaporation as a result of the limited residence time before, in or after the compression unit.
The compression device according to the invention turns out to be well applicable in systems for generating energy, such as compressor units provided with gas turbines as well as installations for gas separation or combustion engines. In principle, the invention is applicable to all gases that have to be compressed, such as natural gas, ammoniac, air, nitrogen and oxygen, hydrogen, synthesis gas, carbon dioxide and inert gases.
The compression device according to the invention may also be used in a rotating or piston engine, such as a combustion engine, e.g. a gas engine, diesel engine and Otto engine. The piston compression in a piston compressor or during the compression stroke in a combustion engine may be reduced in work in the same manner as in the axial or radial (gas turbine) compressor by applying quasi-isothermal compression. In a diesel engine with turbocharger atomisation may take place both before and in the turbocharger and before and in the compression chamber. The finely atomised water will evaporate and the temperature and the compressor-work will be lower than with adiabatic compression.
As indicated above, in a combustion engine the flash atomisation unit is preferably incorporated in the separate compression chamber or compression unit. Thus, quasi-isothermal compression may occur during the compression stroke of the combustion engine. A heat exchanger is arranged between the compression chamber or unit and the combustion chamber of the combustion engine which is in heat-exchanging contact with an exhaust outlet of the combustion engine. Thus it is possible to recuperate heat in the cool, compressed air from the heat of the exhaust gases.
The features stated and other features of the compressor device and of the systems in which such devices are used, will be given below as examples without restricting the invention thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a system for generating energy (biomass TOP Humidified Air Turbine (TOPHAT)); utilising flash atomisation according to the invention;
FIG. 2 is a schematic representation of another system for generating energy (coal-TOPHAT);
FIG. 3 represents a system for air separation;
FIG. 4 is a schematic representation of still another system for generating energy, with specific attention for the cooling of hot gas parts;
FIGS. 5 and 6 are schematic representations of ship diesel engines;
FIG. 7 is a schematic representation of a flash swirl atomiser;
FIG. 8 is a schematic representation of a swirl-flash retrofit system for generating energy;
FIG. 9 is a variant of the system shown in FIG. 8, which uses an evaporation agent comprising evaporation substances with different boiling points;
FIG. 10 shows another system for generating energy according to the invention according to the TOPHAT principle; and
FIG. 11 shows a energy generating system according to the TOPHACE principle (TOP Humidified Air Combustion Engine).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a system 1 for generating energy. The system 1 includes a compressor unit 2 driven via a shaft 3 by a gas expansion turbine 4 , which also drives a generator 5 .
The compressor unit 2 is provided with a (medium) air inlet 6 and an outlet 7 for compressed air. In the air inlet 6 , atomising means 8 are included for atomising evaporation agent, in this case water is supplied via water supply 9 , into the air. The atomising means 8 comprise a casing containing a ring through which the air flows that is to be compressed. This ring contains a large number of (known) flash atomisation units spaced over the circumference at short distances from each other, each connected to the water supply 9 . In the heat exchanger 16 —and if so required in heat exchanger 10 —the water is preheated to 140-250° C. The flash atomisation units are constructed as swirl atomisers (see FIG. 7) and water droplets with a median size of 1-2 μm are ejected into the air. The maximum flow rate of ejected atomised water droplets is 20 kg/s, at an air flow rate of 100 kg/s. For existing compressor units, as present in a gas turbine, the traditional flow rate will be at most 5% of the air supply; for new gas turbines at most 20%.
After passing though a recuperator 10 , the is compressed and heated gas is brought, via outlet 7 , into the combustion unit 11 , to which fuel is fed via the fuel inlet.
The flue gas is cleaned in unit 13 , wherein the ashes are removed via outlet 14 . The cleaned flue gas drives gas turbine 4 . After passing the gas turbine, the gas passes the recuperator 10 and a heat exchanger 16 via line 15 and leaves the system 1 via the stack 17 .
If the fuel is biomass, the dried biomass originating from the heat exchanger 16 is pressurised in unit 18 .
FIG. 2 shows a similar system 20 , for the generating of energy. Identical units are indicated by identical reference numbers.
In system 20 the evaporation agent (water) is supplied via water supply 9 prior and to the various compression stages of the compressor unit 2 . To this end, the compressor unit 2 comprises a number of atomising means, each mounted with flash atomisation units. Thus quasi-isothermal cooling is obtained. Furthermore, reference is made to the presence of a bypass line 21 for the combustion unit 11 such that the combustion temperature and/or the temperature of the turbine can be adjusted. The gas that leaving gas turbine 4 via line 15 is removed via line 22 .
FIG. 3 shows a system 23 for compression for air separation. Via a number of compressors 24 the air supplied via inlet 6 is pressurised. The air is cooled with water that is added to the atomising means 8 , of which at least one contains a flash atomisation unit, via line 9 . The pressurised air is supplied to the conventional air separator 26 . In a variant to the system 23 shown in FIG. 3, which includes only one compressor 24 and atomising means 8 , which atomises the evaporation agent by flash atomisation in the air supplied via inlet 6 . The air (29 kg/s) is compressed quasi-isothermally under flash atomisation of water (100 bar at 200° C.). The air is heated from 15° C. to 83° C. It is subsequently cooled to 25° C. The compression work is 5.3 MW. The cooling capacity is 6.9 MW. If adiabatic compression was applied (5 bar at 200° C.), followed by cooling to 25° C., the compression work is 5.6 MW and the cooling capacity 5.9 MW. By using the system according to the invention the energy consumption is reduced with 5.5%. Moreover, the capacity of the compressor 24 increases by approximately 10%;. The cooling capacity increases notably, as a result of the presence of water in the air and the fact that the increased capacity is caused by condensation of the water.
For the compression of oxygen, nitrogen and hydrogen from ambient pressure to 16 bar, the state of the art uses multi-stage compressors with intermediate intercoolers. For oxygen (32 kg/s), the oxygen is adiabatically compressed in a first compressor stage to 4 bar (temperature 175° C.) and subsequently cooled down to 40° C., whereby the pressure is reduced to 3.8 bar. The compression work is 4.7 MW and the cooling capacity 4 MW. In a second compressor the oxygen is compressed to 8 bar (at 214° C.) and subsequently cooled to 25° C. In this case the compression work is 5.8 MW and the cooling capacity 5.5 MW. The total amount of compressor energy is 10.5 MW and the total cooling capacity 9.5 MW.
In the event of quasi-isothermal oxygen compression according to the invention, utilising the atomising means 8 according to the invention, 4 kg/s water at 100 bar and 200° C. is atomised in the oxygen via flash atomisation. The compressed oxygen (131° C.) is subsequently cooled to 25° C. In this case the compression work is 10.4 MW and the cooling capacity 12.8 MW. The increase of the cooling capacity is caused by the condensation of water, which reduces the costs of cooling. By using one compression step only, the construction of the device is considerably simpler, which reduces the costs of the device substantially. An additional advantage for the compression of oxygen and hydrogen is increased safety, as a result of the inherently lower temperatures over the entire pressure range, together with the presence of water droplets, making the process considerably safer.
FIG. 4 shows a system 25 for generating energy. System 25 includes a compressor 27 mounted with an air inlet 26 , and an outlet 28 for compressed air, which connects to the inlet 29 for the cooling air of turbine 30 . The air inlet 29 is mounted with a flash atomisation unit 31 , in which an evaporation agent, such as water, is supplied via line 32 , sprayed in the compressed air, and supplied to turbine 30 via two inlets 33 and 34 . In this way, it is possible to feed cooled air into the turbine. In fact, the existing rotor air coolers and optionally the booster compressor may be reduced in number or size or replaced by the flash atomisation unit described.
Incidentally, compressed air is also supplied to the combustion unit 37 , via the outlet 35 and the heat exchanger 36 . Fuel is supplied to the combustion unit 37 via line 38 . An outlet 39 for exhaust from the turbine also passes the heat exchanger 36 and is carried away via stack 40 .
In comparison with existing gas turbines mounted with rotor air coolers, the capacity of the gas turbine may be increased by applying the flash atomisation unit, e.g. from 58.7 MW to 60.8 MW or even 61.3 MW (in the latter instance the booster compressor is shut down as well).
FIG. 5 shows a diesel engine 41 , mounted with a turbocharger 42 . Via inlet 43 diesel oil is supplied to six cylinders 44 , to which the inlets for compressed air are connected as well. The air compression takes place in a compressor 46 , which is connected to the main inlet and mounted with an air inlet 47 . Water supplied via line 48 is brought under pressure by pump 50 and is heated in heat exchanger 49 before being supplied to the flash atomisation unit 51 , by which means very finely distributed water droplets are sprayed into compressor 46 .
The exhaust of the diesel engine 41 is carried off via line 52 and passes the turbine 53 , the heat exchanger 49 and the valve 54 and exits the system via the stack 56 , By using the flash atomisation units 51 , cooler and moister compressed air is supplied to the cylinders of diesel engine 41 , thus reducing the NO 2 emission.
As FIG. 6 shows, in a similar diesel 56 engine flash atomisation units 57 may also be utilised in each cylinder 44 for the atomisation of diesel oil. The diesel oil is supplied via line 43 and heated up by passing it via the heat exchanger 58 and if necessary by exchanging heat with the cylinder. The diesel oil has to be brought at such temperature as to enable the flash atomisation to take place at an accepted cylinder pressure, e.g. approximately 40 bar. A further advantage is that the injection pressure may be reduced from approximately 1000 bar or more to e.g. 200 bar.
Fuels like diesel oil have a boiling range. By temperatures of 350° C., a significant flash effect will already occur for diesel oil. This may be lower for kerosene/gasoline (250/150° C.) and higher for slow speed ship diesel engines—up to 400° C. Because the combustion of much smaller droplets is much more efficient, a more homogeneous combustion will take place, which results in a lower emission of soot.
FIG. 7 shows a swirl atomiser 59 , as known in the state of the art. Via line 60 the evaporation agent 61 is tangentially supplied to a swirl chamber 63 via an inlet 62 . The evaporation agent attains a swirling movement 64 and leaves swirl chamber 63 via outlet 65 . The swirling evaporation agent enters the space in which gaseous medium is present in the shape of a cone. The thickness of the layer of evaporation agent is reduced and ends up in very tiny droplets as the result of fragmentation. It may clearly be observed that the thickness of the layer of evaporation agent is less than the diameter of the outlet passage 65 of the swirl chamber 63 . Because of the smaller size and relatively simple construction of the swirl atomiser 59 , large numbers of such swirl atomisers may be applied for the flash atomisation of the liquid evaporation agent in the gaseous medium being or to be compressed.
FIG. 8 shows a system 66 for generating energy. This system 66 includes a compressor 67 , connected to a turbine 69 by a shaft 68 . Turbine 69 drives a generator 70 . From a vessel 71 water at 15° C. is pumped via a heat exchanger 73 by a pump 71 . In heat exchanger 73 the water is heated to 140-250° C. by exchanging heat with the exhaust 74 of turbine 69 . This warm and pressurised water is supplied to the flash atomisation unit 75 , in which the water is atomised in air 76 of 15° C. After quasi-isothermal compression in the compressor 67 the compressed air is supplied to a combustion unit 77 , after which the exhaust gases are supplied to turbine 69 via the line 78 .
The use of the compressor device (of the type shown in FIG. 8 according to the invention) has been studied with an existing system according to the invention: an Allison Centrax 400 kW gas turbine. This gas turbine is retromounted. In an early model 21 swirl atomisers with a 0.2 mm bore are mounted in the air inlet. In a second model 14 swirl atomisers with a 0.4 mm bore are mounted in the air inlet. A series of tests was carried out at charges of 100, 200, 300, and 400 kW respectively. These tests were carried out at these charges with and without water injection. The relative amount of injected water was 1.3% and 1.0%, respectively. During the tests, the charge of the gas turbine was maintained at permanent level by adjusting the turbine inlet temperature. In order to attain a first rate forecast for the increase of capacity, the full load capacity and the NO x emission, interpolations and extrapolations were carried out.
The results are given in the table below.
Relative amount of
water injection (%)
1.0
1.3
Increase full load capacity (%)
+5.4
+9.2
Relative increase of efficiency (%)
+1.5
+2.9
Reduction in NO x emission (%)
+16
+21
The use of the compressor device according to the invention in the Centrax 400 kW gas turbine resulted in a considerable reduction of the No x emission. Moreover, the full load capacity increases as well as the relative efficiency. It may be clear that by retrofitting existing gas turbines the output and full load output may be improved and the emission of No x reduced.
FIG. 9 shows a system 79 for generating energy. In comparison with system 66 —FIG. 8 —not only water 80 is supplied to the vessel 71 but carbon dioxide 81 as well. The water in the vessel 71 is saturated with carbon dioxide. This water is supplied under pressure to the flash atomisation unit 75 by means of pump 72 in order to cool the air 76 by generating very small water droplets. The moistened air is subsequently compressed in the compressor 67 while water droplets are evaporated. After combustion with fuel in the combustion unit 77 , the exhaust is carried off via the exhaust outlet 82 via turbine 69 which drives the generator 70 .
FIG. 10 shows another system 83 for generating energy according to the invention, in accordance with the so-called TOPHAT principle. Air 85 is moistened and cooled in a flash atomisation unit 84 by means of water 86 supplied by means of flash atomisation. The air is supplied to a compressor 87 connected by a shaft 88 to a gas turbine 89 which drives a generator 90 . The cool, compressed air passes a heat exchanger 92 via a line 91 and is supplied to the combustion unit 93 , to which fuel is supplied via the line 94 . The exhaust of gas turbine 89 passes the heat exchanger 92 via line 95 to be brought in heat exchanging contact with the cool, compressed air from the compressor 87 . Via the line 96 the exhaust passes a heat exchanger 97 and the condenser 98 on its way to the stack 99 . In the condenser 98 water is condensed from the exhaust and pumped under pressure by pump 99 to the heat exchanger 97 , after which the water 86 , now under pressure and at the right temperature, reaches the flash atomisation unit 84 . If necessary, water may be added to the condense water from the condenser 98 via line 100 .
FIG. 11, finally, shows a system 101 according to the invention for generating energy in accordance with the TOPHACE principle.
Water at 140-250° C. and 150 bar, is pumped by pump 102 to a flash atomisation unit 103 to which air is supplied via line 104 (at 15° C.). From the flash atomisation unit 103 the air reaches a compressor 105 which works with an efficiency of 0.8. The compressed air (now 140° C.) is supplied via line 106 to a heat exchanger 107 to exchange heat with the exhaust gases of a combustion engine 108 . The combustion engine comprises four cylinders 109 from which an air inlet 110 connects to the line 106 via a valve 111 . From each of the cylinders 109 an exhaust pipe 112 passes the heat exchanger 107 and is led via a heat exchanger 114 via the line 113 and ends up via the condenser 98 in the stack 99 . In the condenser 98 condense 115 is formed which after passing a water purifier 116 and after being brought under pressure by a pump 123 is added to the pump 102 via the heat exchanger 114 .
Fuel is supplied to each of the cylinders by the pump 124 via line 125 and the valves (not shown).
In the recuperator the air is heated from 140° C. to 377° C., whereas the exhaust from the cylinders 109 is cooled down from 465° C. to 210° C. At a pressure of 9 bar, the air is supplied to the cylinders 108 and atomised fuel is injected. The cylinders 109 are also mounted with an ignitor 117 for igniting the mixture in each of the cylinders 109 . The cylinders 109 are all mounted with a piston 118 connected to a shaft 119 which in turn is connected to the shaft 120 of the compressor 105 at one end and with the generator 121 on the other, via a 1:5 gear assembly 122 .
Under ideal conditions, system 101 provides a power of 226 kW at 64% efficiency. A known device according to the Atkinson principle provides power of only 170 kW at 48% efficiency. | 4y
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FIELD OF THE INVENTION
The present invention relates to means for underwater communication. More particularly, the invention relates to a method for carrying out high rate underwater communication, and to an apparatus for carrying out high rate underwater communication according to said method.
BACKGROUND OF THE INVENTION
Performing a reliable underwater communication is a relatively complicated task. It is known that electromagnetic waves are significantly attenuated when propagating through water. The only frequency band that is used for electromagnetic underwater communication is the VLF (Very Low Frequency) band, in the range of up to 10 kHz. In this range, high power transmission is needed, and use of extremely long antennas is required at both the receiving and transmitting ends. Therefore, such use is generally limited to submarine communications, and cannot be exploited for personal use. For shorter range underwater communication, conventional systems use ultrasound acoustic transmission, generally in the frequency range of 20 kHz-600 kHz. Unfortunately, however, in the acoustic frequency range, the water as a communication medium provides practically only a relatively narrow bandwidth, which limits the speed of the data transfer through water. The ability to reliably transfer data through water with acoustic waves is further complicated by the different layers of water density, resulting from non-constant speed of sound in water, multipath propagation of the signal, fading, and other environmental disturbances. Furthermore, it is known that the propagation speed of ultrasonic waves in water is significantly lower than the propagation speed of electromagnetic waves in air. Therefore, when it is desired to communicate in water between two apparatuses, of which at least one is not stationary, or moves at a low speed, the Doppler effect adversely affects the signal and the ability to reliably interpret the transmitted data at the receiving apparatus.
It has been found that many conventional types of electromagnetic air communication techniques are unable to overcome the abovementioned problems, which are typical of underwater communications.
Wireless apparatus for carrying out communication in water is known in the art. Such apparatus is used for example in telemetry systems for transferring data that was accumulated during oceanographic researches, or in communication devices for divers. Copending Israeli Patent Application No. 121561, filed on Aug. 18, 1997, by the same applicant herein, discloses an underwater communication apparatus and a communication network for divers. Communication devices for divers are also shown in CA 2,141,619, WO 97/26551, and in U.S. Pat. No. 4,463,452. Other existing apparatus, which is capable of transferring data at a relatively low rate, generally operates in the range of no more than about 600 bits per second, a rate which is in general sufficient for telemetry purposes, but not for other purposes which require a significantly higher rate of data transfer, such as real time voice or picture transmission. For satisfying these requirements, it is desired to provide an underwater modem which is capable of transferring data at a much higher transfer rate, at least in the range of about 4800 bits per second to 9600 bits per second.
Moreover, existing apparatus enables underwater communication between two locations being at a relatively close range, generally in the range of less than 150 meters, and require a direct "line of sight" between the transmitting and receiving devices. Such apparatus does not provide means for carrying out reliable underwater communication between two sites that may be located several kilometers away from one another, and between which there is no "line of sight".
It is an object of the invention to provide a modem which can reliably transfer and receive data at a high rate through water. The term "underwater modem" or simply "modem", when used herein, refers to an apparatus which is capable of transmitting and receiving high-rate data through water, unless otherwise specifically stated. By "high-rate" data transmission it is meant to indicate a band rate of at least 1200 bps, and preferably of at least 4800 bps.
It is still another purpose of the invention to provide an underwater modem which can efficiently overcome fading, multipath, Doppler and environmental disturbances.
It is still another purpose of the invention to provide an underwater modem which can eliminate Doppler distortions of the transmitted signal which are due to movement of the transmitting modem, the receiving modem, or both.
It is still another object of the invention to provide an underwater modem comprising means for correcting errors.
It is another object of the invention to provide means for using the said underwater modem in underwater sound communication.
Other purposes and advantages of the invention will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
It has been found by the inventors that the fading and multipath problems which significantly affect underwater acoustic communications, resemble the fading and multipath problems which affect HF (High Frequency, short wave) radio communication. One method, originally developed for overcoming the fading and multipath problems in HF communication is the Orthogonal Frequency Division Multiplexing (OFDM). However, the OFDM communication method has not yet been applied to underwater communication.
OFDM has been found by the applicants to be the best modulation method for overcoming fading and multipath problems underwater. However, the use of OFDM in itself is not sufficient for solving all the aforesaid problems of underwater communication, and additional means should be provided in order to overcome the Doppler effect, to ensure communications even when a line of sight between the transmitting and receiving apparatuses does not exist, and to assure a reliable (error free) communication. The Doppler effect is much more severe in underwater acoustic communications than in electromagnetic air communications, as acoustic waves propagate in water at a speed of about 1500 m/sec, while electromagnetic waves propagate at the speed of light, i.e., 300,000 km/sec in air. Furthermore, the propagation speed in water is not constant and depends on the depth, the water temperature, and other factors. The modem according to one embodiment of the invention provides means for overcoming the fading and multipath problems, as well as the signal distortions due to the Doppler effects. As will be shown hereinafter, the modem according to the invention can reliably transfer data at a rate much higher than the transfer rate of any prior art underwater communication apparatus.
According to a preferred embodiment of the invention, the underwater modulator-demodulator (modem) apparatus for transmitting and receiving data at a high rate through water, comprises:
a. A transmitting section comprising:
data source means, comprising digital data to be transmitted through water;
serial-to-parallel data processing means, for splitting a serial data into n parallel channels;
n-channel modulator means, for receiving data from said n parallel channels and for modulating the same with n pairs of ultrasonic carriers, thereby producing a modulated signal; and
hydrophone means, for receiving said modulated signal from said n channel modulator, and for transmitting same through water; and
b. A receiving section comprising:
hydrophone means, for receiving a modulated signal from the water, and for conveying the same to an RF circuit;
RF circuitry, for amplifying and shaping the received modulated signal, and for conveying the same to serial-to-parallel means;
serial-to-parallel means, for receiving shaped data from the RF circuit, and for splitting the same into n parallel channels;
n-channel demodulator means, for demodulating said shaped signal conveyed to the demodulator from said RF circuit, and for outputting n channels of digital data; and
parallel-to-serial means for receiving n parallel channels of outputted data from the demodulator, and for combining the data into serial data.
Preferably, the n-channel modulator means in the transmitting section is an n-channel OFDM modulator means, for receiving data from the n parallel channels and for modulating the same with n pairs of orthogonal ultrasonic carriers, thereby producing a modulated signal, and the n-channel demodulator means at the receiving section is an n-channel OFDM demodulator means, comprising n pairs of orthogonal ultrasonic sines for demodulating the shaped signal conveyed to the n-channel OFDM demodulator from the RF circuit, and for outputting n channels of digital data.
Preferably, the receiving section and the transmitting section are contained within the same case, and the transmitting hydrophone and the receiving hydrophone are incorporated within the same hydrophone, and more preferably, the hydrophone is a multidirectional hydrophone. However, in some applications the receiving section and the transmitting section may be contained within separate cases.
According to one embodiment of the invention, the transmitting section further comprises an n-channel differential encoder for receiving data from the serial-to-parallel means, for differentially encoding the data on each one of said n channels, and for providing the differentially encoded data to the n-channel OFDM modulator, and the receiving section further comprises an n-channel differential decoder for receiving n channels of demodulated data from the demodulator, and for differentially decoding said demodulated data.
Preferably, the transmitting section further comprises a Forward Error Correcting (FEC) device for encoding the digital data to be transmitted, and the receiving section further comprises a Forward Error Correcting (FEC) device for decoding the received encoded data by the use of at least one error correcting code, and for outputting the same to the parallel-to-serial device of the receiving section.
Still preferably, the apparatus further comprises means for compensating for Doppler effects on the transmitted signal propagating through water. Said means for compensating for Doppler effects according to one embodiment of the invention comprise, in the modulator of the transmitting section, additional means for transmitting at least one unmodulated carrier, and in the receiving section, a frequency adjusting device for measuring the frequency of said at least one unmodulated carrier, and for compensating for any deviation in it. When the modem uses OFDM modulation, the frequency adjusting device compensates for Doppler effects by changing the frequency of each one of the n pairs of orthogonal sines of the OFDM demodulator by the same measured deviation.
Preferably, at least the n-channel OFDM modulator at the transmitting section and the demodulator at the receiving section comprises a DSP, incorporated within an integrated circuit.
The invention further relates to a method for carrying out a high-rate underwater communication, comprising performing the following steps:
(i) transmitting data by:
a. Providing a serial data in digital form to be transmitted;
b. Providing means for splitting the serial data into n parallel channels and assigning symbols to groups of data bits;
c. Modulating said symbols by an n-channels OFDM modulation;
d. Transmitting said OFDM modulated data through a hydrophone, into the water; and
(ii) Receiving said transmitted data in understandable form, by:
a. Receiving said transmitted OFDM modulated data by a hydrophone;
b. Demodulating the received signal by an n-channel OFDM demodulator;
c. Decoding the demodulated data in said n channels; and
d. Converting the data from said n channels from parallel into serial form.
The said method performs better when multidirectional hydrophones are used at the transmitting and at the receiving ends. Optionally, each end may be capable of performing bi-directional communication, and if so, one hydrophone may be used for both receiving and transmitting.
Preferably, the said method is further enhanced by further having the following steps:
a. transmitting at least one additional unmodulated ultrasonic carrier (pilot) simultaneously with the OFDM modulated data; and
b. when receiving said OFDM modulated data and said at least one additional unmodulated ultrasonic carrier by the hydrophone, measuring the frequency shift of said unmodulated signal from its expected frequency value, and compensating for said shift by adjusting the OFDM demodulator of the receiving section accordingly.
The underwater modem according to the invention can also be used for communicating sound through water. In such case, in the transmitting section of the modem, the data source means comprises a microphone for receiving a sound and converting it to an analog electric signal, and a voice encoder for receiving said analog electric signal and converting it to digital data. The receiving section further comprises a voice decoder for receiving the serial data from the parallel to serial means and converting the said serial data to an analog electric signal, and loudspeaker means for receiving the analog electric signal and converting it to sound. The voice encoder at the transmitting section can be a vocoder operating in a voice encoding mode, and the voice decoder at the receiving section can be a vocoder operating in a voice decoding mode. The sound can be, for example, a voice of a diver to be communicated through water.
Still preferably, the duration of each symbol includes a guard time and said guard time is used for symbol synchronization at the receiving end.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in block diagram form the structure of a modem according to a preferred embodiment of the invention;
FIG. 2 illustrates in block diagram form the structure of the transmitting section of a modem according to a preferred embodiment of the invention;
FIG. 3 shows the symbol constellation map of a modem according to a preferred embodiment of the invention;
FIG. 4 illustrates in schematic form the structure of the encoder in the transmitting section of the device according to a preferred embodiment of the invention;
FIG. 5 illustrates in schematic form the structure of the OFDM modulator in the transmitting section of the modem according to a preferred embodiment of the invention;
FIG. 6 illustrates in block diagram form the structure of the receiving section of the modem according to a preferred embodiment of the invention;
FIG. 7 illustrates in schematic form the structure of the DFT (Discrete Fourier Transformer) block of the transmitting section of a modem according to a preferred embodiment of the invention;
FIGS. 8a, 8b, and FIG. 9 illustrate the symbol decision algorithm at the receiving section of a modem according to a preferred embodiment of the invention;
FIG. 10 illustrates in schematic form the structure of the symbol synchronizer at the receiving section of a modem according to a preferred embodiment of the invention;
FIG. 11 is a timing diagram illustrating the operation of the symbol synchronizer of FIG. 10.
FIG. 12 graphically illustrates the operation of the average power block of the symbol synchronizer of FIG. 10;
FIG. 13 is an example of a spectrum diagram showing the band spectrum of a modem according to a preferred embodiment of the invention;
FIG. 14 illustrates in block diagram form the structure of a sound modem according to a preferred embodiment of the invention; and
FIG. 15 illustrates in block diagram form the structure of the transmitting section of a sound modem according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 schematically shows in block diagram form an underwater modem according to a preferred embodiment of the invention. Conveniently, the modem 1 comprises both a transmitting section 2 and a receiving section 3. While the existence of said two sections in each modem is necessary in order to carry out a reliable bi-directional communication, there may be cases in which communication be carried out according to the invention between two apparatuses, a first one comprising only a transmitting section 2, and a second comprising only a receiving section 3. Hereinafter, if not specifically stated otherwise, it will be assumed for the purpose of this description that each modem comprises both transmitting and receiving sections.
The data source 4 of the transmitting section 2 represents data of any kind, in digital form, that must be transmitted by the wireless modem through water to a receiving modem located underwater in another location. The data from the data source (hereinafter also referred to as "the original data") is provided into an FEC (Forward Error Correction) encoder 5, which combines with it additional bits for error correction, in order to provide to the receiving modem the capability of correcting errors which occur due to disturbances in the underwater medium, and for recovering the original data as generated by the data source. The FEC encoder 5 is conventional in its structure, applying any type of error correction method known in the art. From the FEC encoder, data combining the original data and additional bits (hereinafter generally referred to as "the encoded data") is conveyed to an OFDM modulator 6, which modulates the digital data by a plurality of low frequency carriers. A modulated signal is then conveyed to an RF circuit 7, which, if necessary, transfers the frequency spectrum of the modulated signal into the ultrasonic range, then amplifies it, and transmits it by means of a hydrophone 17 through the underwater medium 100.
The receiving section 3 receives modulated ultrasonic data from the underwater medium 100 by means of hydrophone 17', which is then provided to an input RF circuit 8, which amplifies it, and transfers it downward into a low frequency range. From the output of the input RF circuit 8, the signal is conveyed to an OFDM demodulator 9, which demodulates the signal, and outputs encoded data. The encoded data from the OFDM demodulator is conveyed into an FEC (Forward Error Correction) decoder 10. The FEC decoder 10 performs a process which is the reverse of the process of the FEC encoder 5 in the transmitting modem. The FEC decoder 10 recovers the original data to be forwarded, as conveyed by the data source 4 to the FEC encoder 5 of the transmitting modem. The FEC decoder 10 contains means for analyzing the encoded data, and if it finds that the data has been corrupted, for example, when passing through the underwater medium, it uses the additional bits added by the FEC encoder 5 to correct errors and recover the original data The FEC decoder 10, similar to the FEC encoder 5, is also conventional in its structure, and is capable of recovering errors only to a certain extent.
When discussing binary systems, it is common to refer to bits, as two signal levels are possible, e.g., ±A. In OFDM, which applies the M-ary technique, there exist more than two signal possibilities, and it is common to refer to each possible transmitted signal as a "symbol".
The symbol duration is defined as the sum of the essential duration T plus the guard time ΔT. First, the essential duration T of the symbol and the bandwidth B of one modulated carrier of the transmitted signal has to be chosen in order to accomplish frequency nonselective (flat) and slow fading. The two requirements for achieving a flat and slow fading are:
B<<1/T.sub.d ; and (1)
T<<1/Δf (2)
wherein B is the bandwidth of the transmitted signal, T d denotes the delay time of the channel, T is the duration of each transmitted symbol, and Δf denotes the Doppler spread.
Assuming that T=1/B, the following conditions should be met:
T.sub.d <<T<<1/Δf (3)
If it can be assumed that T d .sbsb.max =2 msec and 1/Δf max =100 msec, the selected symbol duration T should be in the range of:
2 msec<<T<<100 msec (4)
If a symbol duration of T=10÷20 ms, which is within this range, is used and fulfills this requirement of equation, then this means that the bandwidth of one modulated carrier is B=50 Hz÷100 Hz. It has been found that by using OFDM, it is possible to fulfill requirement (4) and efficiently use a wide spectrum bandwidth (3 kHz, for example). In such a case, the number of carriers N should approximately be:
N=BW·T
wherein BW denotes the total bandwidth available to the whole OFDM signal.
The applicants, have found that for BW=3 kHz, number of carriers=31, and SNR=10 dB, and for a desired BER=10 -3 , a maximal bit rate of 3000 bps can be achieved in accordance with DQPSK modulation, and with, for example (31,16,7) forward error correcting BCH code. According to a preferred embodiment of the invention, which is given herein as an example, 31 carriers are used, although, of course, different numbers of carriers may be applied. Moreover, it was found that if the number of carriers increases, the maximal bit rate also increases. For example, a bit rate of 9600 bps may be obtained for about 100 carriers.
As said, the Doppler effect is a very serious problem in underwater acoustic communications. A frequency shift of as much as 20 Hz is quite normal in underwater communication. In order to overcome such a severe shift, and in order to keep the receiving section of the modem tuned to the frequency of the received signal, two additional unmodulated carriers, referred to hereinafter as "pilots", are transmitted along with the information bearing signal, that, as said, comprises said 31 modulated carriers. The frequency of the first pilot is selected to be slightly below the lowest frequency modulated carrier, and the second pilot above the highest frequency modulated carrier.
A more detailed block diagram of the OFDM modulator 6 of the transmitting section 2 of the modem, according to this particular preferred embodiment of the invention, is shown in FIG. 2. As use of coherent demodulation is very problematic in underwater applications, due to a very random, rapid, and frequent change in the carrier phase, the modem according to the invention obviates the need for carrier recovery by using differential modulation. More particularly, the data of each of the plurality of carriers of the OFDM is modulated by DQPSK modulation (Differential Quadrature Phase Shift Key Modulation).
As shown in FIG. 2, a serial (original) data is inputted into the FEC encoder 5, which combines with it additional bits for enabling error correction at the receiving modem. From the FEC encoder 5, the data in serial form is conveyed to a serial to parallel device 12, essentially a shift register, which divides each section of 62 bits of serial data (hereinafter, each such 62-bit section will also be referred to as a "word") into 31 two-bit symbols of data to be processed in parallel. It should be noted here that, in order to improve reliability, and to provide better error correction, the allocation of the bits from a word to symbols is not sequential, but is performed by taking one bit form the first half of a 62-bit word, and a second bit from the second half of the same word. A vector of one 62-bits word, its bits allocation to 31 symbols, and the symbols allocation to separate carriers of the OFDM modulator, is shown below:
Vector of input bits assigned to one 62-bit word:
______________________________________b.sub.1 b.sub.2 . . . b.sub.30 b.sub.31 b.sub.32 . . . b.sub.60 b.sub.61 b.sub.62______________________________________
Bits allocation to symbols and carriers in the modulator:
______________________________________carriernumber 1 2 . . . 30 31______________________________________bits b.sub.1 b.sub.2 b.sub.30 b.sub.31bits b.sub.2 b.sub.33 b.sub.61 b.sub.62symbols [b.sub.1,b.sub.32 ] [b.sub.2,b.sub.33 ] [b.sub.30,b.sub.61 ] [b.sub.31,b.sub.62 ]______________________________________
Then, all of said 31 symbols of a same data word are conveyed to 31 differential encoders, which perform the following operation: ##EQU1## where n denotes the carrier number (n=1, 2, 3, 4 . . . N), L=4 are the four possible symbols {0, 1, 2, 3} (assuming each symbol comprises two bits) as defined and shown in the constellation map of FIG. 3. A k .sup.(n) are symbols originated in data source 4, encoded by FEC encoder 5, and separated by the serial to parallel device 12, and k denotes the symbol running index. The structure of each one of the 31 differential encoders is schematically shown in FIG. 4. Block 16 indicates a 1-bit adder, and 117 indicates a delay of T seconds, wherein T is the duration of each symbol.
From the said 31 differential encoders 15, encoded symbols B k are conveyed in 31 parallel lines 22 to a 31-carrier quadrature OFDM modulator unit 21. The structure of the quadrature OFDM modulator is shown in FIG. 5. Data splitter 20 maneuvers the data from each line 22 to a corresponding orthogonal modulator 23. Each modulator comprises two multipliers 25 and 25', the first multiplier 25 multiplying the data by a cosine sub-carrier, and the second, multiplier 25', multiplying it by an orthogonal, sine sub-carrier. Adder 26 adds the result from said two multipliers. A similar modulating process is performed in each one of the other 30 modulators. The results from all 31 modulators are first combined by summing means 27, then combined by adder 29 with two additional sub-carriers (pilots), cosω.sup.(0) t and cosω.sup.(N+1) t, and finally provided to a hydrophone 28, which transmits the combined signal into the water. If the signal to the hydrophone 28 is not in the required transmitting frequency, a frequency shift to the required transmitting frequency can be made by any conventional means, before conveying the signal to the hydrophone for transmission. The purpose of the transmission of said two sub-carriers cosω.sup.(0) t and cosω.sup.(N+1) t is to help to overcome the frequency shift due to Doppler effects in water, as will become apparent as the description proceeds. Furthermore, it should be noted that, for synchronization purposes at the receiving modem, a guard interval is used. The duration of the guard interval may vary. However, it should preferably be at least in the order of about 10% of the symbol duration T.
An example of a band spectrum of a modem according to one embodiment of the invention is shown in FIG. 13. As shown, the OFDM transmission is carried out by 31 modulated carriers cosω.sup.(1) t-cosω.sup.(31) t, and two unmodulated carriers (pilots) cosω.sup.(0) t and cosω.sup.(32) t. The frequencies assignments for each one of said carriers according to this example are as follows:
__________________________________________________________________________cosω.sup.(0) t = 200 Hz cosω.sup.(9) t = 1200 Hz cosω.sup.(18) t = 2100 Hz cosω.sup.(27) t = 3000 Hzcosω.sup.(1) t = 400 Hz cosω.sup.(10) t = 1300 Hz cosω.sup.(19) t = 2200 Hz cosω.sup.(28) t = 3100 Hzcosω.sup.(2) t = 500 Hz cosω.sup.(11) t = 1400 Hz cosω.sup.(20) t = 2300 Hz cosω.sup.(29) t = 3200 Hzcosω.sup.(3) t = 600 Hz cosω.sup.(12) t = 1500 Hz cosω.sup.(21) t = 2400 Hz cosω.sup.(30) t = 3300 Hzcosω.sup.(4) t = 700 Hz cosω.sup.(13) t = 1600 Hz cosω.sup.(22) t = 2500 Hz cosω.sup.(31) t = 3400 Hzcosω.sup.(5) t = 800 Hz cosω.sup.(14) t = 1700 Hz cosω.sup.(23) t = 2600 Hz cosω.sup.(32) t = 3600 Hzcosω.sup.(6) t = 900 Hz cosω.sup.(15) t = 1800 Hz cosω.sup.(24) t = 2700 Hzcosω.sup.(7) t = 1000 Hz cosω.sup.(16) t = 1900 Hz cosω.sup.(25) t = 2800 Hzcosω.sup.(8) t = 1100 Hz cosω.sup.(17) t = 2000 Hz cosω.sup.(26) t = 2900 Hz__________________________________________________________________________
The hydrophone, according to a preferred embodiment of the invention, is a multidirectional hydrophone which can transmit or receive essentially equally to or from all directions. It should be noted here that the use of a multidirectional hydrophone, preferably in accordance with OFDM transmission, has been found to significantly improve the reliability of the transmission, and has been found to best overcome various disturbances in the water, such as noise, multipath, and fading. Moreover, such use has been shown to allow an effective, reliable transmission, even when no line of sight exists between the transmitting and the receiving modems. This is indeed surprising since the prior art emphasizes the use of directional hydrophones in underwater communication.
A more detailed schematic block diagram of the receiving section 3 of the modem is shown in FIG. 6. The RF circuit 8 of the receiving section comprises a preamplifier 40, a local oscillator 42 and mixer 41, a band pass filter 43, and an analog to digital converter 44. Data which is received in the hydrophone is first transferred to a preamplifier 40, which amplifies the signal. From the preamplifier, an amplified signal is passed on to a mixer 41. As mentioned hereinbefore, the signal to the mixer spans a bandwidth of 3.5 kHz according to the example given above, and is positioned, for example, between 40.2 kHz and 43.6 kHz. The mixer 41 also receives a frequency of 40 kHz, for example, from the local oscillator, converting down the bandwidth of the signal to span frequencies of between 200 Hz-3600 Hz. Then the signal from the mixer 41 is conveyed to low pass filter 43 and then to an analog to digital (A/D) converter 44, which samples the signal and converts it into a digital representation.
The signal, as said, in digital representation, is then provided into the OFDM demodulator 9. The OFDM demodulator 9 comprises a DFT (Discrete Fourier Transformer) 45, a symbol synchronizer 46, a frequency adjust circuit 47, a decision device and differential decoder 48, and a parallel to serial device 49. It should be noted here that the OFDM demodulator 9 is preferably implemented, according to the invention, by one DSP (Digital Signal Processing) circuit, generally available in one integrated chip. However, it may be also implemented by other means well known to those skilled in the art, for example, by a powerful microprocessor. The signal form the A/D converter 44, as said, in digital form, is conveyed in parallel to the DFT 45, to the symbol synchronizer 46, and to the frequency adjust circuit 47. The symbol synchronizer provides to both the DFT 45 and to the decision device and differential decoder 48 a clock indicating the beginning and the end of a received symbol. The frequency adjust circuit 47 inspects the two sub-carriers that are combined with the transmitted signal, for detecting frequency shift, generally due to Doppler effects on the signal propagated in water. The frequency adjust circuit 47 continuously updates the decision device and differential decoder 48 of any frequency shift. The decision device and differential decoder 48, after detecting 31 symbols simultaneously, provides 62 bits representing the symbols in parallel to the parallel to serial device 49, which separates the symbols into bits, which are then combined into two words, and outputted to the FEC decoder 10.
FIG. 7 shows the structure of the DFT 45 in greater detail. The received signal, after being sampled by the A/D 44, and converted into a digital representation, is conveyed to the DFT on line 50, which is then split into sixty-two parallel lines 51, each one of said parallel lines 51 leading to a corresponding one of sixty-two multipliers 53. The said sixty-two multipliers are divided into thirty-one orthogonal pairs, one multiplier in each pair is provided with a sin(ω.sup.(n) t+θ x ), and a second one with a cos(ω.sup.(n) t+θ x ), wherein n [n=1, 2, 3, . . . 31] indicates the symbol number in a 31-symbol word, and θ x indicates a phase which is not phase-synchronized with sine or cosine entries to other multipliers 53 of other pairs. The output from each one of said sixty-two multipliers is then integrated by a corresponding one of sixty-two integrators 54, each of which, as indicated, performs the integration ##EQU2## during a period T of a complete symbol, a period which is indicated to the DFT 45 by a clock provided from the symbol synchronizer 46. The two outputs from any pair of integrators produce a complex vector Q k .sup.(n), wherein n (n=1, 2, 3, . . . 31=N) indicates the symbol location in the word, and k indicates the symbol index. A vector Q k .sup.(1→N), representing all said 31 vectors, is then conveyed into the decision device and differential decoder 48.
The decision algorithm of the decision device and differential decoder 48 is illustrated in FIGS. 8a, 8b, and 9. If the DFT output for carrier number n and symbols k-1 and k are vectors Q k-1 .sup.(n) and Q k .sup.(n) respectively, and Δφ k .sup.(n) denotes the phase difference between Q k .sup.(n) and Q k-1 .sup.(n), as shown in FIGS. 8a and 8b, the values of sinΔφ k .sup.(n) and cosΔφ k .sup.(n) are computed to determine a point (sinΔφ k .sup.(n), cosΔφ k .sup.(n)) on the decision plane diagram of FIG. 9, where the decision regions are indicated.
The symbol synchronizer 46 performs a symbol synchronization (often also called "timing recovery"), the purpose of which is to recover a clock at the symbol rate (or a multiple thereof) from the input to the DFT 45 at line 50, representing in digital form the input modulated signal. This clock, as hereinbefore noted, determines the boundaries of integration of the DFT 45, and is also provided to the decision device and differential decoder 48 for determining the symbol timing boundaries. FIG. 10 illustrates the structure of the symbol synchronizer 46, and FIG. 11 is a corresponding timing diagram. A received signal x(t) arriving at line 50 is inputted to the symbol synchronizer 46. Signal x(t) is in fact S T (t) corrupted by noise and distorted by the channel. It contains a modulated symbol of duration T+ΔT. The synchronizer 46 comprises a summing component 56 having two inputs, one input is provided with x(t), and a second input is provided with x(t) delayed by the delay block 52 by a period of T (T is the essential part of the symbol). The output from the summing component 56 is provided by line 58 to the average power block 57, which measures the average power of the signal provided to it, in purpose to find a timing of minimum power. Such search for minimum-power timing is carried out by varying the beginning of the integration at block 60, and providing the result of the integration into the minimum search block 61. The output of said block 61 is fed back to adjust the beginning of the integration at block 60. FIG. 11 is a timing diagram illustrating the operation of the symbol synchronizer 46. Assuming that the signal x(t) comprises a digitally modulated signal of symbols of duration T+ΔT, the beginning of the symbols occur at t k , t k+1 , t k+2 , etc., and the symbols include the guarding intervals ΔT, as shown. If the processing operation of the symbol synchronizer 46 starts at a random time λ k =t k +Δt, wherein t k is the correct synchronizing time and Δt indicates the deviation from said correct synchronizing time, then, for an ideal case, with no noise or disturbances, P 1 is zero for 0<Δt<ΔT. For the real case, however, the symbol synchronizer 46 seeks the case in which P 1 is minimal. In FIG. 11, λ k+1 , λ k+2 , . . . indicate the timing of the beginning of processing of the DFT receiving Δt for synchronization, and δ k , δ k+1 , δ k+2 . . . indicate the timing of the end of processing of the DSP. As is clear to those skilled in the art, after a few symbols, the value of Δt converge to such value that guarantees minimum of P 1 .
FIG. 12 shows that a minimum power occurs during the guard periods ΔT. P 1 reaches its minimal power value if and only if the system is in full symbol synchronization. As said, the symbol synchronizer 46 finds the (Δt), for which the power is minimal.
The OFDM signal, when transmitted through the underwater medium, may suffer a frequency shift ΔF. A first and general reason for a frequency shift lies in the frequency accuracy of the transmitter and receiver local oscillators. For example, if the accuracy of the local oscillators is 100 ppm each, then for an RF frequency of 50 kHz, which is the frequency range used by the modem for communication, a frequency shift of -5 Hz≦ΔF≦5 Hz may be expected. Such a frequency shift is generally constant and does not change with time, nor does it depend on the medium of signal propagation. The second reason for the carrier shift, more severe in underwater communication, results from the Doppler effect, particularly due to the movement of either the receiving or the transmitting modem, or both, or due to the change in density of the water. For example, for a relative velocity of 0.5 m/sec between the receiving or the transmitting modem, a Doppler frequency shift of about 16 Hz is expected.
As mentioned hereinbefore, two pure carriers (pilots), one below the lowest modulated carrier, and one above the highest modulated carrier, are transmitted from the transmitting modem, along with the other n modulated carriers. The frequencies of these pilots are tracked at the frequency adjust circuit 47 by two Phase Locked Loop (PLL) devices, each of which is tuned to one pilot frequency. When a shift is detected in said frequencies, an indicative frequency shift is provided to each plurality of sin eω.sup.(n) and cosineω.sup.(n) components at the DFT 45. Such shift in frequency therefore realigns the bandwidth of the receiving modem for any frequency shift which may occur to the signal due to Doppler effect or due to propagation effects in the water.
As seen, the invention provides a modem which can reliably transfer data at a high rate through water. The use of OFDM modulation and a multidirectional hydrophone significantly improve the capability and quality of the data transfer, and provide a significant improvement to the efficient range of transmission. Furthermore, the modem according to the invention is provided with means for efficiently overcoming severe frequency shifts of the transmitted signal due to Doppler effects. It should be noted here that the use of OFDM is preferable for transferring data through water according to a preferred embodiment of the invention, as this modulation method enables simultaneous transmission of data over a plurality of narrow bandwidth channels, wherein each channel is minimally prone to amplitude and phase distortions due to its narrow bandwidth. However, there are other modulation methods, other than OFDM that can also be used, which also enable the simultaneous transfer of data over a plurality of narrow band channels. The use of those other modulation methods using a plurality of parallel narrow band channels for the high rate transfer of data through water is also within the scope of the invention.
The underwater modem of the invention can also be used for sound communication. In order to reliably communicate sound through water by digital techniques, a minimum bit rate of 2400 bits per second is required. As mentioned, this data rate is well within the capability of the modem of the invention.
FIG. 14 illustrates in block diagram form the structure of a sound modem according to a preferred embodiment of the invention. FIG. 15 illustrates in block diagram form the structure of the transmitting section of a sound modem according to a preferred embodiment of the invention. The sound modem, comprises in the transmitting section 2, a microphone 77 for receiving a sound, converting it to an electric signal, and conveying it into a voice encoder 144. The voice encoder 144 converts the elctrical signal representing the sound into a bit stream of data, which is in turn conveyed into the FEC encoder 5, for encoding the bit stream of data for error correction purposes as before. Then ,the encoded bit stream of data is transmitted by the transmitting section 2 in the same manner as described hereinbefore for the digital data modem. The transmitted data is received by a receiving unit 3, and detected as hereinabove described for the digital data modem. Therefore, a bit stream of data, presumably identical to the bit stream that the voice encoder 144 conveyed to the FEC encoder 5 in the transmitting section 2, is conveyed from the FEC decoder 10 of the receiving unit 3 into a voice decoder 11. The voice decoder 11 converts the bit stream into an analog sound signal, which is in turn sent to a speaker 78. Speaker 78 converts the electric sound signal to voice. Speaker 78 may be, for example, earphones of a diver, and the sound may be a voice of a diver to be communicated to another diver.
For the voice encoder 144 of the transmitting section 2 and the voice decoder of the receiving section 3, the same component known in the art as a "Vocoder" may be used. This component generally has two modes of operation: a first mode in which it operates as a voice decoder, and a second mode in which it operates as a voice encoder. For example, a vocoder of the type AC 4802AE2-C by Audiocodes can be used both in the receiving and the transmitting sections.
While some embodiments of the invention have been described by way of illustration, it will be apparent that the invention can be carried out in practice with many modifications, variations and adaptations, and with the use of numerous equivalents or alternative solutions that are within the scope of persons skilled in the art, without departing from the spirit of the invention or exceeding the scope of the claims. For example, the number of carriers, as selected above to be, for example, 31, can vary and is a function of the transfer rate and error correcting consideration. In order to achieve a higher data transfer rate, it is preferably to use a greater number of carriers. Of course, as the number of carriers increases, a more complicated FEC has to be used. According to the invention, it can be assumed that a bit rate of up to about 100 kbs is practically achievable. Furthermore, although the use of a multidirectional hydrophone is preferable, this is not a limitation, as the modem can also function with a directional hydrophone. The bandwidth, and the frequencies of the plurality of carriers, are also selective and may depend on design considerations. The use of a DSP, as well, is optional, and different alternatives may be used. | 4y
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BACKGROUND OF THE INVENTION
A common conduit fitting utilizes a male adapter having a conical nose which engages a flared or conical surface defined upon a conduit, or fitting component associated with the conduit, wherein the conical surfaces of the fitting parts engage in metal-to-metal relationship. A nut, or similar axial force producing device, is used to produce engagement of the conical fitting surfaces.
Unless the conical fitting surfaces are substantially concentric and accurately formed free of scratches and dents, leakage may result even though the nut is fully tightened. Also metal "creep" and cold flow over a duration of time may result in dimensional changes permitting leakage, and in the past, problems have been encountered in fluid systems using conical adapter coupling components permitting leakage, and where such fittings are not located as to be readily observable, the failure of the fitting can produce serious problems, and render the associated fluid conduit inoperable.
The dependability of fittings utilizing conical nose surfaces, such as of the 37° or 45° type, can be improved by utilizing a metal seal intermediate the axially aligned conical surfaces of the fitting parts. The engagement of the fitting conical surfaces with a metal seal permits the seal to deform, if necessary, to accommodate itself to machining inaccuracies and nonconcentric relationships, but such a metal seal is still subject to cold flow displacement over extended durations, and may leak if the nose is scratched or dented. In systems wherein long life dependability is important, metal seals have been utilized between the conical surfaces of fittings, particularly in refrigeration circuits, but cold flow problems have not achieved the absolute 100% dependability desired.
It is an object of the invention to provide a seal for use with conduit fittings employing axially aligned conical surfaces wherein the seal permits metal-to-metal engagement, and additionally, provides elastomeric sealing to maintain the integrity of the seal even in the presence of metal flow.
An additional object of the invention is to provide a seal for use with conical face fittings wherein the seal utilizes both metal-to-metal and elastomeric sealing characteristics, and the seal is economical to manufacture and readily installable.
In the practice of the invention, the seal used with the fitting is mounted upon the male adapter adjacent the conical nose surface thereof, and the seal is of an annular configuration formed of steel, aluminum, brass, etc. The seal body includes a cylindrical portion received upon a cylindrical adapter surface, and a cone depending therefrom which overlies a portion of the adapter conical surface.
The inner end of the seal cone has an elastomeric tip or ring bonded thereto, and the radial dimension of the cone is such that both the metal and elastomeric sections thereof will be located between the conical surfaces of both halves or portions of the assembled fitting. Thus, both the metal and elastomer portions of the seal will be under compression upon the fitting being fully assembled.
The metal conical portion of the seal permits metal-to-metal sealing, while the elastomeric portion provides the efficient sealing characteristics of an elastomer seal. The seal accommodates itself to surface irregularities present in the fitting conical surfaces, and dimensional changes that may occur due to metal flow will be accommodated by the self-expanding characteristics of the elastomer to maintain the integrity of the fitting over long durations.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and advantages of the ivention will be appreciated from the following description and accompanying drawings wherein:
FIG. 1 is an elevational view of a fitting utilizing the seal of the invention, the upper half thereof being shown in diametrical section, and the fitting being fully assembled,
FIG. 2 is an elevational view of the seal, per se,
FIG. 3 is an end elevational view of the seal as taken from the left of FIG. 2, and
FIG. 4 is an enlarged, elevational, sectional view as taken along Section IV--IV of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a conventional fluid conduit fitting is illustrated consisting of the male adapter part 10, the conduit, or conduit associated part 12, and a compression nut 14. The adapter fitting part 10 comprises a metal body affixed at its right end to a conduit, hose, tank, reservoir or the like not shown, and the adapter includes an axial bore 16, a wrench engaging portion 18 having wrench flats 20 defined thereon, and external threads 22 for cooperation with the compression nut 14.
The adapter includes a cylindrical surface 24 adjacent to and intersecting the conical nose 26, and the conical nose is preferably of the conventional 37° configuration and intersects the radial adapter end surface 28. The adapter is conventional in all respects.
The other primary part of the fitting includes the conduit 12 which may be attached to the hose or rigid conduit, or may comprise a metal conduit, itself. The end of the part 12 is provided with an enlarged head 30 defining a conical surface 32 which is of such radial positioning as to be in axial alignment with the adapter conical surface 26 when the fitting parts are axially aligned. The head 30, in some installations, may consist of the well known flared end of a conduit, and the head includes a radial surface 34 engagable by the compression nut 14.
The compression nut 14 includes wrench flats 36 and internal threads 38 for cooperation with the adapter threads 22, and an inwardly extending flange 40 is axially aligned with the head surface 34 for engagement therewith for imposing an axial force upon the fitting part 12.
The seal 42 in accord with the invention is of an annular form and primarily formed of metal, such as brass, aluminum, steel, etc. and includes a cylindrical portion 44 having an inner surface 46 only slightly larger than the adapter surface 24 for engagement therewith, and the outer surface 48 of the seal comprises the maximum circumference thereof.
The cone portion 50 of the seal depends from the portion 44 and comprises substantially parallel inner side 52 and outer side 54 defining a conical portion oriented at approximately 37° to the cylindrical portion 44. The thickness of the cone 50 is defined by the sides 52 and 54, and the thickness of the cone is substantially the same as that of the cylindrical portion 44.
The outer end 56 of the cone 50 has an annular elastomeric ring 58 bonded thereto, and the elastomeric ring seal includes an inner end, FIG. 4, bonded to the cone 56, and an outer end 60 which may be of a radiused configuration. The elastomeric ring includes an inner surface 62 and outer surface 64 which are spaced apart a distance at least equal to the spacing of the cone surfaces 52 and 54, and preferably, the spacing between the elastomer sides 62 and 64 is slightly greater than that of the cone sides.
Bonding of the elastomer seal 58 to the cone 50 may be augmented by forming irregularities, holes, or the like in the outer end of the metal of the cone, and as will be appreciated from FIG. 1, the radial dimension of the cone 50 is such that the elastomer 58 will be axially aligned between the fitting surfaces 26 and 32 when the seal is assembled to the fitting parts as shown in FIG. 1.
In use, the seal 58 is located upon the adapter 10 as appreciated in FIG. 1, i.e. the seal inner cylindrical surface 46 being placed upon the adapter surface 24, and the cone surface 52 engages the adapter surface 26. The fitting part 12 is coaxially aligned with the adapter 10, and the nut 14 is threaded upon the adapter thread 22. The nut is tightened drawing the surfaces 26 and 32 toward each other compressing the cone 50 therebetween to produce an effective sealing relationship.
The compression produced on the cone 50 compresses the elastomer 58, and accordingly, an effective elastomeric sealed relationship is produced between the fitting surfaces 26 and 32, as well as a metal-to-metal seal. The preferred slightly greater thickness of the elastomer 58 causes the compression of the elastomer prior to compression of the seal cone portion 50, and slight extrusion of the elastomer may occur which readily takes place inwardly in that the elastomer ring 58 is unconfined in this direction.
Upon fully tightening the nut 14, the seal 42, due to its relatively thin configuration will conform itself to any irregularities in the surfaces 26 and 32, such as scratches or dents, producing an effective seal. Thus, high pressure sealing is produced, and the dependability of the seal is improved over those arrangements wherein an elastomeric seal is not used with a "flare" fitting. The presence of the elastomer 58 intermediate the conical surfaces will maintain the integrity of the fitting and prevent leakage even if the metal sealing fails. The seal 58 prevents the pressurized medium from engaging the threads, and it will be appreciated that the simplicity of the invention substantially improves the efficiency and dependability of this type of fitting.
It is appreciated that various modifications to the inventive concepts may be apparent to those skilled in the art without departing from the spirit and scope of the invention. | 4y
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FIELD
The present disclosure relates to hybrid vehicle exhaust control strategies.
BACKGROUND
This section provides background information related to the present disclosure which is not necessarily prior art.
Hybrid vehicles may include an internal combustion engine and a hybrid power assembly. Hybrid vehicles may be operated during extended periods of time in a hybrid mode using only the hybrid power assembly. During operation in the hybrid mode, the engine may be off. When the vehicle is switched to an engine operating mode, exhaust gas exiting the engine passes through an exhaust aftertreatment system. Components of the exhaust aftertreatment system may require minimum operating temperatures for proper operation. The engine may be powered on during the hybrid mode, even when not needed for additional power output, in order to maintain the exhaust aftertreatment system at a desired operating temperature. This results in reduced fuel economy.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
An emissions control method may include operating a hybrid vehicle in a first mode during which a combustion engine is off and an electric motor powers propulsion of the vehicle. An electrically heated catalyst (EHC) may be energized during the first mode. The method may further include determining an operating temperature of an additional catalyst in communication with exhaust gas from the combustion engine and operating the vehicle in a second mode after the first mode during which the engine powers propulsion of the vehicle. The engine may operate in a catalyst combustion mode during the second mode when the operating temperature is below a first predetermined limit. The catalyst combustion mode may include operating the engine at an air-fuel ratio of less than stoichiometry and injecting air into exhaust gas from the engine at a location before the additional catalyst to create an exothermic reaction within the additional catalyst.
A control module may include a hybrid vehicle mode control module, an EHC control module in communication with the hybrid mode control module and an electrically heated catalyst (EHC), a catalyst temperature evaluation module, and an engine combustion control module in communication with the hybrid vehicle mode control module and the catalyst temperature evaluation module. The hybrid vehicle mode control module may control vehicle operation between first and second modes. The first mode may include a combustion engine being off and an electric motor powering propulsion of the vehicle and the second mode may include the engine being operated and powering propulsion of the vehicle. The EHC control module may energize the EHC during the first mode. The catalyst temperature evaluation module may determine an operating temperature of the additional catalyst. The engine combustion control module may operate the engine in a catalyst combustion mode during the second mode when the operating temperature is below a first predetermined limit. The catalyst combustion mode may include operating the engine at an air-fuel ratio of less than stoichiometry and injecting air into exhaust gas from the engine at a location before the additional catalyst to create an exothermic reaction within the additional catalyst.
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
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.
FIG. 1 is a schematic illustration of a vehicle according to the present disclosure;
FIG. 2 is a schematic illustration of a control module of the vehicle of FIG. 1 ; and
FIG. 3 is an illustration of control logic for operation of the vehicle of FIG. 1 .
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the term “module” refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality.
Referring to FIG. 1 , an exemplary vehicle 10 may include an engine assembly 12 , a hybrid power assembly 14 , a transmission 16 , a driveline assembly 18 , an exhaust assembly 20 , and a control module 22 . The engine assembly 12 may include an internal combustion engine 24 having a crankshaft 26 rotationally driven by pistons 28 , an intake manifold 30 providing an air flow to the engine 24 and exhaust manifolds 32 , 34 receiving exhaust gas exiting the engine 24 .
The hybrid power assembly 14 may include an electric motor 36 and a rechargeable battery 38 . The electric motor 36 and the rechargeable battery 38 may form a drive mechanism for the hybrid power assembly 14 . The motor 36 may be in electrical communication with the battery 38 to convert power from the battery 38 to mechanical power. The motor 36 may additionally be powered by the engine 24 and operated as a generator to provide power to charge the battery 38 . The hybrid power assembly 14 may be incorporated into and engaged with the transmission 16 . Alternatively, the hybrid power assembly 14 may be external to the transmission 16 .
The driveline assembly 18 may include an output shaft 40 and a drive axle 42 . The motor 36 may be coupled to the output shaft 40 via the transmission 16 to power rotation of the drive axle 42 . The engine 24 may be coupled to the transmission 16 via a coupling device 44 . The coupling device 44 may include a friction clutch or a torque converter. The transmission 16 may use the power from the engine 24 and/or the motor 36 to drive the output shaft 40 and power rotation of the drive axle 42 .
The vehicle 10 may be operable in a variety of modes depending on power requirements. In a first operating mode, the engine 24 may be decoupled from the transmission 16 and the electric motor 36 may drive the output shaft 40 . In a second operating mode, the crankshaft 26 may drive the output shaft 40 through combustion within the engine 24 . In the second operating mode, the engine 24 may drive the output shaft 40 by itself or in combination with the electric motor 36 . In a third operating mode, the engine 24 may drive the electric motor 36 to charge the battery 38 and may drive the output shaft 40 .
The exhaust assembly 20 may include an air injection assembly 46 , an exhaust conduit 48 , an electrically heated catalyst (EHC) 50 , an additional catalyst 52 , first and second oxygen sensors 54 , 56 and first and second temperature sensors 58 , 60 . The air injection assembly 46 may include an air pump 62 and an air injection conduit 63 in fluid communication with the air pump 62 and the exhaust manifolds 32 , 34 . The exhaust conduit 48 may provide fluid communication between the exhaust manifolds 32 , 34 and the EHC 50 and the additional catalyst 52 . The EHC 50 may be located upstream of the additional catalyst 52 . The EHC 50 may be powered by the battery 38 . The additional catalyst 52 may include a three-way catalyst.
The first and second oxygen sensors 54 , 56 may be in communication with an exhaust gas flow upstream of the EHC 50 . More specifically, the first oxygen sensor 54 may be located in the exhaust conduit 48 proximate the outlet of the exhaust manifold 32 and the second oxygen sensor 56 may be located in the exhaust conduit 48 proximate the outlet of the exhaust manifold 34 . The first and second oxygen sensors 54 , 56 may be in communication with the control module 22 and may provide signals thereto indicative of the oxygen concentration in the exhaust gas exiting the engine 24 .
The first temperature sensor 58 may be coupled to the EHC 50 and may be in communication with the control module 22 , providing a signal to the control module 22 indicative of the temperature of the EHC 50 . The second temperature sensor 60 may be coupled to the additional catalyst 52 and may be in communication with the control module 22 . The second temperature sensor 60 may provide a signal to the control module 22 indicative of the temperature of the additional catalyst 52 .
The control module 22 may additionally be in communication with the air pump 62 and the hybrid power assembly 14 . The control module 22 may include a hybrid vehicle mode control module 64 , an EHC control module 66 , an EHC temperature evaluation module 68 , an engine combustion control module 70 , an engine exhaust oxygen concentration evaluation module 72 , and a catalyst temperature evaluation module 74 . The hybrid vehicle mode control module 64 may control operation of the vehicle in the first, second, and third operating modes discussed above, as well as switching between the operating modes.
The hybrid vehicle mode control module 64 may be in communication with the EHC control module 66 . The EHC control module 66 may be in communication with the EHC temperature evaluation module 68 and may receive a signal therefrom indicating power requirements for operating the EHC at a desired temperature. The EHC temperature evaluation module 68 may receive signals from the first temperature sensor 58 indicative of the EHC operating temperature.
The hybrid vehicle mode control module 64 may be in communication with the engine combustion control module 70 and may command engine operation when needed. The engine combustion control module 70 may be in communication with the engine exhaust oxygen concentration evaluation module 72 and the catalyst temperature evaluation module 74 . The engine exhaust oxygen concentration evaluation module 72 may be in communication with the first and second oxygen sensors 54 , 56 and may receive signals therefrom indicative of the oxygen concentration in the exhaust gas. The engine exhaust oxygen concentration evaluation module 72 may provide a signal to the engine combustion control module 70 indicative of the oxygen concentration in the exhaust gas.
The catalyst temperature evaluation module 74 may be in communication with the second temperature sensor 60 and may receive a signal therefrom indicative of the temperature of the catalyst 52 . The catalyst temperature evaluation module 74 may provide a signal to the engine combustion control module 70 indicative of the temperature of the catalyst 52 . The engine combustion control module 70 may control combustion parameters and operation of the air injection assembly 46 based on the inputs from the engine exhaust oxygen concentration evaluation module 72 and the catalyst temperature evaluation module 74 .
Control logic 110 for operation of the vehicle 10 is illustrated in FIG. 3 . The hybrid vehicle mode control module 64 may initially operate the vehicle 10 in the first operating mode at start-up. Control logic 110 may begin at block 112 where the EHC temperature evaluation module 68 determines the temperature of EHC 50 during vehicle operation in the first operating mode. Control logic 110 then proceeds to block 114 where the EHC temperature is evaluated. If the EHC temperature is above a predetermined limit (T EHC - Desired ), control logic 110 proceeds to block 116 where EHC temperature is maintained by the EHC control module 66 . The predetermined limit (T EHC - Desired ) may include a temperature where the EHC 50 maintains nominal hydrocarbon (HC) treatment efficiency, such as two hundred degrees Celsius. The temperature of the EHC 50 may be maintained by controlling the powering of the EHC 50 by the battery 38 . Control logic 110 may then proceed to block 120 .
If the EHC temperature is below the predetermined limit (T EHC - Desired ), control logic 110 proceeds to block 118 where EHC temperature is increased by the EHC control module 66 . The temperature of the EHC 50 may be increased by controlling the powering of the EHC 50 by the battery 38 . For example, when the EHC is operating at a temperature below the predetermined limit (T EHC - Desired ), the battery 38 may provide fully power to the EHC 50 . The EHC 50 may remain powered (or energized) throughout operation in the first operating mode. Control logic 110 may then proceed to block 120 , where the vehicle operating mode is evaluated by the hybrid vehicle mode control module 64 . More specifically, control logic 110 determines whether engine operation is required. If engine operation is not required, control logic 110 may terminate and the vehicle may continue operation in the first operating mode. Otherwise, control logic 110 may proceed to block 122 where the temperature of the catalyst 52 is determined by the catalyst temperature evaluation module 74 . The temperature of the catalyst 52 may be determined before operation of the vehicle in the second operating mode.
The catalyst temperature evaluation module 74 may then evaluate the temperature of the catalyst 52 at block 124 . If the catalyst temperature is above a predetermined limit (T CAT - Desired ), control logic 110 may proceed to block 126 where operation of the vehicle in the second operating mode is initiated by the engine combustion control module 70 using a normal combustion strategy. The predetermined temperature limit (T CAT - Desired ) may correspond to a temperature at which the catalyst 52 is fully functional, such as at or above four hundred degrees Celsius. The normal combustion strategy may include closed loop operation of the engine using a generally stoichiometric air-fuel ratio (an air-fuel ratio of between 14.2-to-1 and 14.8-to-1). Control logic 110 may then terminate.
If the catalyst temperature is below the predetermined limit (T CAT - Desired ), control logic 110 may proceed to block 128 where operation of the vehicle 10 in the second operating mode is initiated using a catalyst combustion strategy. The catalyst combustion strategy may include operating the engine using an air-fuel ratio that is less than stoichiometric (rich operation) to produce higher carbon monoxide (CO) and hydrocarbon (HC) content in the exhaust gas relative to stoichiometric air-fuel ratio operation. More specifically, the catalyst combustion strategy includes operating the engine at an air-fuel ratio between 8-to-1 and 14.2-to-1. The EHC 50 may be operating at or above the predetermined limit (T EHC - Desired ) before air injection. The catalyst combustion strategy may additionally include the injection of air into the exhaust gas using the air injection assembly 46 . The engine exhaust oxygen concentration evaluation module 72 may monitor the oxygen concentration in the exhaust gas exiting the engine and control the air injection assembly 46 to provide an exhaust gas stream having a desired oxygen concentration.
The introduction of oxygen into the exhaust gas stream may provide increased carbon monoxide (CO) and hydrocarbon (HC) oxidation in the catalyst 52 . The carbon monoxide (CO) and hydrocarbon (HC) oxidation produces an exothermic reaction in the catalyst 52 , raising the temperature of the catalyst. After the catalyst combustion strategy has run for a predetermined time, control logic 110 may proceed to block 130 where the temperature of the catalyst 52 is again evaluated.
If the catalyst temperature is below the predetermined limit (T CAT - Desired ), control logic 110 may proceed to block 132 where engine operation is maintained in the catalyst combustion strategy. Control logic 110 may then return to block 130 where the temperature of the catalyst 52 is again evaluated. If the catalyst temperature is above the predetermined limit (T CAT - Desired ), control logic 110 may proceed to block 126 where the normal combustion strategy is initiated. Control logic 110 may then terminate.
Control logic 110 may loop back to start again at block 112 after termination. More specifically, control logic 110 may wait a predetermined time and restart at block 112 . By way of non-limiting example, the predetermined time may be at least 12.5 milliseconds (ms). Therefore, control logic 110 may run continuously during vehicle operation. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to host based storage subsystem management and in particular to a method and associated apparatus for storage of configuration information, shared among a plurality of attached host systems, on a reserved area of a commonly attached storage subsystem.
2. Description of Related Art
It is common in the art relating to storage subsystems that host system programs are, in part, responsible for administration and management of attached storage subsystems. For example, initial configuration of a storage subsystem to allocate available storage capacity to the storage of data may be performed by such a host program. The host program, for example, interacts with an administrative user to determine the desired configuration of the storage space and then transmits any requisite command sequences to the storage subsystem to effectuate the desired configuration. The configuration thereby become known to the host system as well as the attached storage subsystem.
Further, it is known in the art to permit a plurality of host systems to share access to common storage subsystems. In such clustered environments where a plurality of hosts connect to a common storage subsystem, the plurality of hosts communicate their respective configuration and management operations among one another. When a first host system configures, re-configures, or otherwise administers an attached storage subsystem, other host systems attached to that storage subsystem need to be informed of any changes in the configuration or operation of the storage subsystem.
As taught by prior techniques, host systems attached to a common storage subsystem have used a communication channel such as a local area network (LAN) or other communication channel to exchange such administrative messages. Each host system broadcasts messages on the communication channel to other host system to announce the configuration or other administrative operations performed by the broadcasting system. A number of the host systems (frequently all) maintain a store of the current configuration information related to the present state of the storage subsystem. As messages are received from other host systems, each host system updates its model of the present storage subsystem configuration.
These methods and structure taught by prior techniques create a problem for a host system which is newly attached to a common storage subsystem or which is temporarily disconnected from the other host systems. Such a system must seek to synchronize its model of the present state of the storage subsystem by inquiring of one or more of the other systems as to the present status of the storage subsystem. When so inquiring to synchronize status, a host system must determine whether any received status information is more recent than status already known to the host system.
It is therefore a problem to devise a simple method and associated apparatus to permit a plurality of host systems to maintain synchronization regarding state information pertaining to a commonly attached storage subsystem.
SUMMARY OF THE INVENTION
The present invention solves the above and other problems, thereby advancing the state of the useful arts by providing simple methods and associated apparatus for maintaining status information pertaining to a storage subsystem attached to a plurality of host systems. In particular, the methods of the present invention store configuration information regarding a storage subsystem in a reserved area of the storage subsystem--a host store region (HSR). The configuration information is timestamped when stored in the HSR. The information written therein is written and read by host systems using standard read and write commands directed specifically to the HSR.
More specifically, the storage subsystem has a reserved area distinct from the storage capacity used for persistent storage of host supplied data. A portion of this reserved area is set aside as a scratchpad for use by all attached host systems to communicate configuration information among one another. This feature of the present invention obviates the need for a dedicated communication channel between the host systems used for exchange of configuration and other administrative information. Rather, the present invention uses the existing communication channel between each of the attached host systems and the common storage subsystem.
Where, for example, the storage subsystem is a RAID storage subsystem attached to the host systems by SCSI interfaces (e.g., one or more SCSI parallel busses or SCSI Fibre Channel communication links), the SCSI interface is used by each host system to access the HSR thus obviating the need for another communication channel to synchronize all attached host systems. The HSR is reserved in an area outside the defined storage for all logical units (LUNs) presently defined within the RAID storage subsystem. Preferably, SCSI Read Buffer and Write Buffer commands are used to directly address the reserved area without specification of a LUN. Any time a host system modifies the configuration of the storage subsystem (or otherwise administers its state), an appropriate message is written by the host system to the HSR to indicate the configuration or administrative modification. All host systems periodically poll the HSR to determine the present administrative state and configuration information.
A timestamp value is generated by the host system initiating the administrative changes and the timestamps is appended to the configuration or administrative information written in the HSR. The timestamp value is read with each poll by attached host systems. The timestamp value is then used by the host system to determine if its configuration is more or less recent than the presently stored configuration in the HSR.
It is therefore an object of the present invention to provide methods and associated apparatus for enabling the coordination of administration of a storage subsystem by a plurality of attached host systems.
It is another object of the present invention to provide methods and associated apparatus for enabling the coordination of administration of a storage subsystem by a plurality of attached host systems without the need for a dedicated communication channel between the host systems.
It is still another object of the present invention to provide methods and associated apparatus for enabling the coordination of administration of a storage subsystem by a plurality of attached host systems through use of a shared scratchpad area reserved in the commonly attached storage subsystem.
It is yet another object of the present invention to provide methods and associated apparatus for defining and utilizing a scratchpad area reserved in the storage subsystem to eliminate the need for synchronization of host system storage management application to synchronize their respective configuration models via another communication channel.
The above and other objects, aspects, features, and advantages of the present invention will become apparent from the following description and the attached drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a typical prior system as known in the art in which a plurality of host systems are attached to a common storage subsystem but exchange of management synchronization via another communication link;
FIG. 2 is a block diagram of a system in accordance with the present invention in which the methods of the present invention are operable to enable exchange of management information by attached host systems via a shared, reserved scratchpad area in the storage subsystem;
FIG. 3 is a block diagram describing a typical sequence of exchange of management information among a plurality of attached host systems sharing a scratchpad area reserved in the storage subsystem;
FIGS. 4A and 4B are flowcharts describing the methods of the present invention operable within attached host systems and the storage subsystem to write management information changes to the shared scratchpad area of the storage subsystem; and
FIGS. 5A and 5B are flowcharts describing the methods of the present invention operable within attached host systems and the storage subsystem to periodically poll for management information changes from the shared scratchpad area of the storage subsystem.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
FIG. 1 is a block diagram of a typical system as known in the art in which a plurality of host systems 102 and 104 are commonly attached to a storage subsystem 100. Host systems store data on, and retrieve data from, storage subsystem 100 via paths 108. As is known in the art, paths 108 may be any of several well known interface busses or communication media including, for example, SCSI, Fibre Channel, SSA, etc. Controllers 110 and 112 within storage subsystem 100 process data read and write requests on behalf of attached host systems 102 and 104. Controllers 110 and 112 exchange information with storage devices (e.g., disk drives 116-122) via path 114. Path 114 may also be implemented using any of several well known interfaces, protocols, and communication media. For example, path 114 may be SCSI, Fibre Channel, SSA, EIDE, IPI, etc.
It is known to operate storage management processes on host systems 102 and 104 to manage the configuration and operation of storage subsystem 100. These processes are indicated by the labels "S.M." in each of host systems 102 and 104 (also referred to herein as SM or SM processes). SM performs various management and configuration tasks required for proper operation of storage subsystem 100. For example, where storage subsystem 100 is a disk array subsystem (e.g., a RAID storage subsystem), SM processes may add, delete, or modify definitions of logical units (LUNs) in the array of disk drives 116-122. Other options in the operation of RAID storage subsystem 100 may be configured by SM processes in host systems 102 such as levels of RAID operation for particular LUNs or redundancy configurations for RAID storage controllers 112 and 14.
As is known in the art in performing such configuration and management tasks, SM processes in host systems 102 and 104 exchange information among one another via path 106. When one host system (e.g., 102 or 104) reconfigures storage subsystem 100 to define a new operating parameter or storage configuration, it must notify other host systems of such a change. Messages are exchanged via path 106 among the various host systems to update all host systems attached to storage subsystem 100. Maintaining synchronization of the present operating state of storage subsystem 100 among the attached host systems requires significant processing. If a new host system is added to the cluster attached to the storage subsystem, the newly added system will require updating to synchronize its initial state model of the storage subsystem with the current state actually configured in the system. Similarly, if a host system is temporarily disconnected from the storage subsystem, it's model of the storage subsystem state may require updating when it initially reconnects to the storage subsystem.
Path 106 may be a dedicated communication path used exclusively for such management communication. Alternatively, path 106 may be a communication path used for various interprocess communication purposes including the management communication messaging discussed herein. Where path 106 is a dedicated communication path used exclusively for storage management communication, path 106 adds complexity and associated costs to the system of FIG. 1. Where path 106 is a general purpose communication path used for purposes including storage management communication, use of path 106 for such purposes may utilize valuable bandwidth on the communication path 106.
FIG. 2 is a block diagram of a system operable in accordance with the present invention. A plurality of host systems 202 and 204 are commonly attached to a storage subsystem 200. Host systems store data on, and retrieve data from, storage subsystem 200 via paths 208. As is known in the art, paths 208 may be any of several well known interface busses or communication media including, for example, SCSI, Fibre Channel, SSA, etc. Controllers 210 and 212 within storage subsystem 200 process data read and write requests on behalf of attached host systems 202 and 204. Controllers 210 and 212 exchange information with storage devices (e.g., disk drives 216-222) via path 214. Path 214 may also be implemented using any of several well known interfaces, protocols, and communication media. For example, path 214 may be SCSI, Fibre Channel, SSA, EIDE, IPI, etc.
As above with regard to FIG. 1, SM processes are operable on host systems 202 and 204 to jointly administer the operation and configuration of storage subsystem 200. However, unlike the system depicted in FIG. 1, host systems 202 and 204 of FIG. 2 do not rely upon a general purpose communication path or a dedicated communication path to exchange information regarding the present configuration of the storage subsystem. Rather, host systems 202 and 204 of FIG. 2 store and retrieve information regarding present configuration and state of storage subsystem 200 on the storage devices (216-222) thereof.
Specifically, host systems 202 and 204 store configuration information on host storage region 224 (HSR). When one host system (e.g., 202 or 204) reconfigures storage subsystem 200 to define a new operating parameter or storage configuration, other host systems must note the change. Each host system maintains its own copy of the management and configuration information it believes represents the present configuration of the storage subsystem 200. The host system performing the configuration or other administrative operation sends a specially encoded write command to the storage subsystem along with the new configuration data to be written to the HSR. The information so written to HSR 224 is then available for reading by other SM processes operating on other host systems. SM processes operable on the multiple host systems therefore communicate by use of HSR 224 as a "scratchpad" area. Each system writes to the scratchpad to note changes requested in the configuration or operation of the storage subsystem 200.
The information written to, and read from, HSR 224 and as stored locally within each host system includes a timestamp value indicating the time of creation of the corresponding configuration or operation modifications. Periodically, each of the host systems (e.g., 202 and 204) reads (or polls) the information stored in the HSR 224. In particular, the timestamp value recorded in the HSR 224 is inspected to determine if the stored management information in the HSR 224 is newer than the management and configuration information stored locally within the polling host system. Specifically, each host system compares the timestamp value read from HSR 224 with its locally stored timestamp value. If the management information stored in HSR 224 is newer, as indicated by its timestamp value, the polling host system reads the management information stored in HSR 224 to update its locally stored copy (as well as its locally stored timestamp value). Additional detail of the methods of the present invention are presented below with respect to FIGS. 3-5B.
FIG. 3 is a diagram depicting a typical sequence of events updating management and configuration information for a storage subsystem and the timestamp values associated therewith. In FIG. 3 horizontal lines separate distinct, exemplary states in chronological order. Each state is identified by a time label "T" ranging from 0 through 6. At each state, an action is described or the state of each of two exemplary host systems 202 and 204 is presented. The state of host system 202 at time T=x is shown in a box labeled 202.x. Likewise, the state of host system 204 and HSR 224 are presented as 204.x and 224.x. The state of each box is signified by the value of its locally stored timestamp value TS. The value of TS indicates the version (timestamp) of management information stored within the respective element.
At T=0, host system 202.0 and host system 204.0 have an undefined (initial) timestamp value stored within (namely TS=n/a). HSR 224.0 has an initially defined management information version indicated by TS=1. At state T=1, host systems 202.0 and 204.0 perform their respective periodic poll of HSR 224.0. In so doing, both host systems 202.0 and 204.0 update their respective, locally stored copies of management information as indicated by the timestamp values TS=1 in 202.2, 204.2 and 224.2 at state T=2. At state T=3, host system 202.2 reconfigures or otherwise alters the management information related to the storage subsystem. The result of this update at state T=4 reflects host system 202.4 and HSR 224.4 storing management information corresponding to timestamp TS=2. Host system 204.4 has yet to detect the change made by operation of host system 202.4. At state T=5, host systems 202.4 and 204.4 again poll the storage subsystem HSR 224.4 to determine the present state of operation. Finally, at state T=6, host systems 202.6 and 204.6 and HSR 224.6 are all synchronized by host 204.4 updating its locally stored management information from the more recent version found in its last poll of HSR 224.4 at state T=5.
FIGS. 4A-5B are flowcharts describing the operation of the methods of the present invention. FIG. 4A describes the operation of the methods of the present invention within an attached host system to generate a change of state in the configuration or operation of the storage subsystem. Element 400 is first operable to effectuate the desired change in the storage subsystem configuration or operation by appropriate commands exchanged with the storage subsystem. Element 402 is then operable to determine whether the particular change requires that new management data be written to the HSR of the storage subsystem. In the preferred mode of the invention, there are a number of modification which need not be specifically stored in the HSR. Such changes are stored in standard and/or vendor specific locations of the storage subsystem controller(s) in accordance with the standards of the protocols in use. For example, in SCSI interface connections between the host systems and the storage subsystem, creation, deletion, and formatting of a LUN need not be stored in the HSR. Rather, such information is maintained in standard locations (or vendor specific locations) in the SCSI command and sense pages.
If element 402 determines that the specific management data need not be written to the HSR, processing continues at element 406 below. Though there may be no need to write the management data per se, an updated timestamp is required in order to notify other host systems of the potential configuration update required of them. I element 402 determines that data need be written to the HSR, element 404 is next operable to write appropriate management information in the HSR of the storage subsystem. As noted above, the HSR is allocated in a reserved area of the storage space of the subsystem. This reserved area is outside of the space allocable to the storage of user related data. For example, under RAID storage management control, the reserved space in which the HSR resides is never allocated for LUN storage space. In view of this allocation, write and read commands directed specifically to the HSR are used to bypass the defined storage areas for user data (e.g., the RAID LUNs). Specifically, in the preferred embodiment, SCSI Read Buffer and Write Buffer commands are used to access information in the HSR.
Element 406 is then operable to create a new timestamp value from the host system's clock. In the preferred embodiment, the system clock of each host system generating a configuration or administrative change is used to create an associated timestamp value. In a clustered environment, it is common that all host systems have their respective clocks reasonably synchronized to one another. An alternative embodiment permits the storage subsystem to provide the clock for the timestamp generation. Such an alternative embodiment obviates the need to maintain synchronization among a plurality of host system clocks. However, such synchronization is typically provided as a standard feature in a clustered computing environment. Clocks useful for timestamp creation are not as common within the standard control features of many storage subsystems. In general, location for creation of the timestamp values and the associated clock devices is a design choice which may vary in accordance with specific parameters of a particular application.
Element 408 is next operable to write the newly created timestamp value to the HSR. Finally, element 410 is operable to store the newly created timestamp value locally in the host system. The host system has thereby completed processing for the desired configuration or administrative changes and has updated the timestamp value in the HSR in order to notify other host systems upon their next polling sequence (discussed below).
Elements 412 and 414 of FIG. 4B are operable within the storage subsystem in cooperation with elements 400-410 in the host system. Element 412 is operable to receive the host system's new management data destined for storage in the HSR. The controller of the storage subsystem then performs an atomic "read-modify-write" process on the HSR to help assure the integrity of the update operation. The host systems "serialize" the write requests to the HSR by providing a length and address for each field to be updated in the HSR. This permits each field to be updated in an atomic operation which excludes interference from competing update requests. Well known multiprogramming techniques may be employed to further enhance the reliability of update sequences. For example, locking semaphore features may be used to preclude nearly simultaneous update requests from two different hosts. Given the relatively low probability of such an occurrence in view of the low frequency of such updates, such precautions likely provide little benefit as compared to their complexity.
FIGS. 5A and 5B describe the operation of a polling sequence performed within the host systems in cooperation with the storage subsystem controller(s) to determine if an update of the locally stored management information is required. Element 500 of FIG. 5A is first operable within a host system to initiate a periodic poll by reading the timestamp value from the HSR of the storage subsystem. As noted above, a SCSI Read Buffer command is preferred for access to the reserved storage area in which the HSR resides. Element 502 next compare the returned timestamp from the HSR with the locally stored timestamp value. If the two values are equal, then the locally stored management information is synchronized with the current information stored in the HSR of the storage subsystem. Processing is then completed until a next periodic poll is initiated.
If element 502 determines that the HSR and local timestamp values are not equal, the management information stored on the HSR of the storage subsystem is presumed to be more recent than that which is locally stored. Processing continues with element 504 below. As noted above, strict synchronization of the host system clocks is not required for operation of the methods of the present invention. The fact that the timestamp value is different than the locally stored value is sufficient grounds for determining that the locally stored management information is outdated by updated information in the HSR. It matters not that the HSR timestamp value is slightly larger or smaller than the locally stored timestamp value. In either case, the locally stored value and associated management information has been superceded by an update generated by another host system (one whose clock may be somewhat out of sync with the polling system's clock).
Element 504 is next operable to read the updated management information from the HSR, preferably using a SCSI Read Buffer command as noted above. The returned management data is then copied over the locally stored management data by operation of element 506 and the HSR's timestamp value overwrites the locally stored timestamp value to thereby complete processing of the present polling sequence. Processing begins anew with the initiation of the next periodic poll.
FIG. 5B describes the processing within the controller(s) of the storage subsystem in cooperation with the processing of FIG. 5A above. Element 510 is operable to receive the Read Buffer command from an attached host computer. Element 512 then returns the requested data from the HSR to the requesting host system.
Those skilled in the art will note that the controller(s) in the storage subsystem are ignorant of the semantic of the management information stored in the HSR. The semantic is completely defined by the cooperative operation of the multiple host systems. The controller(s) of the storage subsystem merely record the data provided by received write requests (e.g., timestamp value or management data provided by Write Buffer commands) and return data requested by the host systems (e.g., timestamp value or management data previously stored and requested by Read Buffer commands).
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the preferred embodiment and minor variants thereof have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | 4y
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[0001] This application claims priority to provisional application Ser. No. 61/611,610 filed on Mar. 16, 2012, the contents of which are incorporated herein in their entirety by reference.
[0002] This invention relates to devices and patterned structures of a material with regionally tuned porosity and method of making, and more particularly to a patterned array of vertically aligned carbon nanotubes selectively infiltrated with a polymer, deposited by chemical vapor deposition, to tailor the permeability of either all or certain regions of die porous material.
[0003] The efficient isolation of specific bioparticles in lab-on-a-chip platforms is important for many applications in clinical diagnostics and biomedical research. Such particles, including cells, bacteria, and viruses, can span more than three orders of magnitude in size. The majority of microfluidic devices designed for specific particle isolation are constructed of solid materials such as silicon, glass, or polymers. Such devices are hampered by some critical challenges; the low efficiency of particle-surface interactions in affinity-based particle capture, the difficulty in accessing sub-micron particles, and design inflexibility between platforms for different particle types. Existing porous materials, consisting mainly of two-dimensional porous membranes, or monolithic porous plugs, do not offer the structural properties or patterning capabilities to address these challenges.
[0004] Solid materials dominate as structural elements in microsystems including microfluidics, The inclusion of porous elements has thus far been limited to membranes sandwiched between Microchannel layers [ 1 ] or monoliths that fill the inside of channels [ 2 ]. With membranes, geometric control of the porous region is limited to two dimensions, and microscopic observation is usually possible only on the top side of the membrane. For porous monoliths, which can he fabricated from polymer or silicon, the porous region must be bounded on the sides by non-porous channel walls. Even with the limitations of these techniques, porous elements have found a wide mage of biological applications including filtation, solid phase extraction, microdialysis, enzyme microreactors, micromixers, and cell culture [ 3 ].
[0005] It is an object of the present invention to fabricate a porous structure having a selected permeability for use, for example, in microfluidics.
SUMMARY OF THE INVENTION
[0006] According to a first aspect the method according to the invention for tailoring permeability of materials includes establishing a pattern of vertically aligned nanowires on a substrate and providing a physical shadow mask to protect selected features of the pattern. A polymer is selectively infiltrated, using conformal chemical vapor deposition (CVD), into interstices in the vertically aligned nanowires to establish a selected permeability. The nanowires may be carbon nanowires such as single-walled and multi-walled carbon nanotubes.
[0007] In a preferred embodiment, a cover is placed over the infiltrated vertically aligned nanowires. In this embodiment, the pattern of vertically aligned nanowires includes microfluidic channel walls. it is preferred that the polymer be a biocompatible polymer including, but not limited to, a silicone based polymer such as a polymer of trimethyltrivinylcyclotrisiloxane (V 3 D 3 ) monomer. This copolymer is deposited by a CVD method that is tuned to maximize the conformality of the coating, to ensure the polymer infiltrates through into the pores as opposed to forming a surface coating. In a preferred embodiment, this step is performed by initiated CVD (iCVD), where a thermal free radical polymerization initiator and the monomer of interest is fed into a vacuum chamber that contains the vertically aligned nanowire structure and an array of heated wires. Oxidative CVD (oCVD) may also be used. Gaps between the vertically aligned nanowires are tailored from 100 nm down to zero after infiltration by modifying CVD process conditions and time. Polymer infiltration may be limited to a specific region of the substrate by masking the areas that are not desired to be infiltrated.
[0008] In another aspect, the invention is structure having a selected permeability comprising a pattern of closely spaced, vertically aligned nanowires extending from a substrate, the nanowires infiltrated with a polymer to tailor permeability. The nanowires may be carbon nanowires such as carbon nanotubes. Gaps between the nanowires do not exceed 100 nm. FIGS. 1 a, b, c , and d are schematic illustrations showing the process for creating the materials of the invention with tailored permeability.
[0009] FIGS. 2 a, b, c , and d are graphs of energy dispersive x-ray spectroscopy results for polymer infiltration of a 80 μm high vertically aligned carbon nanotube forest (VACNT). Every 100 points on the x-axis corresponds to 10 μum, and counts on the y-axis correspond to elemental concentration. FIG. 2 a is a scanning electron microscope linage of the forest cross section. The substrate is on the right. FIG. 2 b shows oxygen variation across the forest FIG. 2 c illustrates silicon variation and FIG. 2 d illustrates carbon variation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] A suitable method used for fabrication of the patterned VACNT forests has been previously described by Garcia et al. [ 4 ], Carbon nanotube growth may he performed, for example, in a four inch ID quartz tithe chemical vapor deposition (CVD) furnace (G. Finkenbeiner, Inc.) at atmospheric pressure using reactant gasses of C 2 H 4 , H 2 and He (Airgas, 400/1040/1900 SCCM). Catalyst annealing is carried out in a reducing He/H 2 environment at 650° C., leading to the formation of catalyst nanoparticles about 10 nm in diameter. C 2 H 4 is then introduced into the furnace to initiate carbon nanotube growth, occurring at a rate of approximately 100 μm/min until the flow of C 2 H 4 is terminated. The nanotubes grown using this method are multi-walled (2-3 concentric walls), with a diameter of around 8 nm. The foregoing description is merely exemplary.
[0011] The carbon nanotubes (CNT) are spaced by approximately 80 nm, thus yielding a 1 percent volume fraction of CNTs [ 5 ]. This fabrication method enables the creation of very high aspect ratio structures more efficiently tnan some state-of-the-art MEMS processes. For example, whereas deep reactive ion etching (DRIE) can create elements up to hundreds of microns deep at a rate of approximately 2-4 μm/min, this technique yields VACNT elements up to several millimeters in height at a rate of approximately 100 μm/min. The challenge with integrating VACNT elements into microfluidic channels is to create effective sealing so that there is no leakage of flow over the top of the elements (the bottom of the forest is already sealed to the silicon substrate). In the majority of application sit is desirable for flow to go around the VACNT features on either side. However, for certain applications, and or permeability measurements, one needs to create nanoporous filters that are well sealed on all sides.
[0012] The integration strategy depicted in FIG. 1 ensures top and side sealing of the VACNT element against the channel walls. As shown in FIG. 1 a both channels and other features are patterned and grown forming vertically aligned carbon nanotubes forests. A vertically aligned nanotube 10 extends upwardly from a silicon substrate 12 . The nanotubes 10 are grown to form a desired pattern in a forest of nanotubes.
[0013] With reference now to FIG. 1 b , a CVD process is used to fill in the “walls” of the microfluidic channels by depositing a polymer onto the carbon nanotubes by highly conformal CVD. A shadow mask 14 protects selected features from infiltration, so the decreased porosity can be patterned in various ways, e.g., exposing “walls” of the nanochannel while protecting an inner “filter” that needs to remain of higher porosity, creating porous and filled channels over a continuous forest, etc. As shown, the polymer infiltrates the interstices of the forest of nanotubes 10 . This step cannot be performed by the infiltration of a polymer dissolved in a solvent, as this can potentially affect the interactions between the carbon nanotubes and damage the structure of the device. CVD uses reactants in the vapor phase, and hence does not suffer from issues that arise from the surface tension of liquids.
[0014] Most CVD methods (e.g. plasma CVD) are not able to progress in the tight interstices of the VACNT element, which are ˜10 s of nm in effective width and microns and even millimeters in height. This high aspect ratio typically results in higher deposition rates at the top of the forest and limited infiltration of the bottom [ 8 ]. iCVD polymer coating, is selected to provide a desired permeability of the infiltrated structure from highly porous to solid. Short deposition times can result in VACNT with slightly decreased porosity, while longer deposition times can lead to essentially complete filling of the interstices between the CNTs and give an essentially non-pourous material. The choice of the polymer for this step depends on the requirements of the application. If the aim is simply to decrease the porousity to build walls for a microfluidic device for use with biological fluids, a biocompatible polymer is preferred. An example of such a polymer is the polymer of the V 3 D 3 monomer [ 13 ], which is silicone based. V 3 D 3 or other silicone-releated polymers are chemically similar to polydimethylsiloxane (PDMS) and hence may also aid in effective binding between the material and the lid. However, other alternatives are also possible. In another embodiments of this invention, a polymer of a specific functionality may be used to encourage or discourage wall-substrate interactions. Polymers suitable for use with oxidative CVD (oCVD) processing include poly (ethylenedioxythiophene) (PEDOT) and polypyrrole (PPY).
[0015] FIG. 1 c illustrates the making of a top plate to cover the structure created in FIG. 2 b . A thin layer of uncured PDMS 16 is spin coated onto a flat piece of cured PDMS 18 . This structure is then placed on top of the infiltrated forest structure as shown in FIG. 1 d.
[0016] It is noted that both the features and fluidic channel walls are made from patterned VACNT forests such that there is no gap between them. The permeability of the channel walls are then made significantly lower by selectively filling them with a polymer such as the polymer of V3D3, a silicone based polymer very similar to PDMS. Infiltration was performed using initiated chemical vapor deposition (iCVD), at the Massachusetts Institute of Technology [ 6 , 14 ]. The physical shadow mask 14 was laser cut from sheet acrylic.
[0017] Characterization results for the infiltration process are shown in FIG. 2 . one can see from the energy dispersive x-ray spectroscopy (EDS) analysis that the PV3D3 polymer, which contains silicon and oxygen, has reached all the way into the bottom of the 80 μm tall forest down to the silicon substrate. An advantage of the technique disclosed herein is that the channel walls are intrinsically the same height as the VACNT features so no height matching is required.
[0018] After infiltration, the device is completed by the attachment of a PDMS ceiling as discussed above in conjunction with FIG. 1 c . First, a flat piece of cured PDMS 18 2-3 millimeter thick is cut to the same size as the channel footprint with an inlet and an outlet punched out. Then uncured PDMS prepolymer 16 and a crosslinker are mixed at a 10:1 ratio and degassed inside a vacuum chamber. A drop of the mixture is placed on top of the cured PDMS piece and spun at 3000 rpm for 180 seconds, creating a 5 μm thick “glue” layer. The PDMS and glue are then placed on a 70° C. hot plate for six-seven minutes to increase the viscosity of the glue layer. Finally, the piece is placed onto the VACNT channel with the glue side down to complete the device, and then cured inside a 70° C. oven for another four hours to harden. This method attaches a flat ceiling to the open channel that had been formed by the polymer-filled CNT forests.
[0019] The fluid accessibility of a porous material is determined by its permeability which is defined by Darcy's Law, the constitutive equation of porous media flow [ 7 ]:
[0000]
Q
=
-
κ
A
Δ
P
μ
L
[0000] where Q [m 3 S −1 ] is the volumetric flow rate, ΔP [Pa] is the pressure drop along the channel, A [m 2 ] and L[m] are the cross-sectional area and length of the porous channel, μ[kg m −1 s 31 1 ] is the dynamic viscosity of the fluid, and Λ[m 2 ] is the permeability of the porous media. Highly permeable materials are attractive for microfluidic applications as they minimize back pressure (ΔP) for a specific flow rate, requiring less powerful injection systems and allowing for lower specification (and lower cost) interconnects.
[0020] Experiments using the structures made according to the invention were conducted at the Massachusetts Institute of Technology in Cambridge, Mass. The experiments used rectangular forests surrounded by polymer infiltrated CNT channel walls. The devices are well sealed on all sides such that there is no low resistance leakage path around the forest. The rectangular VACNT elements (2 mm wide, 200 μm deep, 100 μm tall) were first wetted using a 0.5% TWEEN in DI water. A solution of 0.1% TWEEN in DI water was then injected for two minutes at a fixed inlet pressure of 2 psi and all the outlet flow connected into an Wppendorf tube. The volume of the collected outflow was measured and used to compute the flow rate which was then input to extract the permeability value Λ. Repeats were performed over five different devices to assess the variation across devices. Using this procedure, the fluidic Permeability of the VACNT structures was quantified as 5.4*10 −14 ±8.3−10 −15 m 2 . We compared this value with the permeability measured using similar devices where the channel walls were constructed of patterned VACNTs but did not undergo polymer infiltration. Experiments show that without infiltration the permeability values obtained are much higher with a very large standard deviation. This resell suggests significant fluid leakage through the channel walls to give unreliable measurements. Thus we conclude that polymer infiltration is required to ensure that the fluid passes only through the desired nanoporous elements and not through the VACNT-based channel walls.
[0021] We compared the permeability of our VACNT forest with other micro and nanoporous materials from the scientific literature. Interestingly, this permeability value is comparable to or higher than that of other porous technologies with much large pore sizes. This result is somewhat counterintuitive as one would expect materials with larger pores to be more accessible to fluids. The large difference in permeability between VACNT elements and porous silicon is also not obvious, as these elements have similar pore dimensions. The high permeability of our VACNT forest can be explained, however, by classical analyses of the effect of porosity on permeability.
[0022] Further details of the present invention may be found in “Nanoporous Elements in Microfluidics for a Multi-scale Separation of Bioparticles,” Grace D. Chen, doctoral dissertation, Massachusetts Institute of Technology, June 2012, the contents of which are incorporated herein by reference in their entirety. It is noted that the numbers in square brackets in this specification refer to the references listed herein. The contents of these references are incorporated herein by reference in their entirety.
[0023] It is recognized that modifications and variations of the present invention will be apparent to those of ordinary skill in the art, and it is intended that all such modifications and variations be included within the scope of the appended claims.
REFERENCES
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[0037] 14. Wardle, B. L. at al., United States published patent application US2010/0255303, Oct. 7, 2010. | 4y
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BACKGROUND OF THE INVENTION
The present invention generally relates to a processor responsive to a plurality of input signals for analyzing a state and transmitting an output signal associated with the state. More particularly, the present invention is concerned with a knowledge compilation/pattern reasoning system for a processor capable of implementing high-speed processing and efficient maintenance by using knowledge data which is generated by a separate apparatus by the conversion of knowledge data. The present invention is advantageously applicable, but not limited to, a control system of the kind having a plurality of input signals and needing rapid circumstantial judgement, e.g. a plant control system or a posture control system for a moving object.
Circumferential judgement systems of the kind using knowledge data heretofore proposed may generally be classified into two types, i.e., a type implementing reasoning which is analogous to the human reasoning system on a processor, and a type using a neural net model which simulates the human neuron net by software or hardware. A problem with the reasoning type system is that it basically is not suitable for a processor adopting a sequential processing principle and, therefore, an extremely long period of time is needed for execution. In addition, with such a system, it is impracticable to achieve parallel processing unless extra work such as elaborating the knowledge to describe or the reasoning procedure is performed to provide knowledge feasible for parallel processing. On the other hand, the neuron net type system basically adjusts the characteristic of an output relative to inputs on the basis of learning which relies on execution and evaluation. This system, therefore, cannot change the characteristic by using abstract knowledge, failing to promote efficient maintenance. Another drawback with the neuron net type system is that when the subject of analysis is complicated, the convergence of characteristic which relies on execution and evaluation becomes unstable.
The prior art reasoning type system is feasible for man-machine interface such as the description and updating of knowledge, but it is disadvantageous when it comes to processing rate. Conversely, the prior art neuron net model type system is advantageous regarding processing rate, but it is disadvantageous from the standpoint of stable characteristic and man-machine interface because the processing is implemented in a mode much removed from abstract knowledge.
As discussed above, the prior art technologies are dilemmatic with respect to processing rate and man-machine interface which involves stability of characteristic.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a knowledge compilation/pattern reasoning system which is desirable in both processing rate and man-machine interface including a stable characteristic.
In order to achieve the above object, a knowledge compilation/pattern reasoning system of the present invention has two independent subsystems: a pattern generating subsystem for interpreting human representation of knowledge and physical models and transforming them into pattern data, and an executing subsystem for performing circumferential analysis by using the generated pattern data and decision criterion data.
An operation system of the kind adopting a pattern type reasoning principle may be loaded with only the executing subsystem which uses pattern data compiled by the pattern generating system beforehand, for the purpose of enhancing rapid execution. The transformation of human representation of knowledge and physical models into pattern data is performed by the pattern generating subsystem which is independent of the executing subsystem, whereby human representation of knowledge and physical models and pattern data are desirably interfaced to each other.
Errors which may occur during the generation of patterns and unpredictable changes in subject environments are accommodated by changing the criterion reference data of the executing subsystem.
In a preferred embodiment of the present invention, the pattern generating subsystem comprises a patterning rule generating section, a pattern data generating section, and a pattern data verifying section. The patterning rule generating section determines, by using data loaded in a knowledge database, the form of pattern data to be generated (format, total number and so forth of patterns) and the states to be indicated by individual patterns, and stores them in a patterning rule database. To determine the states to be indicated by individual patterns as mentioned above is to determine a rule for representing the state of an accident (dangerous state) such as the class of an accident (fire, gas leakage, electric leak, etc.), the phase of an accident, the kind, characteristics, locations and so forth of sensors used.
The pattern data generating section generates pattern data associated with the states represented by the patterns stored in the patterning rule database by forward reasoning, and stores them in a pattern database. The pattern data verifying section verifies the individual patterns stored in the pattern data base by backward reasoning and by using the data of the knowledge database and, if any of them is not consistent, corrects that pattern data.
In a preferred embodiment of the present invention, the executing subsystem is made up of an input normalizing section, a pattern comparing section, an output combining section, and a decision criterion changing section. The input normalizing system normalizes individual input data on the basis of input data normalizing tables. The pattern comparing section sequentially compares for each of the decision criterion data the normalized input data and comparison data sequences of the pattern database which are designated by search tables, calculates their coincidence values, and outputs a pattern having a large coincidence value and the coincidence value. The output combining section calculates corrected coincidence values by correcting coincidence value data, which the pattern comparing section outputs on a decision criterion basis, by use of a characteristic function, time delay function or similar correcting function, thereby selecting a pattern having a large coincidence value and a pattern class for the entire system while calculating their participation values. Here, the participation values are numerical values showing how far the individual decision criterion data have influence the selection of a pattern and a pattern class.
The input normalizing section may be constituted by input normalizers corresponding in number to input signals and operable in parallel with each other, while the pattern comparing section may be implemented by pattern comparators corresponding in number to the decision criteria and also operable in parallel. Such a specific configuration will be successful in increasing the processing rate.
The decision criterion changing section is triggered on the reception of evaluation data which is associated with the output data of the output combining section. In response, the decision criterion changing section changes the data of the individual decision criteria by using the input evaluation data and the participation values, while providing the decision criteria with a learning function.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description taken with the accompanying drawings in which:
FIG. 1 is a schematic block diagram showing a pattern generating subsystem which forms a part of a knowledge compilation pattern reasoning system embodying the present invention;
FIG. 2 is a schematic block diagram of the pattern generating system of the present invention which is applied to a security system;
FIG. 3 is a flowchart outlining the operation of a patterning rule generating section which is included in the pattern generating system;
FIG. 4 is a flowchart demonstrating the operation of a pattern data generating section of the pattern generating system schematically;
FIG. 5 is a flowchart showing the general operation of a pattern data verifying section of the pattern generating system;
FIG. 6 is a schematic block diagram showing an executing subsystem which forms the other part of the present invention and is also applied to a security system;
FIG. 7 is a schematic block diagram showing a specific construction of a pattern comparing section which is implemented by a plurality of pattern comparators in relation to a security system;
FIG. 8 is a schematic block diagram showing a specific construction of one of the pattern comparators shown in FIG. 7;
FIG. 9 is a flowchart outlining the operation of an input normalizing section included in the executing subsystem;
FIGS. 10A and 10B are a flowchart showing the operation of the pattern comparing section schematically;
FIGS. 11A to 11C are a flowchart representative of the general operation of an output combining section also included in the executing subsystem;
FIG. 12 is a flowchart outlining the operation of a decision reference changing section included in the executing subsystem;
FIGS. 13A to 13D are graphs showing an original function and modifications thereof available with the embodiment applied to a security system;
FIG. 14 is a schematic block diagram representative of a procedure for calculating corrected coincidence values in the executing system;
FIG. 15 is a view similar to FIG. 14, showing a procedure for calculating corrected coincidence values particular to a prior art reasoning system;
FIG. 16 is a graph showing a specific characteristic function applicable to the executing subsystem;
FIG. 17 is a graph showing a specific time delay function also applicable to the executing subsystem;
FIG. 18 is a schematic block diagram showing an alarm system (security system) implemented by the present invention; and
FIG. 19 is a diagram showing the operation of a state model deciding section of FIG. 18 sechematically.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will be described which is applied to a security system by way of example. In the illustrative embodiment, pattern data, with which input signals (input values) are compared, consists of data referred to as a membership function and the data is represented by parameters such as a center value, a variance and a vagueness, and a search table. In other words, pattern, data consist of center values of individual input signals each describing normalized data of the associated input signal, variances of individual input signals for changing the characteristic of an original function adapted for comparison, vaguenesses of individual input signals for changing the characteristic of the original function, and search tables describing the next comparison pattern which is associated with a pattern having the largest coincidence value at the moment. These pattern data are collectively shown below in Table 1.
TABLE 1______________________________________ SYM- NAME BOL NUMBER______________________________________CLASS center value P input number/1 patternPATTERN variance V input number/1 patternDATA vagueness Va input number/1 pattern search table Tb 1/1 patternSEARCH coincident ID m constants/tableTABLE pattern next ID n constants/table compare patternCRITERION gravity g input number/1 criterionDATA data charac Pr 1/1 criterion data function (priority in the embodiment) time delay function (not used in the embodiment)______________________________________
FIG. 13A is a graph showing one example of a comparison original function in the membership functions of this embodiment, in which the normalized data of the input signal (input value) is taken along the abscissa and the coincidence value is taken along the ordinate. FIG. 13B is a graph showing a variation of the comparison original function with a variation of the center value P which is the center value of the input values for determining the maximum coincidence value. FIG. 13C is a graph showing a variation of the comparison original function with a variation of the variance v which is the value representing the permissible range of the input values enable to obtain the coincidence value V. FIG. 13D is a graph showing a variation of the comparison original function with a variation of the vagueness Va.
As understood clearly from FIGS. 13A, 13B and 13D, each pattern representing a situation to be compared with the input value can be described by the center value P, the variance v and the vagueness Va.
As shown in Table 1, in this embodiment, criterion data for decision is made up of gravities of individual input signals each describing how far the associated input signal has influenced the decision, and priorities each describing how far the associated decision criterion has influenced the decision. The gravity (weight) is a numerical value indicating the degree of the influences of plural input signals 1, 2, 3 and 4 in each of criterions A, B, C and D, as exemplified in table 5 described later. The priorities are determined as the priorities of the criterions by giving weight to the plural criterions A, B, C and D, as exemplified in table 5.
FIG. 1 of the drawings shows a pattern generating subsystem which forms a part of the illustrative embodiment, while FIG. 2 schematically shows a specific construction of an apparatus for practicing the pattern generating subsystem. As shown in FIG. 2, the apparatus includes a display 21 and an input unit 22 which implement dialogue type man-machine processing. An operator enters knowledge data associated with the subjects of observation by using the display 21 and input unit 22. The entered data are sequentialy stored in a storage 24 built in the apparatus. Herein, the subjects of observation means the objects to be observed in order to attain the aim of a certain system, such as fire, gas leakage and electric leak in a security system. The states of the subjects of observation may be represented by various data. In the case of fire, it can be described how the states such as the occurrence or degree of fire vary with the temperature, humidity and the amount of dust in each room, outside ambient temperature, the amount of infrared ray, and the like. The states of the fire are output from the input unit 22 as knowledge data having a predetermined format.
A processing unit or processor 23 has a patterning rule generating section 12, a pattern data generating section 15 for generating pattern data, and a pattern data verifying section 17. In this embodiment, software is utilized as the means for realizing the functions of respective sections. In other words, the processing unit or processor 23 loads the programs associated with respective sections to the storage, reads each of the instructions in the loaded program in turn sequentially, and executes the read instructions sequentially, whereby realizing respective functions of the patterning rule generating section 12, the pattern data generating section 15 for generating pattern data, and the pattern data verifying section 17. For example, knowledge database 11 is loaded with various kinds of knowledge data such as sensors whose outputs are expected to change in the event of a fire, water leakage or similar emergency which may occur in a particular place, as well as the tendency of the change. By using such knowledge data, the patterning rule generating section 12 determines the format of pattern data to be generated, the total number of patterns and other similar forms, and the states each being indicated by a different pattern, and loads them in a patterning rule database 13. The states represented by the individual patterns are the rules for describing the classes of accidents (dangerous conditions) such as fire, gas leakage and electric leak which are the subject of observation in a security system, for example, the phases and locations of accidents, the number of comparison patterns and the comparison functions which are dependent on information associated with sensors used. The patterning rule database 13 may be understood as performing preliminary editing for producing comparison patterns from the knowledge database 11.
The patterned data generating section 15 generates pattern data associated with states which are represented by patterns stored in the patterning rule database 13, by forward reasoning based on the data of the knowledge database 11. The pattern data verifying section 17 verifies the pattern data stored in the pattern database 16 by backward reasoning which also uses the data of the knowledge database 11, and if any of them is not consistent the verifying section 17 corrects it.
The pattern generating subsystem having the above construction will be operated as follows.
FIG. 3 is a flowchart outlining the operation of the patterning rule generating section 12. As shown, the operation begins with steps 31 and 32 for reading knowledge data and a basic pattern generating rule out of the knowledge database 11. The basic pattern generating rule is to describe a rule for determining, for example, the number of the comparison patterns in accordance with the number of sensors (input signals) used, the number of the functions to be prepared in accordance with the precision of the sensors, and the like, as an "if . . . then" type rule. Based on the knowledge data and basic pattern generating rule, the patterning rule generating section 12 prepares normalizing tables and loads them in an external storage 25 (step 33). As shown in table 6, the normalizing table is a translating table in which a translating rule is defined for translating input numerical value data into another numerical value data within the predetermined range. In this way, a pattern comparing described later can be performed in the same pattern compare section even if a signal of a different kind is input, by normalizing the numerical value data of the input signals using the normalizing table. Further, the pattern rule generating section 12 determines the number of comparison patterns, comparison functions and so forth which should be prepared in association with the individual states, while loading them in the patterning rule database 13 (steps 34 and 35). For example, when the object of the observation is fire and the states of the fire is classified into four phases, the number of comparison patterns is determined as 4 corresponding to respective phases, and the comparison function to be used is determined from the knowledge data in each phase. Herein, the scale of fire means the size or the extent of fire such as small-scale fire, middle-scale fire, large-scale fire for the whole building.
Referring to FIG. 4, the operation of the patterned data generating section 15 will be described. First, the patterned data generating section 15 reads knowledge data out of the knowledge database 11 (step 40), reads the patterning rule out of the patterning rule database 13 (step 41), and then selects a class of occurrence to be detected, e.g. fire or water leakage (step 42). Based on the number of comparison patterns, a comparison function and so forth indicated by the patterning rule, the section 15 prepares a pattern data table for each of the sensors used, as shown in Table 2 (step 43).
TABLE 2______________________________________Sensor #1PHASE OF FIRE PATTERN______________________________________1 P.sub.1, V.sub.1, Va.sub.12 P.sub.2, V.sub.2, Va.sub.23 P.sub.3, V.sub.3, Va.sub.34 P.sub.4, V.sub.4, Va.sub.4______________________________________
In Table 2 which is a specific example of pattern data tables, a sensor #1 is responsive to fires, and fires are identified with respect to four consecutive phases. Each of the phases is distinguished from the others in terms of a center value, a variance, and a vagueness.
Since a plurality of sensors are assigned to each class of occurrence to be detected, the patterned data generating section 15 prepares a table showing the combinations of sensors which should respond together to different phases of occurrence, as shown below in Table 3 (step 44).
TABLE 3______________________________________ SENSOR USED #1 #2 #3 #4______________________________________PHASE 1 ◯ ◯ ◯ ◯OF 2 ◯ ◯ ◯ ◯FIRE 3 ◯ ◯ 4 ◯ ◯______________________________________
Subsequently, the patterned data generating section 15 determines a comparison search route in the plurality of comparison patterns as prepared by the steps 43 and 44, i.e., the order in which the patterns to be compared should be selected. The sequence of steps 42 to 45 stated above is repeated for all the classes of subjects of observation. On confirming the end of such a procedure (step 46), the section 15 determines a search route for a class distinction pattern (step 47). By using the data provided by the above steps, the section 15 generates pattern data (step 48) and writes them in a pattern database area of the external storage 25 (step 49). The pattern data so generated may be formed such as shown in Table 4.
TABLE 4______________________________________PATTERN NAME No. 3CLASS FIRE LOCATION A PHASE ○3 CENTER VARI- VAGUE-INPUT VALUE P ANCE V NESS a______________________________________#1 +40 ±15 10#2 +20 ±15 5#3-#1 +20 ±15 5 • • • • • • • •NEXT SEARCH No. 4PATTERN______________________________________
FIG. 5 indicates the operation of the pattern data verifying section 17 in a flowchart. First, the data verifying section 17 reads the knowledge database 11 for verification (step 51). This is followed by a step 52 for reading the pattern database 16 to be verified, and normalizing tables for restoring the normalized pattern data to original. The section 17 selects the pattern data one at a time (step S53), transforms the selected pattern data into real data by using the normalizing table, and compares a state represented by the real data and a state represented by the knowledge data (step 54). If the two states compare equal, the section 17 verifies the next pattern data; if otherwise, it corrects the pattern data based on the knowledge data (step 56). On completing the verification with all the data (step 57), the section 17 generates and writes criterion data for decision (step 58). The decision criterion data include the names of criteria, priorities, and gravities assigned to the individual data elements (inputs). These data may be provided in a format as shown in Table 5 by way of example.
TABLE 5__________________________________________________________________________ GRAVITY gCRITERION INPUT INPUT INPUT INPUT PRIORITYNAME 1 2 3 4 Pr (CHARAC FUNCTION)__________________________________________________________________________CRITERION A g.sub.A1 g.sub.A2 g.sub.A3 g.sub.A4 Pr.sub.ACRITERION B g.sub.B1 g.sub.B2 g.sub.B3 g.sub.B4 Pr.sub.BCRITERION C g.sub.C1 g.sub.C2 g.sub.C3 g.sub.C4 Pr.sub.CCRITERION D g.sub.D1 g.sub.D2 g.sub.D3 g.sub.D4 Pr.sub.D__________________________________________________________________________
Referring to FIG. 6, an executing subsystem forming the other part of the illustrative embodiment is shown in a schematic block diagram. As shown, an external storage has the pattern database 16 and normalizing tables 14 which were prepared by the pattern generating subsystem. An internal storage is available for storing the decision criterion data 18 generated by the pattern generating subsystem and for saving input data 61 for a moment. A processor has an input normalizing section 62, a pattern comparing section 63, an output combining section 64, and a decision criterion changing section 66. With these sections, the processor normalizes input data, compares patterns, and combines outputs by using the data loaded in the external and internal storages. In this embodiment, software is utilized for realizing the functions of respective sections 62, 63, 64 and 66. In other words, the processing unit or processor 23 loads the programs associated with respective sections to the storage, reads each instruction in the loaded program in turn, and executes the read instructions sequentially, whereby realizing respective functions of the input normalize section 62, pattern compare section 63, output combine section 64, and decision criterion change section 66.
The input normalizing section 62 receives various input data 61 representative of the subjects of observation, e.g., indoor and outdoor temperatures, amounts of dust and gas leakage in the case of a fire-alarm system based on the normalizing tables 14. The normalized data is output in the form of patterns. FIG. 9 shows such a procedure. As shown, the section 62 normalizes each input data based on the data of the assigned normalizing table 14, formats the normalized data for comparison which will follow, and then delivers them to the pattern comparing section 63 (steps 91 to 94). A specific normalizing table which is assigned to indoor temperature is shown in Table 6 below.
TABLE 6______________________________________NUMERICAL DATA PATTERN DATA______________________________________80° C. → +10055 → 80° C. +45 → +10035 → 55° C. +15 → +4520 → 35° C. 0 → +1520 → 5° C. 0 → -15______________________________________
By the normalizing table, temperatures of 20° C. to 5° C. are converted into a range of numerical values 0 to -15, temperatures of 20° C. to 35° C. are converted into a range of numerical values 0 to +15, temperatures of 35° C. to 55° C. are converted into a range of numerical values +15 to +45, temperatures of 55° C. to 80° C. are converted into a range of numerical values +45 to +100, and temperatures above 80° C. are converted into a numerical value 100 collectively.
The pattern comparing section 63 sequentially compares, on a decision criterion data basis, the normalized input data and the comparison data trains stored in the pattern database 16 which are indicated by the search tables written in the pattern data and the decision criterion data. Based on the resulting coincidence values, the section 63 outputs a number assigned to a particular pattern having the largest coincidence value and the coincidence value. Such a sequence of steps is shown in FIG. 10. As shown, the section 63 receives normalized input data from the input normalizing section 62 while reading pattern data out of the individual storages (steps 101 to 103).
A comparison pattern, namely a comparison function {f1 (p), f2 (v), f3 (va)F} (N) is generated by using a predetermined original function F (N) and the center values P, variances V and vaguenesses Va of pattern data (step 104). FIGS. 13A to 13D depict examples of modification of original function which may be effected to generate a comparison function F (N). Specifically, FIG. 13A shows the original function F (N), while FIGS. 13B to 13D show respectively the modifications of the original function which use the center value p, the variance υ, and the vagueness υα.
The coincidence values of the normalized data are calculated by using the generated comparison function (step 105). This is followed by a step 106 for adding (coincidence value×gravity) to the sum of the coincidence values (step 106). Then, the gravities are integrated, i.e., Σg i is produced (step 107).
Whether or not the processing has been completed with all of the input data is determined (step 108). If the answer of the step 108 is YES, the sum of coincidence values produced in the step 106 is divided by the sum of gravities produced in the step 107 so as to obtain a coincidence value V which is a weighted average (step 109). In this step, the following equation representative of a coincidence value V is fully calculated: ##EQU1##
Thereupon, among the compared patterns, a number n assigned to a pattern which immediately follows the pattern having the largest coincidence value (next pattern ID) is selected from the search table associated with that pattern (step 10A), and pattern data corresponding to the pattern number n is set (step 10B). Whether or not the pattern number n is the initial value is determined to see if all the patterns have been compared (step 10C). If the answer of the step 10C is NO, the program returns to the step 103 for repeating the comparison. If the answer of the step 10C is YES, a number m assigned to the pattern having the largest coincidence value as determined in the step 10A is output together with the coincidence value as a result of comparison (step 10D).
The output combining section 64 calculates corrected coincidence values by using the data, characteristic function and time delay function which are produced on a decision reference basis. By using the resulting corrected coincidence values, the section 64 calculates and outputs pattern numbers having large coincidence values, pattern classes and their coincidence values, and pattern numbers of the individual decision criterion data as well as participation values which are associated with the selection of the pattern classes. FIG. 11 demonstrates the procedure executed by the output combining section 64 as stated above. As shown, the section 64 reads pattern numbers and coincidence values out of the pattern comparing section 63 (step 111) while reading priorities out of the decision criterion data 18 (step 112). Then, the section 64 calculates corrected coincidence values for each of the decision criterion data by using the characteristic function (including priority value) and time delay function (step 113). Examples of the characteristic function and time delay function are shown in FIGS. 16 and 17, respectively. As shown in FIG. 15, the characteristic function available with a prior art neuron net model has been limited to either a monotonous incremetal function or a constant. In contrast, the illustrative embodiment implements not only a monotonous increment as represented by a curve a or b in FIG. 16 but also a characteristic including a non-reactive zone as represented by a curve c. Moreover, as shown in FIG. 17, the illustrative embodiment allows the use of a time delay function which drives again on the lapse of a predetermined period of time as indicated by a curve a, or even the transmission which is delayed by negative bias as indicated by a curve b. In this manner, the embodiment shown and described provides unprecedented diversity to the decision.
The patterns and the pattern classes are individually totalized based on the calculated coincidence values. Specifically, concerning the pattern totalization, the corrected coincidence values associated with the same patterns are integrated (step 115), and a pattern having the largest corrected coincidence value is selected (step 116). Then, an output coincidence value is produced by: ##EQU2##
The resulting coincidence value is output together with the pattern number (step 118).
The pattern classes are totalized in the same manner as the patterns as totalized by the steps 115 to 118.
The reference changing section 66 is activated on the reception of evaluation data associated with the output data. Specifically, the section 66 changes the data of the individual decision criteria by using the patterns of the individual decision criterion data as well as their participation values associated with the selection of pattern class. It is to be noted that the participation values refer to the extents to which the individual decision criterion data have influenced the selection of patterns and pattern class, and they are proportional to (coincidence value×priority).
More specifically, the reference changing section 66 has thereinside a storage which is loaded with decision criterion data (priority values in the illustrative embodiment). The section 66 increases the decision criterion data if the evaluation data 65 is positive and decreases them if the evaluation data 65 is negative. FIG. 12 shows a specific operation of the decision criterion changing section 66.
Referring to FIG. 7, a specific construction of the processor of the executing subsystem is shown which performs parallel processing for high-speed operations. In the processor, the input normalizing section 62 is implemented by a parallel connection of a plurality of input normalizers 71 to 73 which function as discussed above with reference to FIG. 9. The pattern comparing section 63 is constituted by a parallel connection of a plurality of pattern comparators 74 to 76. The output combining section 64 is comprised of a single output combiner 77 which function as discussed above with reference to FIG. 11. The input normalizers 71 to 73 and the pattern comparators 74 to 76 correspond in number to the input signals and the decision criterion data, respectively, promoting rapid operations by parallel processing. Respective input normalizers and respective pattern comparators are software modules and their normalizing functions and comparing functions can be realized by the combination of respective programs loaded to the internal storage and the processing unit or processor for executing the programs. It is noted that the pattern compare algorithm is comparatively simple, and it is easy for a person skilled in the art to realize the function by only hardware.
FIG. 8 shows a specific construction of one of the pattern comparators 74 to 76. As shown, the pattern comparator has an input value interface module 81, a coincidence value calculation module 83, and an integration module 84. At the time of initialization, the input value interface module 81 mainly reads gravities of decision criterion data and stores them in its internal buffer (gravity buffer). During execution, the module 81 sequentially reads input data to feed them to the coincidence value calculation module 83 while delivering the gravities from the gravity buffer to the integration module 84 sequentially. A pattern data interface module 82 is constructed to read, on the reception of a comparison pattern number from a pattern search module 85, search table data out of the pattern database 16 and delivers them to the pattern search module 85. During execution, the module 82 reads pattern data (center values, variances and vaguenesses) sequentially out of the pattern database 16 to transfer them to the coincidence value calculation module 83.
A major function of the coincidence calculation module 83 is reading input data and pattern data (center values, variances and vaguenesses), producing a comparison function by using the pattern data and original function, calculating coincidence values on based the input data fed thereto via the interface module 81 and the produced comparison function, and delivering them to the integration module 84.
The integration module 84 mainly clears an integration buffer and a counter buffer in the event of reception of a pattern from the pattern search module 85. During execution, the module 84 reads a coincidence value and a gravity out of the coincidence value calculation module 83 and the interface module 81, respectively, multiplies the coincidence value and gravity, integrates the resulting products and the gravity, increments counter data, and, when the counter data reaches the upper limit, transmits a pattern number, divides an integrated value of the results of multiplications by the integrated value of the gravities and sends data (output value) representative of the result of division to the pattern search module 85.
The pattern search module 85 chiefly functions on the reception of a pattern number to select patterns having the largest coincidence value and store them in the internal buffer, to select the next comparison patterns based on search tables stored in an internal buffer and transmit them to the pattern search interface 82, to read the search tables and store them in the internal buffer, and, when the next comparison patterns are particular patterns, transmit the patterns having the largest coincidence value and the coincidence value to the output combiner 77.
Referring to FIG. 18, a specific arrangement of a security system to which the present invention is applied is shown. As shown, the security system has a signal pattern deciding section 182 and an estimated signal pattern deciding section 184 both of which are implemented by the knowledge compile-pattern reasoning system of the present invention. An input controller 181 converts electric signals fed thereto from sensors into numeral data (input patterns) and delivers them to the signal pattern deciding section 182 and an estimated pattern generating section 183. The signal pattern deciding section 182 compares the input patterns from the input controller 181 with patterns which it holds and are generated by the pattern generating subsystem, and delivers one of the patterns having a large coincidence value and the coincidence value to a state mode deciding section 185, alarm issuing section 186, etc. Further, the signal pattern deciding section 182 changes its own database in response to an evaluation fed thereto from an evaluation inputting section 189. This section 189 constitutes an alarm division in combination with the alarm issuing section 186, an input and output (I/O) controller 187, an alarm displaying section 188, etc.
The estimated pattern generating section 183 generates estimated patterns based on the history of the individual input patterns and applies them to the estimated signal pattern deciding section 184. In response, the estimated signal pattern deciding section 184 compares the estimated patterns with patterns which it holds and sends a pattern having a large coincidence value and the coincidence value to the state model deciding section 185. Further, the estimated signal pattern deciding section 184 modifies its own database in response to an evaluation from the evaluation inputting section 189. The state model deciding section 185 manipulates the state model values based on the signal pattern deciding section 182 and delivers the results to the alarm issuing section 186. In response to evaluation data from the alarm division, the state model deciding section 185 changes a database which it possesses. FIG. 19 indicates a state model. The state model deciding section 185 collects ambiguous data from the signal pattern deciding section 182 and estimated signal pattern deciding section 184 which will not result in an alarm, thereby analyzing the tendency.
The alarm issuing section 186 analyzes the instantaneous state in response to the data from the signal pattern deciding section 182, estimated signal pattern deciding section 184 and state model deciding section 185 and, if it is unusual, feeds alarm data to the I/O controller 187. When the alarm issuing section 186 receives evaluation data from the I/O controller 187, it sends evaluation data to the signal pattern deciding section 182, estimated pattern deciding section 184 and state model deciding section 185, depending on the primary cause of an alarm. The I/O controller 187 sends data to an alarm unit, an equipment controller 18A, and an upper layer system (centralized control system). In response to a command from the I/O controller 187, the equipment controller 18A feeds control commands to sprinklers, ducts and other emergency equipment which are installed in the area allocated to the security system.
In summary, it will be seen that the present invention provides a reasoning system which desirably interfaces human representation of knowledge and physical models and pattern data. This is derived from high-speed execution which is implemented by two subsystems, i.e., a pattern generating subsystem which interprets human representation of knowledge and physical models and transforms them into pattern data, and an executing subsystem which analyzes states by using decision criterion data.
Errors which may occur at the time of pattern generation and unpredictable changes in the subject environments can be accommodated by changing the decision criterion data of the executing subsystem. A section for comparing patterns can be readily implemented by hardware, and the high-speed operation with parallel processing is easy to realize. Further, when an output combining method using a characteristic function and a time delay function is adopted, the present invention is adaptable even to subjects having transitional characteristics.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a thermal dye-transfer type recording sheet, and more particularly to a recording sheet for use in the thermal dye-transfer type recording method, in which a substrate coated with a coloring material is used, the coloring material layer is brought into contact with a recording sheet and the coloring material is transferred to the recording sheet by heating by a thermal head or the like.
2. Prior Art
In the thermal recording method there is widely adopted a method in which a heat-sensitive recording paper having formed thereon a recording layer to be colored under heating by a physical or chemical change is brought into contact with a thermal head, whereby a record of a desirable color is obtained on the heat-sensitive recording paper. The heat-sensitive recording method, however, is defective in that coloration contamination is readily caused in a heat-sensitive recording paper because of pressure or heat unavoidably applied to the heat-sensitive recording paper during storage or at the time of handling and that the manufacturing cost of such heat-sensitive recording paper is high.
As means for overcoming the above defects of the conventional heat-sensitive recording method, there has been proposed a method as disclosed in the Japanese Patent Application Laid-Open Specification No. 15446/76. It discloses that a substrate, such as paper or resin film, is coated with a coloring material which is solid or semi-solid at room temperatures, the coloring material coated on the substrate is brought into contact with a recording sheet and the coloring material on the substrate is selectively transferred to the recording sheet by heating by a thermal head to perform recording. The reason why transfer of the coloring material coated on the substrate to the recording sheet is effected is that the coloring material or a binder containing the coloring material is molten, evaporated or sublimated by heating and adhesion or absorption of the coloring material to the recording sheet is thus caused. The coloring material customarily used in this recording method is a dispersion of a dye or pigment in a binder such as a wax. Even if this dispersion type coloring material is brought into contact with a recording sheet in normal conditions, transfer of the coloring material does not occur. Transfer of the coloring material takes place first when assembly of the coloring material and the recording sheet is heated at, for example, 60 to 300° C. or about 500° C. in some cases. Sublimable dyes having a sublimation temperature of 60 to 300° C., for example, disperse dyes of the nitro, azo, quinoline and anthraquinone types are preferably used as the coloring material. Accordingly, this recording method is characterized in that plain paper can be used as the recording sheet.
However, when plain paper is used as the recording shet in the above recording method, the color density of the obtained record is low and fading of the color with the lapse of time is conspicuous. In other words, a recording sheet suitable for use in this recording method has not been developed.
SUMMARY OF THE INVENTION
An object of this invention is to provide a thermal transfer-type recording sheet which has a very clear record with superior light fastness.
The above object is obtained by using in the coating layer of the present invention at least a mixture of 18 to 24% by weight of saturated polyester and 6 to 12% by weight of polyvinyl pyrrolidone.
DETAILED DESCRIPTION OF THE INVENTION
An example of a saturated polyester which can be used in the present invention is polyethylene terephthalate (PET, melting point=260° C.) obtained by polycondensation of terephthalic acid and ethylene glycol. In addition, polybutylene terephthalate (PBT, melting point=224° C.), poly-1, 4-cyclo-hexanedimethylene terephthalate (PCHT, melting point=290° C.) can be used. Usually, these phthalic acid type polyesters are insoluble in most solvents. However, solvent-soluble or water, dispersive granular products of these polyesters have recently been developed as saturated polyester type binders. In the present invention, a solution of such saturated polyester in solvent may be used, but use of a water dispersible saturated polyester is preferred because handling of the polyester is easier.
Polyvinyl pyrrolidone is a polymer having a very good water solubility and being capable of forming a transparent film, and it is known that polyvinyl pyrrolidone can be applied to manufacture medicines, cosmetics, adhesives and fiber finishing agents.
The thermal dye-transfer type recording sheet of the present invention is prepared by coating on a support with a coating color containing an aqueous dispersion of said saturated polyester or a solution of said saturated polyester in solvent with an aqueous solution of polyvinyl pyrrolidone and if necessary with an ordinary pigment such as calcium carbonate, in a coating weight of 7 to 15 g/m. The thermal dye-transfer type recording sheet is obtained by coating of a mixture of the saturated polyester and polyvinyl pyrrolidone, and the resulting coated paper may be used under such recording conditions that the heating area is very small, as in the case of an electrocardiogram meter. However, when the heating area is large as in the case of a thermal plate, adhesion is caused between the recording sheet and a coloring material-coated substrate just after thermal recording and separation between the two becomes difficult. Accordingly, in order to obtain a general-purpose recording sheet, it is preferred that pigments are added to the coating color composition for facilitating separation of the recording sheet from the substrate. As the pigment, there may appropriately be chosen and used ordinary pigments such as natural ground calcium carbonate, precipitated carbonate, talc, kaolin, natural or synthetic silicate, amorphous silica, aluminum hydroxide, zinc oxide and titanium dioxide. Among these pigments, calcium carbonate is most preferred because it provides a good optical color density and a high separation effect. It is preferred that the pigment be added in an amount of 50 to 900 parts by weight per 100 parts by weight of the mixture of the saturated polyester and polyvinyl pyrrolidone. In the present invention, in order to attain special purposes, the above-mentioned binder may be used in combination with other binders customarily used for processing of paper, such as modified starch, hydroxyethyl cellulose, methyl cellulose, a styrene-butadiene copolymer latex (SBR latex), an acrylic polymer latex, polyvinyl alcohol, a derivative thereof, protein, gelatin, casein, and guar gum.
When the saturated polyester is used in combination with polyvinyl pyrrolidone, if the polyvinyl pyrrolidone is incorporated in an amount of 6 to 12% by weight with 18 to 24% by weight of the saturated polyester as described in the following Example, there can be obtained a recording sheet which is most excellent in optical color density and color fastness.
As the support of the thermal recordng sheet of the present invention, there can be used plain papers such as fine papers, namely papers made from a bleached chemical pulp, such as NBKP, NBSP, LBKP or LBSP, to which are added according to need a mechanical pulp such as GP or TMP, a semi-mechanical pulp such as CGP, a dry strength additive such as starch, polyacrylamide resin or its derivative, melamineformaldehyde resin or a urea-formaldehyde resin, a sizing agent such as rosin, a synthetic polymer or an alkylketene dimer, a precipitant such as aluminium sulfate, an inorganic filler such as talc, clay, natural ground calcium carbonate or precipitated calcium carbonate, aluminum hydroxide, a natural or synthetic silicate or titanium dioxide and an organic filler such as a powdery urea-formaldehye resin, and papers obtained by externally adding oxidized starch or other dry strength additives to the foregoing papers. However, it must be noted that the composition of the paper used as the support is not particularly critical. Furthermore, in some application fields, a resin film can be used as the support of the recording sheet of the present invention.
The present invention will now be described in detail with reference to the following Example that by no means limit the scope of the present invention.
EXAMPLE
A 40% aqueous dispersion of a saturated polyester ("Vilonal MD-1200" manufactured and supplied by Toyobo Co., Ltd.) was mixed with a 40% aqueous solution of polyvinyl pyrrolidone at a mixing ratio shown in the Table and a slurry of natural ground calcium carbonate ("Super 1500" manufactured and supplied by Maruo Calcium Co., Ltd.) was added to the mixed binder to obtain coating colors. On the other hand, two coating colors were prepared by mixing 30 parts by weight (as solids) of a 40% aqueous dispersion of a saturated polyester ("Vilonal MD-1200" manufactured and supplied by Toyobo Co., Ltd.), a 40% aqueous solution of polyvinyl pyrrolidone independently with 70 parts by weight (as solids) of a slurry of natural ground calcium carbonate ("Super 1500" manufactured and supplied by Maruo Calcium Co., Ltd.). These coating colors were coated in a coating weight of 10 to 14 g/m 2 on a fine paper having Stockigt sizing degree of 12 seconds, a basis weight of 66 g/m 2 and a thickness of 97 μm to obtain thermal recording sheets Nos. 10, 14, 18, 19, 20 and 21.
Separately, sublimable thermal transfer inks of blue, yellow and red were prepared by kneading 10 parts by weight of each of the following three sublimable disperse dyes; namely Disperse Blue 24 (marketed under the tradename "Duranol Blue 2G"), Disperse Yellow 42 (marketed under the tradename of "Resolin Yellow GRL") and Disperse Rde 1 (marketed under the tradename of "Celliton Scarlet B"), independently with 3 parts by weight of polyvinyl butyral and 45 parts by weight of isopropyl alcohol by means of a three-roll mixing ill. A fine paper having a basis weight of 30 g/m 2 was solidly gravure printed with these inks to obtain a transfer substrate. The printed surface of the transfer substrate was brought into contact with the coated surface of the above-mentioned thermal dye-transfer type recording sheet and the assembly was pressed for 5 seconds to a thermal plate of 3 cm×3 cm maintained at 300° C. so that the back face of the transfer substrate was faced to the thermal plate, whereby thermal transfer to the thermal recording sheet was performed. The reflective optical densities the so-prepared transfer substrate. The reflective optical densities of the blue, yellow and red recorder surfaces of the thermal transfer sheets were measureed by a Macbeth densitometer after 24 hours had passed from the time of thermal transfer. Furthermore, in order to examine the change of the record with the lapse of time, the obtained record was exposed to carbon arc beams for 10 hours by using a fade meter and then the optical color densities of the exposed record where similarly measured. This exposure corresponds to about 20 days of outdoor exposure in and around Tokyo. Incidentally, the reflective optical densities were measured by using a visual filter (Wratten No. 106) for the blue color, a blue filter (Wratten No. 47) for the yellow color and a green filter (Wratten No. 58) for the red color. The obtained results are shown in the Table.
TABLE__________________________________________________________________________Results Obtained in ExampleThermal Dye-Transfer Reflective OpticalType Recording Paper Densities Binders Pigment MeasuringNo. (% by weight) (% by weight) Time Blue Yellow Red__________________________________________________________________________10** polyester (30) natural ground after 24 hrs. 1.19 0.70 1.18 calcium standing carbonate (70) after exposure 1.19 0.69 1.18 by fade meter18* polyester (24) & natural ground after 24 hrs. 1.20 0.70 1.20 polyvinyl calcium standing pyrrolidone (6) carbonate (70) after exposure 1.20 0.69 1.20 by fade meter19* polyester (18) & natural ground after 24 hrs. 1.21 0.69 1.20 polyvinyl calcium standing pyrrolidone (12) carbonate (70) after exposure 1.20 0.69 1.19 by fade meter20** polyester (12) & natural ground after 24 hrs. 1.20 0.70 1.19 polyvinyl calcium standing pyrrolidone (18) carbonate (70) after exposure 1.19 0.68 1.15 by fade meter21** polyester (6) & natural ground after 24 hrs. 1.21 0.70 1.20 polyvinyl calcium standing pyrrolidone (24) carbonate (70) after exposure 1.18 0.66 1.12 by fade meter14** polyvinyl natural ground after 24 hrs. 1.21 0.70 1.20 pyrrolidone (30) calcium standing carbonate (70) after exposure 1.17 0.64 1.07 by fade meter__________________________________________________________________________ Note: *present invention **reference example
As is apparent from the Table, in the case of the thermal dye transfer type recording sheets Nos. 18 and 19, the reflective optical densities after 24 hours of standing were especially high, and no substantial color fading was observed even after exposure by the fade meter. That is, with regard to reflective optical densities for blue color and the red color after 24 hours of standing, (reflective densities), sheets Nos. 14, 18, 19 and 21 are superior to the sheet No. 10. With regard to reflective optical densities for the blue color and the red color after exposure by the fade meter (light fastness), sheets Nos. 18 and 19 (of the present invention) are superior to the sheet No. 10, 14, 20 and 21 (of the reference examples).
Consequently the sheet Nos. 18 and 19 of the present invention (wherein 18 to 24% by weight of saturated polyester and 6 to 12% by weight of polyvinyl pyrrolidone is utilized) has superior reflective optical densities after 24 hours of standing (reflective density) and after exposure by the fade meter (light fastness) as compared with sheet Nos. 10, 14, 20 and 21 of the reference examples. As is described above, when 18 to 24% by weight of saturated polyester and 6 to 12% by weight of polyvinyl pyrrolidone is utilized as in the present invention, there can be obtained a thermal recording sheet of high quality which is especially excellent in both the reflection density and the sunlight fastness of the record. | 4y
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FIELD OF THE INVENTION
[0001] This application is a divisional of U.S. patent application Ser. No. 11/861,389, filed on Sep. 26, 2007, entitled “LEG ASSEMBLY” herein incorporated by reference in its entirety. This invention relates generally to a leg assembly, and more particularly to a leg assembly that may be removably secured to a storage case to provide a stable and lightweight base so that the case may be optionally used as a support structure such as a table.
BACKGROUND OF THE INVENTION
[0002] Known storage cases may be selectively converted for use as a support structure such as a table. One such case has been used in military applications and in particular as a chest to store equipment for use by medical personnel. The case is manufactured from metal and includes four relatively wide metal legs that attach to both a base portion of the case and a lid portion, which forms a support surface. These cases are typically rectangular and include front, back and sidewalls. When configured as a table, the base portion has an open interior cavity that can be accessed by reaching between the legs.
[0003] Such cases are relatively unstable, however, as the legs are secured through a passive bracketing system. This system employs substantially U-shaped brackets secured to exterior walls of the base and lid. The legs slide into the brackets and are held against the exterior walls of the case. The brackets are located on the sidewalls of the base and lid and on the back walls of the same. The brackets are passive in that they merely receive the legs and do not clamp or tighten down on them in any way. As will be appreciated, wear and tear on these cases during use can cause tolerances between the passive brackets and the legs to increase. Tolerance increases can, in turn, result in lateral movement of the lid relative to the base and instability of the support structure.
[0004] Additionally, known cases do not include any ancillary structural supports, such as cross members, that bridge and stabilize the legs and help support the weight of the relatively heavy metal lid. This lack of supplemental support further adds to the instability of the legs and impairs the efficacy of such cases in the field.
[0005] Moreover, the legs of known cases do not allow attachment of lids with varying depths. As will be appreciated, cases with larger capacities have lids and bases with deeper sidewalls. In known systems, different sets of legs are required for each size lid to keep the support surface of the lid at a height that is comfortable for use as a table or the like. This requires the manufacture, stocking and deployment of multiple legs depending on the capacity of the case and size of the lid.
[0006] The legs of these cases are also quite wide and spaced in a configuration that does not allow for easy access to an interior cavity of the base. As stated above, two of the legs are secured to the sidewalls of the case. More specifically, the legs are secured to a portion of the sidewalls that is proximate the front wall of the base. Given the width of the legs, access to the interior cavity of the base is partially obstructed. This can be problematic if the cases are deployed for field use by military medical personnel who need to quickly locate and extract equipment.
[0007] With the foregoing problems and concerns in mind, the general object of the present invention is to provide a leg assembly for a storage case, in particular a leg assembly that provides superior stability, allows for attachment of case lids of various sizes, and provides easy access to an interior cavity of a storage case base.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a leg assembly.
[0009] It is an additional object of the present invention to provide a leg assembly for a storage case.
[0010] It is an object of the present invention to provide a lightweight leg assembly for a storage case.
[0011] It is a further object of the present invention to provide a leg assembly for a storage case that can be used to securely and stably support a lid of the case to that the case may be used as a support structure such as a table.
[0012] It is yet another object of the present invention to provide a lightweight leg assembly for a storage case that can be used to securely and stably support a lid of the storage case to that the case may be used as a support structure through the use of an active bracketing system and cross-braces.
[0013] It is an additional object of the present invention to provide a leg assembly for a storage case that may be used with case lids of varying sizes.
[0014] It is a further object of the present invention to provide a leg assembly for a storage case that allows for unobstructed access to an interior cavity of a base of the storage case.
[0015] These and other advantages of the present invention will be better understood in view of the Figures and preferred embodiment described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a perspective view of a closed storage case for use with a leg assembly according to the preferred embodiment of the present invention.
[0017] FIG. 2 shows a perspective view of a leg assembly according to the preferred embodiment of the present invention, with the leg assembly secured to a base and lid of the storage case of FIG. 1 .
[0018] FIG. 3 a shows a front view of a single leg and mounting bracket of the leg assembly of FIG. 2 .
[0019] FIG. 3 b shows a back view of the single leg and mounting bracket of FIG. 3 a.
[0020] FIGS. 4 a - 4 c show various additional views of the single leg and mounting bracket of FIG. 3 a.
[0021] FIGS. 5 a and 5 b show various views of the mounting bracket of the single leg of FIG. 3 a.
[0022] FIG. 6 shows a side view of a cross-brace according to the preferred embodiment of the present invention.
[0023] FIG. 7 shows an enlarged perspective view of the bottom portion of the single leg of FIG. 3 a wherein the leg has been secured to a base of a storage case through a latching mechanism.
[0024] FIGS. 8 a - 8 d show the leg assembly and storage case of FIG. 1 and graphically illustrate the process by which the leg assembly is secured to the storage case for use as a support structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] FIGS. 1 and 2 show a perspective view of a preferred embodiment of a storage case 10 and leg assembly according to the present invention. The case 10 includes a bottom portion or base 12 and a top portion or lid 14 . The base 12 has a horizontal bottom panel 16 and four vertical panels or walls, which include a front wall 18 , a rear wall 20 , and two sidewalls 22 . The vertical walls form an inner cavity 24 . The base 12 also has a parting line edge 26 member around the periphery of the vertical walls. The term “parting line” refers to the portion of a case where the base and lid meet. Similarly, the lid includes four vertical panels or walls, i.e., a front wall 28 , a rear wall 30 , and two sidewalls 32 . The lid 14 includes a horizontal bottom panel 34 and peripheral parting line edge member 36 , which aligns with the parting line member 26 of the base 12 when the case 10 is closed. The bottom panel 34 and vertical panels of the lid 14 form an inner cavity 38 .
[0026] The case is secured in a closed position through the use of multiple latching mechanisms 40 spaced apart along the vertical walls of the base and lid. Each latching mechanism 40 is comprised of a strike 42 that is secured to the case lid 14 and a latch 44 on the base 12 that is in alignment with the strike 42 . The latch 44 has a hooked upper portion 46 that is designed to engage the strike 42 . The latch also includes a cam member 48 , which allows the hooked upper portion 46 to be clamped down on the strike 42 to secure the lid 14 to the base 12 . Each strike 42 and latch 44 are located in aligned recesses in the lid and base, 50 , 52 respectively. The general operation of the above-described latching mechanism is described in U.S. Pat. No. 5,370,254, which is incorporated by reference in its entirety herein.
[0027] The case 10 is preferably manufactured from plastic through a rotomolding process. As will be readily appreciated, however, other materials and processes may be utilized provided they are suitable to protect whatever equipment or supplies are stored within the case.
[0028] The preferred embodiment of the inventive leg assembly for use with the case 10 is depicted in FIG. 2 . As shown, the assembly is comprised of four generally linear legs 54 . The legs 54 are attached to the front and back walls of the base, 18 , 20 , and the front and back walls of the lid, 28 , 30 . The legs 54 extend from the base 12 to the lid 14 to support and stabilize the lid 14 enabling it to function effectively as support surface. The legs 54 are attached to portions of the front and back walls of the base 12 and lid 14 that are proximate the sidewalls, 22 , 32 . The legs are preferably manufactured from a lightweight metal and, in one configuration, are 0.06-inches thick. The legs also have a series of spaced apart apertures or holes 55 which reduce weight.
[0029] The location of the legs on the base and lid are an important aspect of the present invention as they allow easy access to the interior cavity 24 of the base. Prior art support structures have relatively wide legs located on the sides and back of base and lid hindering access to the interior of the base. As will be appreciated, in military and medical applications efficiency is critical. Moreover, the legs are located such that they do not extend out from the base or lid and therefore do not require any additional floor space.
[0030] As shown, the legs 54 have a lower portion or end 58 and a generally U-shaped upper portion or end 60 and a central body portion 61 . The upper end 60 attaches to the lid 14 and the lower end 58 attaches to the base 12 . The upper end 60 includes a flat portion 57 and upper and lower slots 64 , 66 . The legs 54 are shaped to fit into the lid and base recesses 50 , 52 , respectively. Preferably, the legs 54 have a corrugated cross-section or profile, which corresponds to the shape of the recesses 50 , 52 and increases strength of the legs. The inter-engagement or mating of the legs 54 and recesses 50 , 52 helps align the lid 14 and base 12 for use as a support structure. As discussed in greater detail below, the legs 54 are also connected and stabilized by two cross members 56 , which extend between the front and back leg on opposite sides of the base 12 and lid 14 .
[0031] The mating relationship of the legs and the recesses of the base and lid are yet another important aspect of the present invention. The recesses help to locate the legs so that they are properly aligned and stabilize the support structure preventing lateral movement. Known cases do not include this feature. As such, the mating relationship imparts a structural stability not found in the art.
[0032] Turning now to FIG. 3 a - FIG. 5 b , the legs 54 are secured to the base 12 through mounting brackets 62 , that are attached to the lower end 58 of each leg. As shown in FIGS. 4 a and 4 c , the mounting bracket 62 and lower leg end 58 form a substantially U-shaped bracket or opening 80 in which the lower end of the leg 58 forms a first sidewall 82 and a downwardly extending portion of the mounting bracket 62 forms a second sidewall 84 . When installed, the first and second sidewalls 82 , 84 of the legs 54 are placed over the front wall 18 of the base 12 so that the front wall 18 is between the sidewalls 82 , 84 . When attached, the brackets 62 distribute weight from the legs, cross members and lid on the base parting line 26 and abutingly contact the interior and exterior of the front wall 18 of the base 12 providing stability to the legs 54 . The mounting brackets 62 , which are load bearing, are preferably manufactured from a strong, lightweight metal such as aluminum/magnesium alloy 5052-H32. Other materials may be used as long as they are sufficiently strong to prevent a material failure.
[0033] The first and second sidewalls 82 , 84 are important aspects of the present invention. Unlike known support structures which attach to either a front or back side of a base wall, the present invention employs a U-shaped bracket having two side walls 82 , 84 one of which contacts a front side of a base wall and the other a back or reverse side of a base wall. This configuration provides a degree of stability and strength not achieved with known systems.
[0034] The brackets 62 also include a series of weight reducing holes 55 and are secured to the legs through a plurality of bolts or like fasteners. Further, the mounting bracket 62 preferably includes a rubber liner 69 on an inner portion of the bracket that contacts the parting line 26 to protect the line and base 12 from damage. As will be readily appreciated, it is desirable that the mounting bracket 62 be as wide as possible to distribute the weight of the legs, cross members and lid over a larger area and increase stability. The width of the mounting bracket 62 is limited, however, by an inside radius between the front wall 18 and sidewalls 22 of the base 12 .
[0035] As shown in FIG. 5 a , the downwardly extending leg or second sidewall 84 of the bracket 62 is angled outward and away from the leg 54 at an angle Θ. As will be readily appreciated the angle is acute. The angled sidewall 84 causes the legs to extend slightly outward and away from the base 12 when the cross member is not installed. Upon the addition of a cross member, the legs move inward to a substantially vertical position and the mounting bracket 62 contacts the latch 44 to effectively “preload” the leg 54 with the latching mechanism 40 so that the latch may then be cammed downward to secure the leg 54 to the base 12 .
[0036] In addition to the mounting brackets 62 , the legs 54 are secured to the base 12 through the case's latching mechanism 40 . As shown in FIGS. 3 a , 3 b and 7 the lower end 58 of each leg 54 includes a latching slot 63 that is sized to accommodate the hooked upper portion 46 of the latch 44 that is normally used to secure the lid 14 to the base 12 . When a leg 46 is secured to the base 12 , the mounting bracket 62 is first placed on the front wall so that it extends into the base inner cavity and the leg 54 is lowered toward the base. After the leg 54 has been lowered a certain distance, the hooked upper portion 46 of the latch 44 is placed through the latching slot 63 and the latch 44 is urged downward thereby securing the leg 54 to the base 12 .
[0037] The attachment of the legs to the base 12 through the latching mechanism 40 is yet another important aspect of the present invention. Known cases use a passive attachment means in which legs are simply inserted in metal brackets on the exterior of a case. Repeated use of such cases in the field leads to increased lateral movement of the legs and renders the cases unstable. In sharp contrast, the present invention employs both a mounting bracket and an active latching system in which the mechanism used to latch the lid to the base is utilized to secure and stabilize the legs. As will be readily appreciated, stability of support structures is critically important in medical and military applications for which many of such cases are used. The active latching mechanism of the present invention provides a level of stability and strength not found in known cases.
[0038] Referring back to FIG. 2 , the lid 14 rests on the cross members 56 which are attached to the legs 54 . The lid 14 is held in place by the inter-engagement of the corrugated profile of the leg 54 and the lid recess 50 which have corresponding or mating surfaces. As discussed above, this inter-engagement prevents the lateral movement of the lid 14 relative to the legs 54 and base 12 .
[0039] The cross members 56 are secured to the legs 54 at attachment points located on the legs. More specifically, the cross members 56 are attached to the legs 54 through slots machined in the body 61 of each leg. The slots are sized and shaped to accept the cross members 56 , support the lid 14 , and provide stability. As shown, there are two attachment points or slots per leg 54 , an upper slot 64 and a lower slot 66 . The cross members 56 may be placed in either the upper or lower slots 64 , 66 depending on the size of the lid 14 . In its preferred configuration, the upper slot 64 allows a 2-inch deep lid to be employed. The lower slots 66 provide for the use of a deeper lid having 9-inch sidewalls. The upper slot 64 is located at the upper end 60 of each leg 54 and has an open end into which the cross member 56 is lowered. The lower slot 66 is located at approximately the midpoint of each leg 54 and does not include an open end. As such, the cross member 56 is inserted laterally into the lower slot 66 and then lowered into position. As will be appreciated, the upper and lower slots are located at the same positions on each leg 54 in the assembly so that the cross members 56 , when installed, are horizontal and parallel to the lid. Both the upper slot 64 and lower slot 66 have end portions 65 , 67 , respectively, which support the weight of an inserted cross member 56 and the lid 14 .
[0040] The slots 64 , 66 are spaced on the leg body 61 so that top of the leg 54 is flush with the parting line 36 of the lids. That is, if the lower slot 66 is employed with a 9-inch lid 14 , the top of the legs 54 are flush with the parting line 36 . If the upper slot 64 is used with a 2-inch lid 14 , the top is flush with the parting line 36 as well. This keeps the lids 14 , i.e., the table top, at a consistent comfortable height regardless of whether a 2 or 9-inch lid is used. Additionally, the distance between the flat portion 57 of each leg 54 and the top of a cross member 56 installed in the upper slot 64 is great enough so that a lid 14 can be placed cavity side down without damaging the strikes 42 on the lid exterior.
[0041] The leg slots are a significant aspect of the present invention as they allow cross members to be attached at multiple locations to accommodate lids, and cases, of various sizes. Known cases do not allow for this and would require multiple sets of legs for each size case. This would require the manufacture, stocking and deployment of multiple leg sets, which is inefficient and expensive.
[0042] Turning now to FIG. 6 , the cross members 56 are generally linear in shape and include two opposing end portions 68 . Each end portion 68 has a mounting slot 70 that is generally S-shaped with an open end 72 and a terminal end 74 having an abutment surface 76 . The abutment surface 76 contacts the end portions 65 , 67 of the leg slots 64 , 66 and is weight bearing. The mounting slot 70 is sized and shaped to accommodate attachment to the legs 54 . When a cross member 56 is inserted into a leg slot 64 or 66 , a portion of each leg 54 directly below each leg slot extends into the mounting slot 70 of the cross member 56 until the end portion 65 , 67 of the mounting slot 70 contacts the abutment surface 76 of the leg slot.
[0043] The shape of the mounting slot 70 is such that there are four points of contact between each leg 54 and an inserted cross-member 56 . The contact between the abutment surface 76 of the cross member 64 and the end portions of the leg slots 65 , 67 is weight bearing. The remaining three points of contact between the mounting slot 70 and the body portion 61 of each leg 54 provide stability. This configuration, as opposed to a linear mounting slot, reduces friction between the legs and cross members and simplifies the manufacturing process.
[0044] The cross members are preferably manufactured from a lightweight metal. In a preferred embodiment, the cross members are 0.25-inch thick aluminum. This thickness was chosen to maximize the contact area of each cross member 56 and the lid 14 . As will be appreciated, thicker materials may be used provided they are sufficiently lightweight and strong. The cross members also contain cut away holes 55 to reduce weight.
[0045] As will be readily appreciated, the cross members are another important feature of the present invention. The cross members act to stabilize the legs and securely support the lid. Known cases do not include cross members or any ancillary support structure other than the legs themselves. The cross members of the present invention help create a support that can be used under the most rigorous of conditions and deployments.
[0046] Although the cross members 62 are a critical component of the present invention, the legs 54 may be used temporarily without cross members if they are unavailable. In this configuration, the strike 42 of the lid 14 contacts the flat portion 57 of the leg 54 to support the lid 14 ( FIGS. 2 and 3 b ).
[0047] FIGS. 8 a - 8 d graphically depict the assembly of the preferred embodiment of the present invention. The mounting brackets 62 of the legs 54 are first attached to the base 12 by placing them over the front and rear walls 18 , 20 . The cross members 56 are then inserted in the leg slots 64 , 66 until the abutment surfaces 76 of the mounting slots 70 contact the terminal ends 74 of the leg slots. The hooked upper portion 46 of the latch 44 is then inserted through the latching slot and the latch is closed securing the legs to the base. The lid 14 is then lowered onto the cross members so that it rests on the cross members and so that its recesses 50 matingly engage the legs 54 securing the lid 14 and preventing its lateral movement.
[0048] As will be appreciated, the present invention also has utility without the lid 14 and without all four legs 54 . For example, a single leg 54 may be attached to the base 12 for use as a support structure for hanging equipment such as IV bags.
[0049] In sum, the present invention through the use of an active latching system, mounting brackets, slots, cross members and mating surfaces, provides a support structure that is stronger, lighter and more stable than known systems. Moreover, the present invention provides a versatile support assembly that can be used with cases of various sizes and capacities. Known cases do not provide these benefits.
[0050] While many advantages of the present invention can be clearly seen from the preferred embodiment described, it will be understood that the present invention is not limited to such an embodiment. Those skilled in the art will appreciate that many alterations and variations are possible within the scope of the present invention. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This Invention pertains to a bed patient monitoring system and more particularly to a system for detecting the undesired movement of a bed-restricted patient and providing a system of alarms to facilitate returning the patient to a proper position in the bed.
2. Background of the Invention
It is often desirable to restrict patients to their beds and not permit their movement from the bed without supervision of medical personnel or, in many instances, without the direct aid and assistance of such personnel. With the increase of litigation and legal liability in the area of medical care, the consequences of bed-restricted patients getting out of their beds and then being injured, or worsening their condition as a result thereof, is of major economic significance in the health care field. As a result of this and related problems concerning bed-restricted patients, a need has developed to monitor the activity of such patients and to be forewarned that the patient is about to or is trying to leave their bed. One such attempt to solve this problem is set forth in U.S. Pat. No. 4,179,692 issued Dec. 18, 1979, to Dwight A. Vance and entitled "APPARATUS TO INDICATE WHEN A PATIENT HAS EVACUATED A BED OR DEMONSTRATES A RESTLESS CONDITION". The system disclosed in the Vance patent utilizes a variety of switches for detecting patient movement and/or restlessness. The system is arranged to detect the movements of a patient and thereafter try to determine a level of restlessness which when exceeded will indicate that the patient may be getting ready to leave the bed. This and other systems which have attempted to solve this problem have had a variety of shortcomings which are overcome in the present system. If a patient is adjusting themselves in the bed and activates a detecting device which is indicative of an undesirable movement, but in fact the patient is not moving from the bed and resumes a more normal position which would not activate the detecting device, an alarm which may have been activated oftentimes continues to operate even if the patient's activity has ceased.
Other systems do not interface with the nurses' call light which is stationed in the hall over the patient's door and at the nurses' station; or if the systems do interface, they do not differentiate between a patient call and a patient trying to leave a bed, the latter condition normally being a much greater emergency than the former under normal circumstances. On the other hand, some systems require that they be interfaced with the nurses' call station system in order to operate. Many of these systems require rather complex procedures for activating or reactivating the system or for resetting the system if it has been activated. It is desirable to have very simple procedures for activating the system so that doctors, nurses, orderlies or the like, or even visitors or family members who are not familiar with the system, will not inadvertently set off the alarm or if they have deactivated the system in order to move a patient from the bed, forget or be prone to avoid activating or resetting the system because of the complexity of the system or because of forgetfulness. It is also important that any alarm device at a remote location have some means for identifying the discreet room number that houses the patient making an undesirable move. Another problem with such prior systems is that a malfunction in the system is not readily detectable and thus the system may not be working and this not be known to the health care staff. Yet another problem is that of the patient having some way to intentionally or unintentionally either disarm the system or trigger a false alarm. In some systems, once an alarm is set off, each bed must be reset.
Although it is the express object of the Vance patent, cited above, to provide and signal a level of restlessness, it is more desirable to know if the patient is moving from a desired condition and yet not set off an alarm which must be reset in the patient's room should the condition return to normal. In some systems the sensor is placed directly beneath the patient or beneath a sheet and because it is easily moved by the patient's movements, can be moved out of its desired position and then produce false alarms because the detector is mispositioned rather than the patient. In some systems the detector, when placed on top of the mattress, becomes contaminated by contact with the patient or the patient's body fluids and as a result must be replaced with each new patient or after each occurrence of suspected contamination.
One such detecting device is shown in U.S. Pat. No. 4,565,910, issued on Jan. 21, 1986, to Musick, et al, and entitled "SWITCH APPARATUS RESPONSIVE TO DISTORTION". This device, because of its construction, must be placed under sheets, bedding or the like on top of the mattress and thus is protected from patient contact or body fluid contact by only thin layers of materials. Hospitals using this product routinely require its replacement with a new detector unit with each patient turnover.
It is therefore an object of the present invention to provide a new and improved bed patient monitoring system which will overcome the drawbacks of the prior systems.
SUMMARY OF THE INVENTION
With this and other objects in view, the present system contemplates a bed patient monitoring system including a detection device that when placed beneath the mattress of a bed is sensitive to the weight distribution on top of the mattress to effectively monitor the patient's movement. The detection device is comprised of a ribbon switch array having a pair of parallel conductive strips which are arranged to move away from one another in the absence of pressure and to contact one another under a sufficient pressure source to make an electrical contact. The ribbon switch is sandwiched between a pair of substantially parallel plates that are arranged for relative movement laterally and transversely and are encased in a sealed cover which permits such relative movement between the plates and at the same time holds the plates and the switch in assembly. The cover also seals the assembly from contamination in the environment of the bed patient. The contacts in the ribbon switch are electrically connected to a control device that translates the making and breaking of the contacts into a movement signal for use in operating various alarm devices. One such device includes an already existing nurses' call station alarm system usually consisting of a patient controlled call button positioned at the patient's bedside, a hall light over the patient's door and signal lights and/or audible device at the nurses' station. The control device, when receiving a signal indicative of undesired patient movement, deactivates the regular nurses' call light system and superimposes an alert signal on the nurses' call light system which is distinguishable from the regular signal indicative of the patient calling for help. The alert signal also activates an audible alarm in the patient's room which is designed to encourage the patient to discontinue the undesired movement and to return to the desired position on the bed. If the patient returns to the desired position, the alarm system is automatically reset and the alert signal ceases.
In addition, the movement signal initiates operation of a radio frequency transmitter which sends a discreet signal to a central processing unit at a remote location for identifying the discreet room location of the alert signal and for further transmitting the signal to other remote alarm stations in the system.
In one embodiment of the invention, a switch device is positioned on the bed and movable bed rail so that if the bed rail is lowered, in order to voluntarily move the patient from the bed, the alert system is deactivated and no alarms are initiated. Then, when the patient is returned to the bed and the bed rail is raised to confine the patient, the system is activated to provide an alarm under appropriate circumstances.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a circuit diagram showing the bed patient monitoring system of the present invention;
FIG. 2 is a schematic illustration of a bed rail switch for use in the circuit diagram of FIG. 1;
FIG. 3 is a side elevation view of a hospital bed having a bed rail switch for use with the present invention;
FIG. 4 is an exploded perspective view of a movement detection device in accordance with the present invention; and
FIG. 5 is a perspective view of the assembled movement detection device of FIG. 4 positioned over a portion of a bed frame; and
FIG. 6 is a cross sectional view of a ribbon switch for use in the movement detection device of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
REFERRING first to FIG. 1 of the drawings, a bed patient monitoring system is shown for use in a health care facility having patient rooms and a nurses' station remote from the patient's room. It is readily appreciated that many arrangements of such facilities are possible and that the present invention is described with respect to but a few of such arrangements. A bed sensor 12 which would normally be positioned on or about the patient's bed is shown having a circuit path 14 connected to a control relay 24, the connection is made by means of a male/female quick disconnect microphone jack 25 which has a built-in spring loaded means for closing the circuit path 14 when the male portion of the jack 25 is removed from the female portion of the jack 25 which is shown mounted on the housing of the control relay 24. As will be described later wit reference to FIG. Z of the drawings, a bed rail switch is interposed in the circuit path 14 to provide a functionally unique way to automatically open and close this circuit path 14. A dampening circuit operates in the input to the control relay 24 to provide a momentary delay in the activation of the relay 24 should the bed sensor 12 provide a momentary movement signal. This dampening is provided by a capacitor across the coil of the control relay which gives a time delay of about .2 of a second if the bed sensor switch is opened. As will be described later, the bed sensor includes a ribbon switch which has contacts that are held closed when a patient is properly positioned on the bed. If the patient moves their weight off of the sensor for more than the momentary delay described above, the open contacts of the switch cause the control relay which is normally closed, to open. A first signal path from control relay 24 leads to a light emitting diode 26 which is positioned on the bed or in the patient's room in view of health care workers. A second circuit path from the control relay 24 passes to a flasher timer 28 such as a "555 timer". A third circuit path from the output of control relay 24 passes to a nurses' call station control relay 30.
Most health care facilities have a nurses' call station system already in existence which permits a patient, by pressing a call button 31, to send a signal to a light 35 positioned over the patient's door and to a light and/or audible alarm at a remote nurses' station 38. There are of course a variety of such systems but for purposes of illustration the system described herein, which is one of the more prevalent systems, includes a low voltage power supply 32 for providing power to one leg 23 of the hall light 35 and nurses' call station display 38.
When not powered by a signal from control relay 24, nurses' call station control relay 30 is normally closed to provide a ground path 29, 33 to the hall light 35 and nurses' call station display 38. Ground path 29 is connected to the nurses' call button 31 which has its other lead connected to the ground leg 27 of power supply 32. The other power leg 23 of the power supply is connected to the hall light 35 and nurses' call station display 38. When the control relay 24 sends a signal to control relay 30, relay 30 is opened to break the ground leg 33 to the hall light 35 and nurses' station 38.
Another output of control relay 24 to flasher 28 causes flasher 28 to intermittently operate the flasher relay 40. An intermittent signal from the flasher 28 is passed to an audible alarm 42 which may be in the form of a beeper, voice synthesizer or the like, in the patient's room.
Another normally open output 41 of relay 40 is activated by the relay 40 to provide a ground leg to the nurses' call station 38 and hall light 35. This will provide an intermittent ground because the relay 40 is driven by an intermittent signal from flasher 28. Thus when control relay 24 operates control relay 30 to open the ground leg 33 in the nurses' call light system, the ground to the hall light 35 and nurses' call station 38 is taken up by the intermittent ground on leg 41 from flasher relay 40.
A 12-volt D.C. power supply 46 provides power to all components of the system thus far described except those components of the already existing nurses' call station system which are shown utilizing a 24-volt A.C. power supply 32.
Yet another circuit path 43 from the flasher relay 40 is normally closed to ground out an operating signal to a discreet frequency transmitter 16. When relay 40 operates, the ground leg 43 is intermittently broken to permit transmitter 16 to intermittently operate at its discreet frequency. In order to utilize the radio frequency signal generated by transmitter 16, a remote alarm portion of the system is placed at a central station for remote room monitoring, usually the nurses' station. This remote portion of the system includes a central processing unit 48 which has a receiver for receiving the radio frequency signal from the transmitter 16. The signal from the transmitter 16 is modulated by a programmable modulating device to provide a discreet signal so that each room in which the transmitter 16 is placed may have a discreet signal which is then discernable by the central processing unit 48 to identify the room from which an alarm signal originates. A system produced by Interactive Technologies, Inc., of North St. Paul, Minn., and described as their SX-IVB SECURITY SYSTEM, provides a system including the transmitter 16 and Central Processor thus far described. This system is powered by an 8-volt D.C. power supply 50. The central processor 48 also provides a visual digital readout of a number indicative of the transmitter location originating the discreet alarm signal which is programmed into both the transmitters 16 and the central processor 48. This visual readout would most likely be provided to the nurses' station display 52. In addition, the system utilizes the 110 electrical circuit in the vicinity of the system to provide any number of alarm units such as audible hallway devices 54 which are merely plugged into a wall outlet and which receive a radio frequency signal interposed upon the 110-volt A.C. power supply.
Referring now to FIGS. 2 and 3 of the drawings, a bed rail switch device is shown including a first switch component 18 mounted on a bed rail 66. The first switch component 18 may be a magnet or magnetic device which when positioned near a second switch component 22 such as a magnetic reed switch, will cause the switch to operate. The switch component 22 is a normally closed relay switch which provides a closed circuit path between the bed sensor 12 and the control relay 24. The normally closed state exists when the magnetic switch component 18 is spaced from the stationary component 22. When component 18 is brought into the magnetic proximity of component 22, the switch is opened and in the open position, the relay switch provides a constant signal to the control relay 24 independent of a patient's weight being present to operate the bed sensor. The switch component 22 is mounted on a stationary portion 63 of the frame of the bed 56 so that when the bed rail 66 is in an up position, components 18 and 22 are spaced sufficiently to maintain the relay switch in its normally closed position. When the bed rail 66 is lowered to permit an authorized removal of the patient from the bed, components 18 and 22 are placed in magnetic proximity to operate the switch and thereby provide a constant signal to control relay 24, which simulates the patient's presence in a proper position on the bed. FIG. 3 shows a hospital bed 56 having a mattress 52 positioned over a bed framework including a stationary center frame member 60 and movable hand and foot end portions 62, 64. The bed sensor 12 is shown positioned between the mattress 58 and the stationary center frame member 60. The mattress 58 and the stationary frame member 60 are shown to be separated vertically for purposes of clearly illustrating their relative arrangement on the bed. Their position under actual circumstances is the sensor 12 being sandwiched between the mattress and stationary frame portion 60. A movable bed rail 66 is slideable on vertical supports 68 to raise and lower the bedrail alongside the bed frame and thereby provide in its raised position a means for confining a bed patient to a desired position on the bed, and in its lowered position, permitting the patient to leave the top of the bed area.
Next referring to FIG. 4 of the drawings, the bed sensor 12 is shown in an exploded view and includes an upper plate 70 made of a stiff plastic material such as 1/8 inch thick acrylic plastic or plexiglas. A bottom plate 74 is constructed of a similar acrylic material approximately 1/4 inch thick to provide a firm and steady base for the detector assembly. Bottom plate 74 has a drilled opening 71 sized just large enough to pass a pair of conductors 72 which are sealed with a silicon sealant where they pass through opening 71 as will be described later. A pair of ribbon switches 76 are arranged parallel to one another on top of plate 74 and are sandwiched between the top and bottom plates 70, 74 when the detector is assembled. The ribbon switches used herein are manufactured by Tapeswitch Corporation of Farmingdale, N.Y., as 102-BP ribbon switch. This switch is also described in U.S. Pat. No. 2,896,042 entitled "Tape Switch", which was issued to R. H. Koenig on July 21, 1959. As shown in FIG. 4, the parallel rows of ribbon switches are electrically connected in parallel to circuit wire 72. The ribbon switches 76 are arranged in the assembly so that their outer edges and ends are spaced inwardly from the outer edges of the top and bottom plates. A configuration that has proven effective is a side spacing "a" of 11/2 inches from the edges of the top and bottom plates 70, 74 to the outer edge of the ribbon switches which are each about 1/2 inch wide. An end spacing "b" of approximately 2" works well. A spacing "c" of about 23/4 inches between the parallel rows of ribbon switches is appropriate for this assembly. The ribbon switches are about .156 inches thick. This switch material is shown in cross sectional detail in FIG. 6, and is comprised of a pair of spaced conductor ribbons which when forced together under pressure to make electrical contact. A cover 78 of polyethylene plastic of approximately 71/2 mil thickness and completely sealing the assembly (also see FIG. 5) is next provided to seal the assembly from environmental contamination and to hold the parts of the detector thus far described in assembly. The cover 78 is preferably formed into a bag which closely fits about the assembly so that the assembly can be easily slid into the bag while leaving enough space for the top and bottom plates 70, 74, to move vertically and transversely relative to one another. The end 80 of the bag 78 is then heat sealed to provide a sealed environment within the bag for the assembled detector. This sealed configuration permits the detector to be cleaned with a disinfectant and reused from one patient to another. This reuse procedure is permitted due to the detector being placed below the mattress and also being sealed against fluid contamination. The advent of the discovery of Anti Immune Deficiency Syndrome (AIDS) has caused health care facilities to become extremely cautious regarding the contamination of health care equipment and products which are subjected to the body fluids of patients. Detectors which are placed on top of the mattress under bed clothing are routinely discarded after each patient use. The present detection system is arranged so that its sensitivity and construction features lend it effective for under mattress use, thus removing it from the immediate environment of potential body fluid contamination. In addition, the sealed configuration permits its being cleaned for reuse after each patient turnover. The circuit cord 72 from the ribbon switches 76 passes through a hole in the cover, the hole and cord 72 being again sealed by any good grade of silicon sealant. FIG. 4 also shows end plates 84 which are made from a thin tough material such as 0.03 inch acrylic plastic. The end plates 84 are bonded by glue, epoxy or the like to the bottom outer surface of the cover 78 of the assembly and are positioned at the ends of the assembly. Referring now to FIG. 5, a side angle iron bed frame member 86 is shown having a matrix of wire webbing 88 spanning between the side frame members 86 for supporting a mattress, box springs, or the like in a supple manner. The webbing is attached to the frame by means of coiled spings 90 having their curved ends hooked to the webbing and through spaced holes in the frame members 86. These springs 90 will tend to wear through and rupture the cover 78 of the detector assembly 12. The end plates 84 provide a protective barrier at the ends of the detector assembly 12 so that when the detector assembly is placed on the stationary portion 60 of the bed frame, and lengthwise is dimensioned to lap over the edge of the side frame member 86, the end plates 84 covering that portion of the detector assembly 12 overlying the coil springs 90 will prevent rupture of the environmental sealed cover 78. The stationary center portion 60 of a typical hospital bed frame has a width dimension "e" of approximately 9 inches. The detector assembly 12 has a width dimension "d" of 63/4 inches which approaches the minimum width which is used for the top and bottom detector plates 70, 74. It is preferable to make the detector assembly 12 wide enough so as to fill as much as possible the space occupied by the non-movable center portion 60 of the bed frame. In addition, the length of the detector assembly should be such that it extends onto at least a portion of the frame portion 86 on either side of the bed to give a firm and resistive support to the bottom of the sensor. Such filling of this space with the detector assembly maximizes the detector sensitivity to patient movement. When the detector is placed under the mattress as shown herein, this maximizing of sensitivity becomes even more important because of the attenuating effect of the intervening mattress between the bed patient and the detector.
FIG. 6 of the drawings shows a cross sectional view of the ribbon switch 76 which is used in detector 12. The switch 76 includes an upper ribbon contact 92 which is spaced upwardly from a lower ribbon contact 94, and has an insulating strip 95 which is positioned under the contact 94 and folds over the edges of the lower contact 94 to provide a separating member between the ribbon contacts 92 and 94. The longitudinal edges 96 of the insulating strip 95 are formed in a "Z" shape to provide a spring effect to the separating member for keeping the contacts 92 and 94 from normally coming into contact. The assembly described above is encased in a plastic sheath 97 which transmits force to the contacts 92, 94. Electrical conducting wires 98 are electrically connected to the contacts 92, 94 to provide an electrical indication of when the contacts are spaced or touching. This ribbon switch shown in FIG. 6 is described in detail in U.S. Pat. No. 2,896,042 described above.
In the operation of the system described thus far, reference is first made to FIGS. 2, 3 and 4. When a patient is positioned on the bed mattress 58, enough weight is present on the mattress to sufficiently compress the ribbon switch 76 so that the ribbon contacts 92, 94 therein are electrically connected. The construction of the detector 12, such as size of the detector assembly and these features permitting lateral movement of the top and bottom plates permits patient weight in any number of normal positions on the mattress to provide this contact closing pressure. Thus, the circuit path 14 is closed when a patient is positioned on the bed. This in turn provides a holding voltage to the control relay 24 to hold the relay in a deactivated or open state. A capacitive delay circuit is connected across the coil of the relay to provide a delay of approximately .2 seconds so that momentary opening of the ribbon switch contacts due to a patient shifting positions, will not set off the alarm system. In this deactivated state the control relay passes a power signal to the LED 26 to provide a visual signal to health care workers in the room that the system is activated and ready to operate. When patient weight is removed from the detector 12, a movement signal is passed by the control relay to the nurses' call station relay 30. Activation of relay 30 opens a ground leg circuit path passing from the power supply 32 through the patient operated call button 31 and relay 30 to the nurses' hall light 35 and nurses' call station display 38. This in turn disables the normal operation of the nurses' call station call button 31, so that if this system is being operated by the patient's button 31, it is disabled by the patient trying to move from the bed. At the same time another output of control relay 24 drives the flasher 28 to generate an intermittent signal to operate flasher relay 40 in an intermittent fashion. Operation of flasher relay 40 provides an intermittent alternative ground path 41 to the hall light 34 and nurses' call station display 38 to cause their intermittent operation. In addition, if the patient bed monitor portion of the system should fail, such as by power failure, the nurses' control relay 30 which is normally closed, will remain normally closed in the absence of a movement signal from control relay 24. The circuit path from control relay 24 is normally open absent a movement signal from the bed sensor which closes the relay for sending out a control signal to flasher 28 and nurses' call station relay 30. When flasher 28 signal operates the flasher relay 40, an intermittent signal is also passed to audible alarm 42 which provides a signal within the normal audible range of a patient to let the patient know that he has caused an alarm by his movement which in many cases will remind the patient that he/she is exceeding the desired movement range and thereby encourage the patient to return to the desired position on the bed. One such audible alarm is a voice synthesizer which would speak a phrase such as "Please return to your bed" or the like so that if the patient in fact is getting out of bed, they will be encouraged to return. Another output 43 of the flasher relay 40 operates a transmitter 16 which outputs, on an intermittent basis, a discreet frequency RF signal that is modulated so as to provide a discreet signal that is different for each transmitter 16 in a particular hospital system. A remote receiver for the transmitter's discreet signal is housed in a central processing unit 48 which is located at a central monitoring station such as a nurses' station. The central processing unit 48 has a visual display readout that identifies the location of a transmitter being activated by undesired patient movement. The central processor 48 also provides an output signal that can be used to operate a remote alarm 54 in the hospital corridors for example. In the system shown in FIG. 1, the bed sensor output passes through circuit path 14 through a quick disconnect jack 25 to the control relay 24. The control relay is in a normally open state until the circuit path 14 is opened by the patient lifting their weight from the detector 12 for a sufficient time to overcome a capacitive delay circuit across the coil of control relay 24. The delay circuit causes the relay 24 to delay about 0.2 of a second before being activated to provide a power signal output to the nurses' call station relay 30. When relay 30 is activated it breaks a grounding leg to the nurses' call station and hall light as described above with respect to FIG. 1. Operation of relay 24 also shuts off the power to LED 26. This would always tell a staff person that the system is either not operating or that patient's weight is not closing the detector 12. If it is desired to move the patient from their bed, the circuit path 14 is opened by removing a male jack end of circuit path 14 from a female connector in quick disconnect jack 25. A jack switch, not shown, closes to simulate a closed circuit path 14 which is the condition existing when a patient is on the bed over the detector 12. Thus the system's alarms are not activated.
An alternative system is shown in FIG. 2 for connecting the bed sensor circuit path 14 to the control relay. As described with respect to FIG. 2, a magnetically operated switch is interposed in the circuit path 14, with the switch having a stationary switch component 22 mounted on the bed frame 63 and a proximity switch component 18 mounted on the bed rail 66. When the bed rail is raised to confine the patient to the bed area, the switch components 18, 22 are spaced so that the relay switch component 22 remains in a normally closed condition to close the circuit path 14 with the sensor 12 included in the circuit. When the bed rail is lowered, the magnetic component 18 of the switch is brought into magnetic proximity of the magnetically activated switch component 22 to operate the switch 22. When operated, switch 22 maintains a constant power signal to the control relay 24 which disables the detector 12 from the circuit and in effect simulates the presence of a person in the bed in a proper position to avoid the actuation of any alarm systems when the bed rail is down. In this manner when a patient is removed from the bed by lowering the bed rail, the system will not sound any alarms and when the patient is repositioned on the bed surface and the rail is again raised, the system is once again operable with the detector 12 in series in the circuit path 14.
It is readily seen that there are any number of combinations of alarm schemes that might be utilized in a health care facility since each facility of course has its own set of criteria that must be accommodated to provide a workable system. It is the purpose of this system to provide a detection device that is safe and reliable and a system for providing alarms that will maximize the probability of avoiding the unauthorized patient movement from their beds. This system provides the flexibility necessary to carry out these purposes.
While particular embodiments of the present invention have been shown and described, it is apparent that changes and modifications may be made without departing from this invention in its broader aspects and therefore the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of this invention. | 4y
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FIELD OF THE INVENTION
[0001] This invention relates to systems and methods for fluid level detection, and more specifically, to systems and methods for measuring fuel levels within fuel tanks using optical fibers.
BACKGROUND OF THE INVENTION
[0002] Many types of vehicles and machines consume fuel during operation, including aircraft, ships, construction vehicles, and a wide variety of other machinery. As vehicles and machines operate, the level of fuel within a fuel tank decreases. As fuel is added, the fuel level increases. A variety of systems and methods are known to provide an indication of the amount of fuel within the fuel tank, including, for example, those systems disclosed in U.S. Pat. No. 6,571,626 B1 issued to Herford, U.S. Pat. No. 6,408,692 B1 issued to Glahn, and U.S. Pat. No. 4,627,283 issued to Nishida et al. Although desirable results have been achieved using such prior art systems, there is room for improvement.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to systems and methods for sensing fluid levels using optical fibers, including measuring fuel levels within fuel tanks, and transmitting this data through optical fibers. Embodiments of systems and methods in accordance with the present invention may advantageously allow fluid levels within a tank to be determined without the need to transmit electrical signals into the tank, and may also improve the costs associated with maintenance and repair of fluid level sensors in comparison with the prior art.
[0004] In one embodiment, a sensor assembly adapted to sense a fluid level includes at least one optical fiber adapted to at least one of transmit and receive an optical signal, and a moveable float member. The float member is adapted to move in a first direction as the fluid level increases and in a second direction as the fluid level decreases. The float member blocks the optical signal at a first value of the fluid level, and allows the optical signal to pass at a second value of the fluid level. The presence or absence of the optical signal is detected to determine the level of fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Preferred and alternate embodiments of the present invention are described in detail below with reference to the following drawings.
[0006] FIG. 1 is a side elevational view of a fuel tank assembly in accordance with an embodiment of the invention;
[0007] FIG. 2 is an enlarged, side elevational view of a sensor assembly of the fuel tank assembly of FIG. 1 in accordance with an embodiment of the invention;
[0008] FIG. 3 is a flow diagram of a method of sensing a fuel level in accordance with a further embodiment of the invention;
[0009] FIG. 4 is a side elevational view of an aircraft in accordance with yet another embodiment of the invention;
[0010] FIG. 5 is a side elevational view of a sensor assembly in accordance with an alternate embodiment of the invention;
[0011] FIG. 6 is a side elevational view of a sensor assembly in accordance with another alternate embodiment of the invention; and
[0012] FIG. 7 is a side elevational view of a sensor assembly in accordance with a further embodiment of the invention.
DETAILED DESCRIPTION
[0013] The present invention relates to systems and methods for measuring fuel levels within fuel tanks using fiber optics. Many specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 1-7 to provide a thorough understanding of such embodiments. The present invention may have additional embodiments, or may be practiced without one or more of the details described for any particular described embodiment.
[0014] FIG. 1 is a side elevational view of a fuel tank assembly 100 in accordance with an embodiment of the invention. In this embodiment, the fuel tank assembly 100 includes a tank 102 and a sensor assembly 110 coupled to the tank 102 by a support 104 . FIG. 2 is an enlarged, side elevational view of the sensor assembly 110 of FIG. 1 . In this embodiment, the sensor assembly 110 includes an optical sensor 112 coupled by first and second optical fibers 114 , 116 to a converter switch 120 . The converter switch 120 may be a conventional component, including, for example, those converter switches commercially available. The first and second optical fibers 114 , 116 pass through a sealing member 118 disposed within the wall of the fuel tank 102 . A power source 122 is coupled to the converter switch 120 .
[0015] As further shown in FIG. 2 , the optical sensor 112 includes a float 124 disposed within a guide member 126 adapted to partially limit a range of motion of the float 124 . The first optical fiber 114 is coupled to an upper portion of the guide member 126 , and the second optical fiber 116 is coupled to the guide member 126 opposite from the first optical fiber 114 . An end portion of the first optical fiber 114 thus forms an emitter 128 , and an opposing end portion of the second optical fiber 116 forms a receiver 130 .
[0016] Referring again to FIG. 1 , the converter switch 120 may be coupled to a processor (or CPU) 132 which, in turn, may be coupled to a display device 134 (e.g. a gauge, digital readout, display, etc.), and to a pump 136 . A first conduit 138 is coupled between a fuel source (not shown) and the pump 136 , and a second conduit 140 is coupled between the pump 136 and the tank 102 .
[0017] In operation, power is provided by the power source 122 along an input lead 121 to the converter switch 120 . The converter switch 120 outputs and optical signal along the first optical fiber 114 . The optical signal may be composed of visible or non-visible light (ultraviolet or infrared), may be monochromatic or non-monochromatic, and may be continuous or non-continuous. As best shown in FIG. 2 , at a first fuel level 142 , the float 124 is positioned at a lower position 144 in which the float 124 is not disposed between the emitter 128 and the receiver 130 , allowing the optical signal to transmit the between the emitter 128 and the receiver 130 . The optical signal then passes along the second optical fiber 116 to the converter switch 120 . A corresponding output signal may be transmitted along an output lead 123 to the processor 132 . The processor 132 may interpret the output signal and may provide an indication of the fuel level within the fuel tank 102 to the display 134 .
[0018] The processor 132 may also provide a control signal to the pump 136 , including, for example, a first control signal that causes the pump 136 to pump additional fuel from the fuel source (not shown) into the fuel tank 102 . As the fuel level within the tank 102 rises and approaches an upper fuel level 148 ( FIG. 1 ), the float 124 is raised to a second position 146 in which it is disposed between the emitter 128 and the receiver 130 thereby blocking the optical signal. As the optical signal is no longer received at the converter switch 120 , the output signal may cease to be transmitted along the output lead 123 to the processor 132 . In response, the processor may transmit a second control signal that causes the pump 136 to stop pumping.
[0019] FIG. 3 is a flow diagram of a method 300 of sensing a fuel level in the tank 102 in accordance with one embodiment of the invention. In this embodiment, the method 300 includes transmitting the optical signal from the converter switch 120 along the first optical fiber 114 at a block 302 . At a block 304 , a determination is made regarding whether the optical signal is being received at the receiver 130 . If the optical signal is being received, then at a block 306 , appropriate action is taken to operate the pump 136 to raise the fuel level within the tank 102 , and the method 300 returns to the determination block 304 . Alternately, if the optical signal is not been received, then appropriate action is taken to stop the pump 136 at block 308 , and again, the method 300 returns to the determination block 304 . The method 300 may continue indefinitely, or may be terminated at any desired time.
[0020] Embodiments of the present invention may provide significant advantages over the prior art. For example, because the sensor assembly 110 utilizes an optical signal rather than an electrical signal, there is no need for an electrical signal to be transmitted within the tank 102 , thereby improving the safety of the assembly. Furthermore, the simplicity of the sensor assembly 110 may increase reliability and reduce the costs associated with maintenance and repair.
[0021] Embodiments of the present invention may be used in a wide variety of applications, including aircraft, ships, construction vehicles, and a wide variety of other machinery. For example, FIG. 4 is a side elevational view of an aircraft 400 in accordance with yet another embodiment of the invention. The aircraft 400 generally includes a variety of components and subsystems generally known in the pertinent art, and which, in the interest of brevity, will not be described in detail. For example, the aircraft 400 generally includes one or more propulsion units 402 that are coupled to wing assemblies 404 , or alternately, may be coupled to a fuselage 406 or even other portions of the aircraft 400 . Additionally, the aircraft 400 includes a tail assembly 408 and a landing assembly 410 coupled to the fuselage 406 , and a flight control system 412 (not shown in FIG. 4 ), as well as a plurality of other electrical and mechanical systems and subsystems that cooperatively perform a variety of tasks necessary for the operation of the aircraft 400 . The aircraft 400 also includes one or more fuel tank assemblies 414 (not visible) in accordance with the present invention. The fuel tank assemblies 414 may be disposed within the wing assemblies 404 and within the fuselage 406 of the aircraft 400 .
[0022] The aircraft 400 shown in FIG. 4 is generally representative of a commercial passenger aircraft, including, for example, the 737 , 747 , 757 , 767 and 777 commercial passenger aircraft available from The Boeing Company of Chicago, Ill. In alternate embodiments, however, embodiments of the invention may be incorporated into flight vehicles of other types. Examples of such flight vehicles include other commercial aircraft, manned or unmanned military aircraft, rotary wing aircraft, or types of flight vehicles, as illustrated more fully in various descriptive volumes, such as Jane's All The World's Aircraft, available from Jane's Information Group, Ltd. of Coulsdon, Surrey, UK.
[0023] It will be appreciated that a variety of alternate embodiments of sensor assemblies in accordance with the present invention may be conceived, and that the invention is not limited to the particular embodiments described above. For example, FIG. 5 is a side elevational view of a sensor assembly 500 in accordance with an alternate embodiment of the invention. In this embodiment, the sensor assembly 500 includes a float 502 having an opaque portion 504 and an optically-transmissive portion 506 . In operation, when the fuel level within the fuel tank 102 approaches the upper fuel level 148 ( FIG. 1 ), the optically-transmissive portion 506 of the float 502 is disposed between the first and second optical fibers 114 , 116 , allowing the optical signal 508 to pass therebetween. As the fuel level within the tank 102 drops, the float 502 moves in a downward direction 510 until the opaque portion 504 of the float 502 is disposed between the first and second optical fibers 114 , 116 , blocking the optical signal 508 . The sensor assembly 500 may be suitably coupled to one or more other components to perform other desired functions, including, for example, to monitor or maintain a desired fuel level within the fuel tank 102 . More specifically, with reference to FIG. 1 , the sensor assembly 500 may be coupled to the converter switch 120 which may, in turn, transmit an electrical signal to the processor 136 when the fuel level is at or near the upper fuel level 148 . As the fuel level decreases and the opaque portion 504 blocks the optical signal 508 , the converter switch 120 may cease transmitting the electrical signal to the processor 136 , which may in turn transmit a control signal to the pump 136 to cause additional fuel to be supplied to the tank 102 .
[0024] FIG. 6 is a side elevational view of a sensor assembly 600 in accordance with another alternate embodiment of the invention. In this embodiment, a single optical fiber 602 is directed toward a reflective surface 604 . In operation, an optical signal 606 emitted by the optical fiber 602 is transmitted toward the reflective surface 604 , and a reflected signal 608 is transmitted back from the reflective surface 604 to the optical fiber 602 . As a fuel level within the fuel tank 102 rises, an opaque float 610 moves in an upward direction 612 until it blocks at least one of the optical signal 606 and the reflected signal 608 . The sensor assembly 600 may be suitably coupled to one or more other components to perform other desired functions, including, for example, to monitor or maintain a desired fuel level within the fuel tank 102 . More specifically, the sensor assembly 600 may be coupled to the converter switch 120 ( FIG. 1 ). As the reflected signal 608 is received by the single optical fiber 602 , it may be transmitted back to the converter switch 120 which may, in turn, transmit an electrical signal to the processor 136 , indicating that the fuel level is not at or near the upper fuel level 148 . The processor 136 may, in turn, cause the pump 136 to provide additional fuel to the fuel tank 102 . As the fuel level increases and the opaque float 610 blocks at least one of the optical signal 606 and the reflected signal 608 , the converter switch 120 may cease transmitting the electrical signal to the processor 136 , which may in turn cause the pump 136 to cease.
[0025] FIG. 7 is a side elevational view of a sensor assembly 700 in accordance with a further embodiment of the invention. In this embodiment, the sensor assembly 700 includes a plurality of transmitting fibers 702 , a plurality of receiving fibers 704 , and an opaque float 706 . In operation, an optical signal 708 transmitted from each of the transmitting fibers 702 is either received by a corresponding receiving fiber 704 , or blocked by the opaque float 706 . As a fuel level within the fuel tank 102 rises, the opaque float 706 moves in an upward direction 710 , blocking an increasing number of the optical signals 708 .
[0026] The sensor assembly 700 may be suitably coupled to one or more other components to perform other desired functions, including, for example, to monitor or maintain a desired fuel level within the fuel tank 102 . More specifically, the sensor assembly 700 may be coupled to one or more converter switches 120 ( FIG. 1 ) which may, in turn, be coupled to the processor 132 . Based on the number of optical signals 708 blocked by the opaque float 706 , the processor 132 may determine the fuel level within the fuel tank 102 , and they send appropriate control signals to raise the level as desired.
[0027] As mentioned above, embodiments the present invention may be used in a wide variety of applications, including aircraft, ships, construction vehicles, and a wide variety of other machinery. It will be appreciated that embodiments of the present invention may also be used to monitor the level of fluids other than fuel, including other flammable liquids (e.g. liquid propane, oil, etc.), or nonflammable liquids (e.g. water, juice, milk, etc.). Therefore, although embodiments of the present invention had been described above with respect to the measurement of fuel within a fuel tank, it will be appreciated that embodiments of the present invention may be used in a wide variety of applications that do not involve the measurement of fuel.
[0028] While preferred and alternate embodiments of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of these preferred and alternate embodiments. Instead, the invention should be determined entirely by reference to the claims that follow. | 4y
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RELATED APPLICATIONS
[0001] The present application is a National Phase of International Application Number PCT/CN2014/071434, filed Jan. 25, 2014, and claims the priority of China Application No. 201410034576.X, filed Jan. 25, 2014, which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention specifically describes a development of conceptions, and proposes three concepts, three new technologies, three new products, six high-voltage power grid connection methods, a new type of reactive compensation connection method, proposes a new solution to usage of AC voltage regulator. The present invention relates to the technical fields of power electronics, transformer, high voltage or ultra-high voltage power grid transmissions, stepless voltage regulation technology, reactive compensation technology.
[0003] The above development of the conceptions direct to a superposition principle of waveform based on conceptions of waveform continuity and flexible regulation of voltage.
[0004] The above three concepts respectively are flexible AC transformation, flexible power transmission and transformation and flexible voltage regulation.
[0005] The above three new technologies respectively are a transient impedance technology, a flexible stepless voltage regulation technology and a flexible stepped voltage regulation technology.
[0006] The above three new products are: an AC voltage regulating electronic switch, a transient impedance transformer and a high-speed voltage regulating transformer.
[0007] The six high-voltage power grid connection methods are: a power grid connection method of a transient impedance transformer, a power grid connection method of a transient impedance transformer with split windings, a power grid connection method of a transient impedance step up auto transformer, a power grid connection method of a transient impedance step up auto transformer with split windings, a power grid connection method of a high-speed voltage regulation step down auto transformer and a power grid connection method of a high-speed voltage regulating step down auto transformer with split windings, etc.
[0008] When a new reactive compensation connection method is used for reactive compensation, a reactive compensation device may be connected with a terminal of a secondary outgoing wire of a main transformer of a series voltage regulating transformer in series or in parallel.
[0009] Eight basic single phase switch are included in the AC voltage regulating electronic switch of the above three new products: a new AC voltage regulator, a linear regulating switch, a reversing change-over switch, a coarse-fine regulating switch, an intermediate regulating switch (2 types), an end portion regulating switch and a neutral point voltage regulating switch, etc., which are flexibly combined when working in three phases situation.
[0010] A power transformer, a special transformer and a voltage regulator type transient impedance transformer, etc., are derived from the transient impedance transformer of the above three new products, which relate to different technical fields, and 17 types of transformer are summarized herein. The 17 types of transformers are: a transient impedances power transformer, a transient impedances power transformer with split windings, a transient impedance step up power auto transformer, a transient impedance step up power auto transformer with split windings, a high-speed voltage regulating step down power auto transformer, a high-speed voltage regulating step down power auto transformer with split windings, a transient impedance converting transformer, a high speed voltage regulating step down auto transformer, a transient impedance electric furnace transformer, a high-speed voltage regulating electric furnace auto transformer, a transient impedance traction transformer, a transient impedance power source transformer, a transient impedance step up power source auto transformer, a high-speed voltage regulating step down power source auto transformer, a transient impedance voltage regulator, a transient impedance step up auto voltage regulator, a high-speed voltage regulating step down auto voltage regulator, etc.
BACKGROUND ART
[0011] Background technology of an AC voltage regulator is that two semiconductor elements (such as, thyristors, hereinafter using thyristor as semiconductor elements) are connected in an AC circuitry in series after connected in anti-parallel, and AC output may be controlled by controlling the thyristors or other power electronic components. This circuit, which does not change the frequency of alternating current, is termed as an alternating current control circuit. The single/three-phase circuitry constituted by the control circuit is an AC voltage regulator. That is, a control device constituted by the semiconductor elements for converting an alternating current into another alternating current with the same frequency and different voltages.
[0012] Background technology of a transformer switch is that the voltage regulation is performed on transformer in voltage in order to supply stable voltage through the power grid, and control the current flow or regulate the load current. At present, the method for voltage regulation on transformer is a stepped voltage regulation method which is performed by disposing tap switch on the coil at one side thereof, so as to increase or decrease wire turns, achieving the for changing voltage ratio. Such a circuitry for regulating voltage by coil tap is termed as a voltage regulating circuit. The component for changing tap to regulate voltage is termed as a tap switch. The voltage regulating in which the secondary winding applied with no load and the primary winding disconnected with the power grid is termed as a non-excitation voltage regulating, and the voltage regulating applied with a load for changing coil tap is termed as an on-load voltage regulating. Consequently, the transformer switch is classified into two types, namely, a non-excitation tap switch, and a loaded switch. The insulation level of the loaded switch is determined by the max ground potential of the voltage regulating coil under a surge voltage, and total insulation is determined by the shock gradient of the voltage regulating coil under a surge voltage. As the level of insulation and the offset voltage are high, the switching capacitor discharges.
[0013] Background technology of a conventional series voltage regulating transformer is that, in low-voltage and high-current system application, the series voltage regulating transformer is constituted by two transformers, one for main transformer (constant at low voltage side), and another for series voltage regulating transformer (adjustable at low voltage side). A single voltage regulating winding provided on the main transformer is required for supplying power to series high voltage side. The low-voltage windings of main and series transformers are connected together in series and utilize a splayed coil structure, the voltage of low voltage windings of main transformer are constant, and the voltage of low voltage windings of series transformer are adjustable, so that the voltage of the two serially coupled low voltage windings are changed, thereby changing the synthetic voltage of the two low voltage windings. The main transformer comprises a high voltage winding, a low voltage winding, and a voltage regulating winding. The series transformer comprises a high voltage winding and a low voltage winding which are used in low-voltage and high-current system application.
[0014] Background technology of high voltage or ultra-high voltage AC power transmission system is that: the ultra-high voltage power transmission system is a new power transmission method for transmitting greater power to further distance than 500 KV AC power transmission method. It includes AC ultra-high voltage (UHV) and high voltage direct current (HVDC), and has the following advantages: cheap transmission costs, simple power grid structure, small short-circuit current, less transmission corridors occupation and improved power supply quality, etc. AC ultra voltage represents for a voltage higher than 1000 kV as defined by the International Electrotechnical Commission. In China, the ultra voltage represents for 1000 kV or more AC power, or 800 kV or more DC power. UHV AC transmission has disadvantages of higher voltage, long transmission lines, large distribution capacity, small wave impedance, obvious fault wave process. Even though the UHV transmission lines are typically mounted with paralleling reactor so as to compensate charge current of transmission lines, and suppress the occurrence of overvoltage, as well as decrease transmission capacity of the transmission lines, which is opposite to the fundamental purpose of UHV power transmission.
[0015] The main advantages for utilizing high voltage or ultra-high voltage AC power transmission is as follows: (1) improved transmission capacity and transmission distance; (2) improved economical efficiency for power transmission, wherein higher power transmission voltage means cheaper transmission capacity per unit; (3) saved floor space of the corridors for transmission and floor space for transformer substation; (4) reduced power loss for transmission line; (5) convenience for networking, simplified network topography, decreased failure rate.
[0016] Background technology of high voltage DC power transmission system: with development of power electronic technology, DC high-voltage power transmission becomes feasible, and is possible to become fully effective in all its aspects. At present, almost over 80 high voltage DC power transmission projects have been put into operation all over the world. In China, more than 10 high voltage DC power transmission projects are utilized in the national electricity grid, which play an important role in optimizing energy configuration, guaranteeing national energy security, and promoting national economic development. With the implementation of the Chinese national strategic guidelines, such as, “Western Power to the East, North and South to Share Power, National-link Network”, it has become a tendency to accelerate the construction of millions volts level of AC and ±660 kV, ±800 kV, ±1000 kV level of DC system UHV power grid as a centre power grid architecture. The concept of high voltage DC power transmission is a way of power transmission that the AC power generated by power plants is changed into DC power by rectifiers to be transmitted to receiving ends, and is changed into AC power by inverters to be transmitted to receiving ends. This way of transmission is mainly utilized in long-distance and high-power power transmission and networking of networking of nonsynchronous AC systems, has lower transmission line costs in economy, and lower power loss per year.
[0017] There are lots of advantages of DC power transmission in technology, firstly, the problem of system stability does not exist, and nonsynchronous interconnection in the power grid may be possible, while in the AC power system, the entire synchronous generator in the AC power system keep synchronized. The transmission capacity and distance in DC power transmission are not influenced by stability of synchronized operation, and may be connected to two systems with different frequencies, thereby achieving nonsynchronous networking and improving stability of the system. Secondly, the DC power transmission has limit on short-circuit current. If the AC power transmission line is used for connecting two AC systems, the capacity of short circuit is increased, and even a circuitry breaker is required to be replaced or a current-limiting device is required to be added. However, when the DC power transmission line is used for connecting two AC systems, the “constant current control” of the DC system limits the short-circuit current near rated power, and thus the capacity of short circuit is not increased due to interconnection. Moreover, the regulation is very fast, and operation thereof is reliable. The DC power transmission may rapidly adjust the active power through silicon controlled rectifier converters to achieve “current tipping” (change of flow direction of the power). In DC power transmission, under normal condition, stable output is ensured. When a failure is occurred, urgent support to fault systems by sane systems is achieved, and suppression on oscillating damping and sub-synchronous oscillation may be achieved. When the AC/DC lines run in a manner of paralleling operation, if the AC transmission lines short out, the DC transmitting power may be increased briefly to decrease the acceleration of the rotor of the generator, thereby improving the reliability of the system. Thirdly, there is no capacitor charging current. Under steady state of the DC transmission line, there is no capacitance charging current, the following voltage is stable, and when there is no idle load or light load, abnormal incensement in voltage is observed at the AC long line-receiving end and mediate portion, and there is no need for connecting reactance in parallel to compensate. Furthermore, the floor space of the corridors is saved.
[0018] Background technology of electrochemically electrolytic system: in a electrochemical electrolytic system, the electrolytic current is required to maintain constant to ensure stability of the electrolysis bath thermal scheme and improvement of current efficiency, so as to relief labor intensity of the workers, and there is great advantage to reduce anode effect of aluminum electrolysis. If the electrolytic current is larger or smaller than rated value for a long time, then the thermal equilibrium in the electrolysis bath may be broken, so that the bath is overheated or subcooled to influence production and yield. The existing electrolytic silicon rectifier units are not silicon controlled units due to power factors, and barely provided with saturated reactor. And even it was provided, the units have small modulation range in view of economy. Those rectifier units without saturated reactor have power factors up to 0.94. Thus, the regulation of DC output voltage is mainly based on loaded tap switches in the transformer. However, the loaded tap switches have slow operation speed, and thus may not amend momentary fluctuation of the electrolytic current, such as, when anode effect occurs in aluminum electrolysis (depend on the difference line voltages, line current may be decreased by 5-10% which lasts for several minutes). If the tap switches are utilized for elevating voltage to maintain the series current, when the anode effect does not exist, current impact will occur due to lower operation speed of the tap switches. Thus, this transitory variation of current is typically not regulated. In addition, in order to reduce the times of operation for the loaded tap switches, it is impossible to respond to transitory variation of current. The operations of loaded voltage regulation switches are very frequent. There are at least 36000 times based on 100 times per switch each day, and the tap switches are required to be maintained once per 3000 times, which means long repair cycle, and has a strong impact on production. Thus, it is very important to reduce frequent operation of the loaded voltage regulation switch and prolong its service life. Thus, a constant current control scheme of rapid self-regulation which is turned off or on upon anode effect is typically not utilized in aluminum electrolysis, in order to reduce frequent operation of loaded tap switch, and the voltage fluctuation with time of duration less than 2 minutes causes frequent operation of loaded tap switch.
[0019] It is also very important to obtain a high-precision, long-life and high-speed current regulating system. In the field of electrolytic producing, yield is directly related to ampere-hour, and various process indexes are closely related to average current. In this case, it is desirable to obtain an automatic high-speed current stabilizer capable of maintaining the error of average current or ampere-hour less than 0.25% to 0.1% in several hours. However, it is very difficult to achieve the above accuracy only by utilizing the loaded tap switches in the system. The operations of the loaded tap switches are very slow with respect to the response for current modulation system. Typically, there is no response to variation of current within 10% lasting for several minutes, and there must be transient response to large variation of current exceeding normal range of operation. However, the variation time for voltage regulation of the loaded switch is 10 s to 20 s, when the range of voltage regulation is large, the response time will fail to follow up with the variation time of current.
[0020] Background technology of electric furnace smelting: the smelting process of electric furnace is divided into two processes, i.e., a melting period and a refining period. In the melting period, the cover is sealed and three-phase electrodes are connected after steel scrap is loaded. After the three-phase power is turned on, large-current arc is generated between the electrodes and the steel scrap, and the steel scrap is melt due to heat of the arc. Compared with the arc of the melting period, the arc in the refining period is relatively stable, the current is basically constant, and at this time, the voltage variability and flicker effect are exceedingly small.
[0021] Typically, the smelting period of AC arc furnace is about 1 h to 3 h, and the supplied voltage is 110 KV or 35 KV. When a specially designed arc furnace transformer is powered, the voltage between secondary side electrodes is typically between 100V to 700V, wherein the voltage drops of the electrodes are about 40V, the arc drop is about 12V/cm, and the longer the arc, the larger the voltage drop. The current control of arc furnaces is achieved by switch between taps of high-voltage side winding of the transformer of the arc furnace and regulation of electrode voltage, i.e., the furnace transformer defines a value for input arc voltage by using a switch, and three-phase graphite electrodes are controlled to insert into the furnace, and the lifting device of the electrodes is controlled to move up and down, the input power of the furnace is controlled, thereby controlling the arc current in the furnace. The arc furnace consumes large reactive power, and has a large variation. In the melting period, due to direct arc between steel scrap and electrodes, as the steel scrap melts, the length of the arc will certainly change, thereby causing movement of the arcing points, and the electrode controlling system cannot follow up with saltatory variation of the arc and cannot compensate timely due to mechanical inertia response time within several seconds to ten or more seconds, and thus the arc is not stable. At the beginning of the melting period, as the temperature in the furnace is lower, the arc is hard to be maintained, and is not stable frequently, and thus the current is discontinuous. In order to maintain the arc stable, the power factor of the arc furnace is not high, and sudden variation of the current will cause concurrent and sudden variation of the active power and reactive power extracted by the arc furnace from the power supply system, i.e., in the process of smelting in the arc furnace, the arc current is rapidly changed by a large margin. Since the electric arc furnace is a high inductive load, when the high-power arc furnace operates in melting period, the power factor is even lowered to 0.1 to 0.2, which causes serious fall in bus bar voltage. When voltage is reduced, and active power of the electric-arc furnace is decreased correspondingly, the molting period is prolonged, and the productivity is decreased. The power factor of the arc furnace is 0.1 to 0.2 when the electrode is shorted out, and is 0.7 to 0.85 under rated operation. As the melting proceeds, the electrode voltages are decreased, scrap is melted from the lower portion. After the lower scrap is melted, the upper part of the steel block fall down, causing sudden two-phase short-circuit of electrode ends, and thus the arc current will change sharply by a large margin. Variation of arc current causes sudden variation of voltage, and rapid variation of arc due to movement of arcing point is called period sudden variation, sharp variation caused by electrode short circuit is called abnormal sudden variation, which will cause serious voltage fluctuations and sudden variation on public buses of the power system. Meanwhile, the caused voltage fluctuations and sudden variation is very fierce. When the two-phase electrodes are shorted out, and one phase is open, the amplitude of variation of the current is the largest, and thus the caused voltage fluctuations and sudden variation is the largest. The arc furnace system is a strongly nonlinear system with a three-phase coupled feature, and its parameters are time-varying, and at the same time, are influenced by random perturbation. It is a world-wide puzzle for control engineers to adjust proper length of the arc and make it stable through an electrode regulation system. As for power saving in smelting steel by arc, power consumption per ton of steel is lowered by 1-2 kwh once the smelting time is shorted by 1 minutes, and it is effective to shorten the smelting period by using computers to control the smelting period of the arc furnace. In the melting period, the power consumption is over 60% of the whole smelting process, the power consumption is directly influenced by the power supply during the melting period, but the condition in the furnace during the melting period is complicated, which is accompanied by firing, penetration, short circuit, arc breaking, splatter, and evaporation, which cause unceasing variation of arc power and operation current. Under manual control, It is hard to achieve the objectives of lowering the temperature of the steel, reducing the waiting time for steel, stabilizing arc current, reducing the times of short circuit and breaking arc, shortening the melting period, lowering power consumption per ton of steel. However, the automatic control of the furnace is mainly control of voltage of the electrodes, and control of the input power, while the electrode controlling system consists of a hydraulic system, due to mechanical inertia, the regulation of the electrodes is slow in speed and weak in sensitivity, and cannot follow up with the sharp variation of the arc, and thus cannot compensate timely, which is the most hardest part. In the process of smelting period, the length of the three-phase electrodes should be changed with respect to the length of the arc, and regulated based on the relative distance between the electrodes and the raw materials, thereby ensuring the length of the arc stable to make best use of the arc to melt the furnace burden. As the controlled objects of the AC arc furnace in smelting has characteristics of highly nonlinear, strong coupling, time-dependent nature and time-lagging nature, in the process of melting, external perturbations are very obvious, and variation of arc length and deviation is large, which requires a electrode controller having a characteristic of relatively higher fast response without overshoot.
[0022] Background technology of electric locomotive traction: high-speed railways are system integration of innovative and high technology, and its construction and operation reflect the scientific and technological strength of a country. In May, 1985, the Economic Commission for Europe of the United Nations stipulated that passenger transport line with running speed over 300 km per hour and mixed passenger and freight line with running speed over 250 km per hour are high speed railways. The existing traction transformer mainly use non-excitation regulator, which has small range of voltage regulation. The traction transformer is used for transmitting the power of three-phase power supply system to two single-phase traction lines with loads respectively. The two single-phase traction lines are used for powering the uplink and downlink locomotives. In an ideal case, the two single-phase loads are the same. Thus, the traction transformer is used as a transformer for transforming three phases into two phases. The traction transformer is a power transformer of a special voltage class, should meet the requirement of fierce variation of traction load and frequent external short circuit, and thus is the “heart” of the traction substation. In China, the traction transformer is divided into three types, i.e., a three-phase, a three-phase to two-phase, and a single phase, and thus the traction substation is divided into three types, i.e., a three-phase, a three-phase to two-phase, and a single phase. Background technology of voltage regulator: a voltage regulator is voltage regulating power source for supplying adjustable voltage to loads; it can convert the distribution voltage of the uncontrollable power grid; it can be used for any load voltage which may be regulated in a stepless manner in a certain range, and is divided into, based on the electromagnetism principle and structure, a contact voltage regulator, a induction regulator, a magnetic voltage regulator, a moving-coil regulator, a purification regulator (stabilizer), a saturated reactor, an auto regulator and the like.
[0023] The contact voltage regulator has a capacity of 0.1 to 1000 KVA, a voltage class of 0.5 KV, a range of voltage regulation of 0 to 100%.The induction voltage regulator has a capacity of 6.3 to 4500 KVA, a voltage class of below 10 KV, a range of voltage regulation of 5 to 100%.The magnetic voltage regulator has a capacity of 5 to 1000 KVA, a voltage class of below 0.5 KV, a range of voltage regulation of 15% to100%.The moving-coil regulator has a capacity of 1000 to 2250 KVA, a voltage class of below 10 KV, a range of voltage regulation of 5 to 100%.The contact auto regulator has a capacity of 20 to 1000 KVA, a voltage class of 0.5 KV, a range of voltage regulation of ±20%.The induction auto regulator has a capacity of 20 to 5600 KVA, a voltage class of below 10 KV, a range of voltage regulation of ±20%.The purification stabilizer has a capacity of 1 to 300 KVA, a voltage class of 0.5 KV, a range of voltage regulation of ±25%. The thyristor voltage regulator has a capacity of below 450 KVA, and a voltage class of below 10 KV.
[0024] Background technology of reactive compensation: it is common knowledge of the designers and decision makers all over the world to use the reactive compensation technology to improve the power factor of a system, and the investment of the reactive compensation device has been listed in the integrated planning of electric power investment, which has become an indispensable link At present, the power factor of the main power network equipment is on the order of 1, the law of Russia provide that the power factor should greater than 0.92, and Japan and other countries have established nationwide reactive power management committee to research technical economic policy about reactive compensation. Practically, almost all the developed countries have higher power factors of power grids. Thus, it is a tendency in power grid to greatly improve the power factors of power grids, lower line loss, save energy, and develop the capacity of power generation assemblies.
TECHNICAL PROBLEM
[0025] Technical problem of AC voltage regulator: the voltage generated by the existing AC voltage regulator when regulating voltage is not continuous, and its waveform is discontinuous. There are lots of zero crossing point, the voltage and current is non-continuous, which cause large voltage fluctuation, and non-continuous current causes too many times of arc breaking and arc starting, the power input is non-continuous and the harmonics wave is large. Poor arc stability affects the yield and quality of the product, causes internal overvoltage in the transformer and load, which has adverse effect on isolation of the transformer, switches, motors and other loads, affects their useful life, increases energy consumption, and causes significant problems of unbalanced input power of resistive, inductive, and capacitive loads and related devices. The AC voltage regulator uses a thyristor phase controlling circuitry, and high-voltage and low-current controllable power source may include lots of thyristors connected in series, or may use AC voltage regulation circuitry to adjust the secondary voltage of the transformer, low-voltage and high-current power source may include lots of thyristors connected in parallel. The circuitry topography thereof is complicated, expensive, and tends to produce non-continuous waveforms.
[0026] With the rapid economic development, a variety of electrical equipments are developed toward a high-voltage, and large-capacity direction, the development of power electronics technology cannot keep up with the needs of development, and thus it is desirable to obtain a stepless or stepped voltage regulation technology by using a small-capacity, low-voltage, and low-current AC voltage regulator to control a high-current, large-capacity and high-current transformer or other loads.
[0027] Technical problems of the existing transformer switches: the transformer switches has slow response, and their service life is short, after 3000 times of usage, the switches are required to change oil and maintain. Also, they have complicated structures, discharge arc at the contact terminals, and pollute transformer oil in the transformer having oil immersed structure. Currently, it is a urgent need to develop a transformer switch capable of eliminating offset voltage and preventing the capacitor discharge in reversing change-over voltage regulating, and having fast response, long life, no arc and easy maintenance in normal use.
[0028] Technical problems of the conventional series voltage regulating transformer: conventional series voltage regulating transformers are applied to 10000 KVA or higher furnace transformers, or, sometimes, to rectifier transformers, are conventional form of furnace transformers, which are rarely utilized due to higher cost and development of smelting technologies. Currently, as the series voltage regulating transformer adopts AC voltage regulating electronic switches, the usage and functions of the series voltage regulating transformer are largely extended, we must modify and improve the series voltage regulating transformer to meet different needs.
[0029] Technical problems of the ultra-high voltage AC power transmission: the main drawbacks exist in ultra-high voltage power transmission is the stability and reliability of the system. From 1965 to 2010, 7 AC large power system collapse accidents happened, wherein 5 accidents happened in US, and 2 accidents happened in Europe. These serious large power system collapse accidents illustrate that the power system which adopts AC interconnection has drawbacks of poor safety and stability, accidents chain reaction, and massive power outage.
[0030] As for system stability, short-circuit reactance of a power system is a key factor. One of the main measures to limit capacity of short circuit by the power system is using high impedance transformers. The increasing of reactance of the transformer will improve the stability of the system, and limits on short-circuit current will cause decrease in electromagnetic force of short circuit and heat effect of the current, and meanwhile, it is also possible to decrease the cut-off capacities of line breaker and other electrical equipments, and reduce or even cancel current limiting reactor, but the high impedance transformer will increase the reactive power of the power grid. The reactive power consumed by the transformer is about 10%˜15% of its rated capacity, when the supplied voltage is higher than its rated value by 10%, the reactive power will rapidly increase due to saturation of magnetic circuit. According to statistics, when the supplied voltage is 110% of the rated value, the reactive power will typically increase about 35%. When the supplied voltage is lower than the rated value, the reactive power will decrease correspondingly, so that the power factor will be improved. But, the decrease of supplied voltage will affect proper functioning of the electrical equipments. Thus, measures should be taken so that the power supplied voltage of the power system remains stable.
[0031] A transformer will play an important role in high voltage, ultra-high voltage and extra-high voltage AC power grids, if it has the following characterizes. That is, the transformer capable of regulating in a high speed, functioning reliably, regulating active power in a high speed, and achieving “current tip” (change of flow direction of power), and in normal condition, has lower impedance to ensure stable output, in accident conditions, can make the system stable in a high speed, and can suppress oscillating damping and synchronous oscillation, has functions of splitting phases voltage regulation, and high-speed voltage stabilization, the transformer has lower impedance in normal condition, and will transform into a high-impedance or even ultra-high impedance transformer instantaneously in sudden short circuit or other emergencies.
[0032] Technical problems of the DC power transmission: the DC convertor station has many devices, a complicated structure, high costs, high loss, high operating expense, and lower reliability. The convertor will generate lots of harmonics during operation. And if the harmonics are not processed properly and flowed into the AC system, it will cause a series of problems to normal operation of the AC power grid. Thus, lots of and groups of filters must be provided to eliminate these harmonics. Secondly, conventional power grid commutation direct-current transmission will absorb lots of reactive power while transmitting the same power, which is about 50%-60% of the active power. Thus significant reactive power compensating devices and corresponding control strategy are required. Additionally, there are some technical difficulties in grounding electrodes in DC power transmission and DC circuitry breakers.
[0033] Technical problems of the electrochemical electrolytic system: if there is no fine regulation of reactor, currents among various parallel rectifier units and three phases are hard to be equilibrated and the circulating current is extremely large, sometimes, even accidents of burning transformer will happen, due to incapable of fine regulation of various phases and various units. In this case, various parallel rectifier units or single unit are required to have rectifier cabinets with the same commutation reactance, so as to avoid unbalancing of loaded current distribution caused by lack of fine regulation of saturated reactors among units or rectifier cabinets. As for silicon rectifier units provided with saturated reactor and loaded tap switches, instantaneous variation of current may be reflected rapidly. However, the units have large floor space, extremely large noise, large harmonics, high costs, high energy consumption, and significantly lowered power factor, and thus barely utilized currently. Currently, switch stages are increased to maintain constant current in electrolytic industry.
[0034] At the present, in the electrochemical electrolytic system, there is an urgent need for a rectifier transformer which is an automatic high-speed current stabilizer, and which enables the electrolytic system utilizing a constant current control scheme and having small harmonics, fast voltage regulation speed, the stabilize is capable of split-phase voltage regulation, responding to current variation in a high speed, and operating in a high speed when three-phase short circuit occurs, and increasing the impedance of the transformer or even increase the system reactance close to 100%.
[0035] Technical problems of the AC/DC furnace smelting system: at the present, the arc furnace electrode regulation control system has high costs, frequent maintenance, complicated controlling links, high failure rate, slow response speed, failure to follow up with saltatory variation of the arc and compensate timely, which causes lower degree of automation in furnace smelting industry. Due to current control of the arc furnace, the above electric equipment are often regulated by controlling the lifting device of the electrodes, thereby controlling the input power of the furnace, and the arc voltage drop is about 12V/cm, the longer the arc, the larger the voltage drop. If the electrode voltage regulation function is accomplished by other components, and the length of the arc is controlled in a certain range, lots of electrical power will be decreased. Sudden short-circuit of electrodes often occurs in the above electrical equipment, and arc current has seen a dramatic change significantly. The caused voltage fluctuations and sudden variation are the largest, and thus it is desirable to obtain an electrical equipment capable of rapidly regulating voltage within milliseconds or setting automatic control programs according to characteristics of respective furnace in advance, thereby reducing voltage fluctuations and sudden variation obviously.
[0036] Electric furnace smelting system: at present, in the prior art, all the arc furnace and submerged arc furnace systems utilize a conventional smelting process to adjust the input power by controlling lifting of the electrodes in various power regulation solutions. Currently, it is an urgent need for an electric furnace smelting system capable of regulating voltage, stabilizing current, without lifting up/down the electrode. At the same time, the system is capable of responding rapidly, ease to auto control, saving energy and reducing consumption. The system may operate very fast in three-phase short circuit, and make the impedance of the system increase or even close to 100% in high speed. However, in resistance furnaces and related smelting systems requiring temperature regulation, a technology for maintaining continuous voltage and current with continuous waveforms and waveforms even close to sine waves is required, and in electric furnaces requiring stepless voltage regulation, the voltage regulator has lower voltage class, lower capacity, and cannot be produced in large scale.
[0037] Technical problems of the electric locomotive traction system: lower power factor, unbalanced loads. In unbalanced loads, split-phase voltage regulation is not possible, the traction transformer cannot suppress short-circuit current and stabilize voltage, the traction transformer cannot adjust voltage and stabilize voltage in a high speed, and adjust capacities for two systems at the same time. Three-phase imbalance in high-voltage side and large harmonics in DC systems make the traction transformer incapable of control the system safely, efficiently, synchronously and intelligently, and make the transformer suffering from high over load or mechanical pressure generated upon short circuit.
[0038] Technical problems of the voltage regulator: as can be known from the above, all types of voltage regulator have capacities below several KVA. Voltage classes below 10 KV cannot meet the requirement of various industries, and thus it is desirable to obtain a new voltage regulator having large capacity of voltage regulation, higher voltage class, small harmonics, and range of voltage regulation in 0 to 100%, to meet the market requirement.
[0039] Technical problems of reactive compensation: as the development of long-distance Extra High Voltage transmission system, the reactive power consumption in the power grid is also increased. Especially, as the application of power electronic devices increasingly widespread, however, most of the electronic devices have lower power factors, which result in quality decreasing of power supply, as well as bringing additional burden on the power grid. Technical solution of the high voltage parallel reactive compensation device is the simplest and cost-optimal compensation solution. However, it has three drawbacks. Firstly, the reactive compensation of the reactive compensation device is an average compensation in an operation process, may not compensate the voltage drop of the bus bars, and may not reduce the voltage fluctuations of networks caused by fierce variation of loads. Secondly, it cannot improve the active power of electrical equipment loads. Thirdly, the used reactive compensation device has high voltage class, and is expensive.
[0040] There are three types of low-voltage reactive compensation device solution. The first one is a compensation solution that the low-voltage devices are directly connected to the reactive compensation device in parallel. This compensation solution has the best effects of saving energy and reducing costs, but has drawbacks of only applicable to electrical equipments with constant secondary voltage. The second one is a compensation solution that a reactive compensation device is connected to the network through a step up transformer (compensation transformer), and this solution has constant loading parameters, and belongs to voltage regulation compensation. It has drawback that as one compensation transformer is added, the primary capitalized cost is too large, and the loop inductive reactance and electrical loss are increased substantially, and the parallel reactive compensation device has higher voltage class. The third one is a compensation solution that the parallel reactive compensation device is connected to the network through low-voltage compensation winding, wherein compensation windings are added at the low-voltage side, and reactive compensation devices are connected thereto in parallel, and the solution has drawback of only applicable to electrical equipments with constant secondary voltage.
TECHNICAL SOLUTION
[0041] The theoretical basis for technical solution: a superposition principle of waveform based on conceptions of waveform continuity and flexible voltage regulation is characterized in that, a plurality of pulse bursts formed by a sine wave or a plurality of sine waves with the same frequency, synchronized (the same) initial phase or having a phase difference of π (staggered by a half wave), amplitude of which depend on the phase controlling degree or chopping degree of an AC voltage regulator, and a waveform with a part of itself missed or chopped, is/are superposed on circles of a (or a plurality of) constant voltage (or adjustable voltage, referred to as constant voltage, hereinafter the same) sine wave, or the waveform and amplitude are waveform and amplitude output by conventional voltage regulator regulating sine wave voltage respectively, the combined voltage waveform is determined by two superposed waveforms, thus the problems of interrupted voltage waveform, voltage regulating and oversize harmonics are resolved by superposition of two waveforms. That is, a technology of synthesizing voltage by superposing a voltage, the amplitude of which can be continuously regulated in a stepped or stepless manner, and which can be positive or negative polarity, on a sine wave constant voltage, is a technology of forming continuous waveform and removing harmonics contents. The formula of combined voltage is presented as U=U 1 ±U 2 (wherein, U represents for the combined voltage, U 1 represents for the constant voltage, U 2 represents for the superposed and adjustable voltage).
[0042] Conventional voltage regulators comprise a contact voltage regulator, an induction regulator, a magnetic regulator, shifting coil voltage regulator, a purification voltage regulator, a saturation reactor, an automatic voltage regulator, thyristor voltage regulator and the like.
[0043] A superposition principle of waveform based on conceptions of waveform continuity and flexible voltage regulation from the viewpoint of power electronics technology is characterized in that, a plurality of pulse bursts or sine waves formed by a sine wave with the same frequency, the same initial phase or having a phase difference of π (staggered by a half wave), amplitude of which depended on the phase controlling degree of an AC voltage regulator or chopping degree of the AC transformer, and a part of the waveform part of which is missed or chopped, is superposed on circles of a constant voltage sine wave, and the combined voltage waveform is determined by two superposed waveforms.
[0044] Even semiconductor devices are not linear units, but they regulate the voltages of the primary windings of the transformer used by voltage regulation power source (as described below). However, the superposed waveforms according to the superposition principle of waveform of the present invention are waveform of a sine wave or approximate sine wave superposed and obtained by voltage waveforms output by the secondary side of the transformer used by the voltage regulation power source and voltage waveforms output by another sine wave power source (or power grid or secondary winding of the transformer, they output sine waves). The superposition principle of waveform used by the present invention is based on voltage waveform continuity and flexible voltage regulation, and in a series voltage regulation circuitry of the secondary voltage (obtained and synthesized by secondary voltage of the transformer used by the voltage regulation power source and the secondary voltage of the power source or other transformer) synthesized by two power sources, the used transformer operates in the unsaturated region, and the series voltage regulation circuitry of the secondary voltage may be considered as a linear circuitry at any moment at any steady state. The circuitry is divided in two situations. In one aspect, when the AC voltage regulator is used as a switching element, its output waveform is a sine wave, and there is no problem to apply superposition principle of waveform. In another aspect, the secondary winding of the AC voltage regulator is connected to a sine wave power source with the same frequency in series in a phase controlled process, the two voltage source may be replaced by a voltage regulation power source, which act on a linear circuitry together (in accord with replacement theorem), and thus the two power source waveforms may be superposed. At this time, the output voltage of the voltage regulation power source is defined, and in this process, the secondary series voltage regulation circuitry may be considered as a liner circuitry, and it may be referred to as a instantaneous linear circuitry which is a secondary circuitry consisting myriad instantaneous linear circuitries, and to which the superposition principle of waveform may be applied, and thus the method for superposing waveforms based on the superposition principle of waveform according to the present invention is possible. The flexible voltage regulation technology combined with superposition principle of waveform enables the application of AC voltage regulators and semiconductor elements to break through the limit of voltage class and capacity, which is very important to the development of power electronics technology.
[0045] The superposition principle of waveform based on conceptions of waveform continuity and flexible voltage regulation is the theoretical basis of flexible AC transformation technology, flexible power transmission and transformation technology, a flexible voltage regulation technology and a transient impedance technology, and the combination of high-speed stepless voltage regulation technology and high-speed stepped voltage regulation technology enables the stepless voltage regulation outputting waveform to be infinitely close to a sine wave in principle, and it is very important to the development of stepless voltage regulation technology.
[0046] The flexible AC transformation technology according to the present invention, characterized in that, by combining the power electronics technology with AC conversion technology, the capacity, voltage, reactance and other technical indexes of the power transformation devices are controlled in a high speed by using the function of high-speed control of an AC power control circuitry.
[0047] The flexible power transmission and transformation technology according to the present invention, characterized in that, by combining the power electronics technology with AC conversion technology and AC/DC transmission technology, the high voltage or ultra-high voltage AC/DC power transmission power grid is safely, efficiently and synchronously controlled by using power electronics technology to regulate power transformation devices in a high speed.
[0048] The flexible voltage regulation technology according to the present invention, characterized in that, formed by combining power electronics technology and AC conversion technology, by using the high-speed control capability of the power electronic components on phase control and on-off of the waveform of the sine waves, and the performs high-speed stepless voltage regulation, or high-speed stepped voltage regulation or both of stepless voltage regulation and the stepped voltage regulation as well as arbitrary switching between the stepless voltage regulation and the stepped voltage regulation in a high speed based on superposition principle of waveform, so as to output a voltage waveform close to sine wave while using stepless voltage regulation, and intelligently regulate secondary output voltage of the transformers in a high speed while using stepped voltage regulation. The flexible voltage regulation technology can be classified into flexible stepped voltage regulation technology and flexible stepless voltage regulation technology.
[0049] The flexible AC transformation technology and flexible voltage regulation technology may be applied to large capacity and high voltage class. It is required to regulate the voltage continuously by step regulation, and also to regulate the voltage smooth by stepless regulation, especially, in a resistance, resistance-inductance or resistance-capacitance AC load system requiring continuous voltage waveform without discontinuation region. Technical solution of the AC voltage regulator: the principle features of the new AC voltage regulator of the present invention are that the regulator to which the AC voltage regulator and the superposition principle of waveform are applied is referred to as the new AC voltage regulator. The voltage regulation principle is that an AC power source (voltage regulation power source) controlled by an AC voltage regulator is connected to an AC power source with constant voltage (or adjustable voltage, but the voltage is determined when the AC voltage regulator is in a phase control state) sine waves in series, the two power sources outputs periodic waves with continuous voltage waveforms and the same frequency, the generated capacity of harmonics is changed from the harmonics generated by whole capacity regulation in the prior AC power control circuit to harmonics generated by a part of capacity of the regulated range of voltage (capacity of the voltage regulation power source), and thus the harmonic content is largely reduced.
[0050] The structural features of the new AC voltage regulator is that, a sine periodic wave is further superposed on the periodic wave having non-continuous waveform output by the AC voltage regulator based on the superposition principle of waveform, so as to resolve the problem of non-continuous voltage waveforms. In brief, the primary voltage of a transformer is regulated by the AC voltage regulator, so that the induced secondary voltage is connected in series to the voltage output by a sine wave power source (power grid or the secondary winding of another transformer) to output voltages together, as the voltages at a and x terminals in FIG. 1 . The AC voltage regulator to which this kind of voltage regulation solution is applied is the said new AC voltage regulator.
[0051] When the two AC switches connected to the voltage regulation power source at two sides thereof in parallel are combined into a positive/negative regulating switch, and then connected to a constant voltage power source in series, the formula for combined voltage is expressed as U=U 1 ±U 2 (wherein, U represents for output voltage, U 1 represents for voltage of constant voltage power source, U 2 represents for the output voltage of the voltage regulating power source).
[0052] The structural features of the voltage regulating power source are that the voltage regulating power source is an electromagnetic induction device controlled by an AC voltage regulator, which is typically formed by a two-winding transformer (or other form of transformer), the AC voltage regulator control the primary side winding voltage to regulate the secondary winding voltage, and the output voltage and voltage waveform of the secondary winding are the output voltage and voltage waveform of the voltage regulating power source, as the voltages at a and x4 terminals in FIG. 1 . Properly speaking, the principle of the new AC voltage regulator is that the primary winding of a transformer is phase controlled by an AC voltage regulator, and then the secondary side winding of the transformer is connected to anther constant voltage power source in series.
[0053] Technical solution of the transformer switch: the existing transformer switch is replaced by an AC voltage regulating electronic switch. The principle, objectives and characteristics of the AC voltage regulating electronic switch are that: the principle of voltage regulator of the AC voltage regulating electronic switch is based on that the new AC voltage regulator regulates the voltage of a tertiary side voltage regulation winding of a series voltage regulating transformer (as described below) by utilizing the characteristics of basic voltage regulator circuitry of the transformer. The method for voltage regulation is that the linear voltage regulation portion employs the technology of high-speed sequential step latching stage turns by using an AC voltage regulator, that is, sequentially cut or add the stage turns (stepped voltage regulation) in the voltage regulation circuit, or adjust the turns of the tertiary side winding (i.e., voltage regulation) by using the method of high-speed sequential step phase controlled level voltage (stepless voltage regulation). Reversing change-over switch is used for reversing change-over voltage regulating to control the polarity of the tertiary side winding in a high speed, and coarse-fine regulation is formed by connecting two portions of linear regulation in series (two portions of linear regulator are connected in series after regulating voltage), so as to control the voltage and polarity of the primary winding of the series transformer, thereby achieving the aim of regulating the voltage and polarity of the secondary winding of series transformer, and the electronic switch has voltage regulation range of 0 to 100%.
[0054] One of the characteristics of the AC voltage regulating electronic switch according to the present invention is that: it is a series voltage regulation circuitry formed by a constant voltage power source (basic windings), a voltage regulating power source (stage voltage in the regulating windings, also referred to as stage turns, all the voltage regulation power source are regulating windings), an AC voltage regulator (or AC switches), and a measuring and control device based on the superposition principle of waveform, which includes the following three basic voltage regulation principles.
[0055] The first is the linear regulation principle ( FIG. 2 ). That is, in the series voltage regulation circuitry, the voltage of the entire constant voltage power source (basic windings) is set to the lower limit of the range of voltage regulation (i.e., the upper limit of the required voltage is subtracted from the lower limit of the required voltage). As long as the output maximal voltage of the voltage regulating power source (all the voltage regulation power source are regulating windings, and each voltage regulation power source is the stage tunes of the regulating windings) is equal to the range of voltage regulation. When regulating voltage, the AC voltage regulator is used to lock the voltage regulating power sources one by one, that is, by using a method of removing (or adding) the voltage regulating power sources from (or into) the series voltage regulation circuitry one by one.
[0056] The second is the reversing change-over voltage regulating principle ( FIG. 3 ). That is, in a series circuitry of linear voltage regulation, the voltage of the constant voltage power source is determined by adding the lower limit of the range of voltage regulation and a half of the range of voltage regulation, the maximal voltage output by the voltage regulating power source is a half of the range of voltage regulation, reversing change-over switches are mounted at two ends of the voltage regulating power source or the constant voltage power source. By regulating the polarity of the constant voltage power source and the voltage regulating power source and addition or subtraction of the voltage of the two power sources, the combined voltage finally output will meet the requirement of the range of voltage regulation.
[0057] The third is the coarse-fine regulating principle ( FIG. 4 ). That is, in a series circuit, a constant voltage power source is connected to several voltage regulating power sources for coarse regulation in series, and then connected to several voltage regulating power sources for fine regulation in series. The voltage of all of the voltage regulating power sources for fine regulation can be equal to the voltage of a voltage regulating power sources for coarse regulation. The voltage of the constant voltage power source is set to be the lower limit of the range of voltage regulation, and the voltages of several the voltage regulating power sources for coarse regulation plus the voltages of several the voltage regulating power sources for fine regulation is equal to the range of voltage regulation. When outputting the minimal voltage, it is only need to remove all of the power sources for coarse regulation and fine regulation. When outputting the maximal voltage, it is only need to add all of the power sources together in series. When outputting intermediate voltage, the series voltage regulation circuitry can be formed by the constant voltage power source connecting, in series, the circuitry which can remove the voltage regulating power sources for coarse regulation step by step in a high speed, and then connecting, in series, the circuitry which can remove or add the voltage regulating power sources for fine regulation step by step in a high speed.
[0058] These are three most common basic voltage regulation circuitries, from which various voltage regulation circuitries can be derived. Such as, a coarse-fine regulating circuit, the voltage regulating power sources for coarse regulation of which having reversing change-over function, can be obtained by mounting a reversing change-over switch at the voltage regulating power sources for coarse regulation in the coarse-fine regulating circuitry. A coarse-fine regulating circuit, the voltage regulating power sources for fine regulation of which having reversing change-over function, can be obtained by mounting a reversing change-over switch at the voltage regulating power sources for fine regulation in the coarse-fine regulating circuitry. And there are many ways of derivation, which are not specifically described herein. The above only describes situations of single phase, and only one of three methods for combining the voltage regulation method with the AC voltage regulators is described. In practice, there may be more than one constant voltage power source, and there may be more than one voltage regulating power source. The voltage regulating power sources for coarse regulation can have one or more stages, and the voltage regulating power sources for fine regulation can have two or more stages. All the voltage regulating power sources for fine regulation is not necessary to be equal to a voltage regulating power sources for coarse regulation. There are many options for positions of voltage regulation, such as, intermediate voltage regulation ( FIG. 5 and 6 ), end portion voltage regulation ( FIG. 7 ), and neutral point voltage regulation ( FIG. 8 ) and so on, and even an auto transformer can be formed by tapping on the constant voltage power source or the voltage regulating power source which are connected in series. There are various combinations for voltage regulation methods and voltage regulation positions and extracting positions for each tap terminals of the winding, and various combinations thereof. And furthermore, the AC voltage regulators are regulated based on the voltage regulation properties, the AC voltage regulators remove the voltage regulating power source step by step, anyway, as long as the voltage regulation principles of the combinations are the same to the principle of the AC voltage regulating electronic switch, similar in usage, and the principle for combining phases is the same to the principle for combining loaded switches of the transformer, the combinations fall into the scope of the AC voltage regulating electronic switch of the present invention. The formula for combined voltage of the AC voltage regulating electronic switch based on the linear regulation principle is recited as U=U 1 +U 2 or U=U 1 −U 2 (wherein, U represents for output voltage, U 1 represents for voltage of constant voltage power source, U 2 represents for the output voltage of the voltage regulating power source).
[0059] The formula for combined voltage of the AC voltage regulating electronic switch based on the principle of reversing change-over voltage regulating is recited as U=U 1 ±U 2 (wherein, U represents for output voltage, U 1 represents for voltage of constant voltage power source, U 2 represents for the output voltage of the voltage regulating power source).
[0060] The feature (2) of the AC voltage regulating electronic switch is that: by applying the AC voltage regulating electronic switch to the transformer according to the superposition principle of waveform as described by the present patent, using the constant voltage power source as a basic coil, using all the voltage regulating power sources as voltage regulation coils, using each of the voltage regulating power sources as stage voltage (stage turn), the switch, which has a high-speed stepped voltage regulation function or a high-speed stepless voltage regulation function and transient impedance regulation technology to cope with short-circuit and other emergencies, is the AC voltage regulating electronic switch for transformer as defined by the present patent, which is also referred to as the AC voltage regulating electronic switch.
[0061] The AC voltage regulating electronic switch can be used for stepless voltage regulation (when the AC voltage regulator is used for phase controlling, preferably, each of the AC voltage regulators only phase control a stage of voltage to ensure minimal harmonics) and stepped voltage regulation (when the AC voltage regulator is on or off). The design of applying conventional voltage regulator and other stepless voltage regulation devices to the tertiary side winding of the series voltage regulating transformer, or combining the AC voltage regulating electronic switch with conventional transformer switches, falls into the scope of the AC voltage regulating electronic switch.
[0062] The formula for combined voltage of the AC voltage regulating electronic switch based on the principle of reversing change-over voltage regulating is recited as U=U 1 ±U 2 (wherein, U represents for output voltage, U 1 represents for voltage of constant voltage power source, U 2 represents for the output voltage of the voltage regulating power source), the formula for combined voltage of the AC voltage regulating electronic switch based on the linear regulation principle is recited as U=U 1 +U 2 or U=U 1 −U 2 (wherein, U represents for output voltage, U 1 represents for voltage of constant voltage power source, U 2 represents for the output voltage of the voltage regulating power source).
[0063] The feature (3) of the AC voltage regulating electronic switch is that: the technology of locking stage turns by the AC voltage regulator of the AC voltage regulating electronic switch is using an AC voltage regulator to remove undesirable stage turns from the voltage regulation winding circuitry in a high speed or add the removed stage turns into the voltage regulation winding circuitry step by step. There are many such kind of methods, a simple one of which is described herein. That is, by leading out all the stage turns of the voltage regulation coil, except for the head end A, connecting each of the leading-out terminals (including the tail end) to an AC voltage regulator, and then shorting out the other terminals of all the AC voltage regulator as X. When a stage of voltage is required, it is only required to turn on the AC voltage regulator to which the stage of voltage belongs, and turn off all other AC voltage regulators. If it is required, the terminal A may also be connected to the AC voltage regulator, and the other terminal of the AC voltage regulator is shorted out. There are many removing methods, which are not described completely. But any methods using an AC voltage regulator for removing, in high-speed, undesirable stage turns for the voltage regulation winding from the voltage regulation winding circuitry step by step or adding the removed stage turns into the voltage regulation winding circuitries through any series parallel methods, belong to the technology of locking stage turns by the AC voltage regulator of the AC voltage regulating electronic switch as defined by the present patent.
[0064] The feature (4) of the AC voltage regulating electronic switch is that: there are many methods for regulating the polarity of the windings by the reversing change-over switch through series or parallel AC voltage regulators. A simple one of which is described below. That is, each of the both ends of the voltage regulation winding is connected to an AC voltage regulator, and the other ends of the two AC voltage regulators are shorted out to a K terminal, which is connected to the head end or tail end of another coil. One AC voltage regulator is turned on and the other is turned off when performing forward voltage regulation, and the latter is on and the former is off when performing backward voltage regulation. The reversing change-over switches, which switch the polarity of the voltage regulation winding (or tertiary winding supplying power thereto) by using any series parallel methods, are the reversing change-over switch as defined by the present patent.
[0065] The feature (5) of the AC voltage regulating electronic switch is that: the AC voltage regulating electronic switch is formed by connecting a group of semiconductor device in series or in parallel (in principle, there are various series parallel methods). No matter which method, as long as the switch is formed by semiconductor devices and is conform to the principle of voltage regulation of the AC voltage regulating electronic switch, and is in conformity with the superposition principle of waveform as defined by the present patent, and is connected to the tertiary winding of the series voltage regulating transformer as defined in claim 2 in series or in parallel, and can regulate voltage in high speed, the switch is the AC voltage regulating electronic switch as defined by the present patent.
[0066] The feature (6) of the AC voltage regulating electronic switch is that: the AC voltage regulating electronic switch is formed by connecting a group of semiconductor device in series or in parallel (in principle, there are various series parallel methods). No matter which method, as long as the switch is formed by semiconductor devices and is conform to the principle of voltage regulation of the AC voltage regulating electronic switch, is applied to the primary or secondary side winding of any one of the high voltage transformer, it is the AC voltage regulating electronic switch as defined in the present patent. But it has large harmonic waves, and is easy to have accidents when applied to high-voltage and middle/high capacity devices, has lower voltage class under the same number of AC voltage regulators, lower capacity, which is not applied in general case.
[0067] The feature (7) of the AC voltage regulating electronic switch is that: the AC voltage regulating electronic switch (or the new AC voltage regulator) when applied to reactor is referred to as an AC voltage regulator reactor electronic switch, which is called the AC voltage regulating electronic switch for short. Of course, it can be applied to other circuitries requiring for voltage regulation, or the switch, belonging to an AC circuitry in which a component or device is required to be replaced (i.e., to be removed or added), is referred to as the AC voltage regulating electronic switch.
[0068] The feature (8) of the AC voltage regulating electronic switch is that: the semiconductor components in the AC voltage regulating electronic switch can be replaced by other switching elements, such as, contactors, breakers and other switching elements, and is in conformity with the superposition principle of waveform and AC voltage regulating electronic switch principle or applied transient impedance technology, which belongs to the AC voltage regulating electronic switch as defined in the present patent.
[0069] Any electronic switches, which are conform to the 8 features of the new AC voltage regulator and the AC voltage regulating electronic switch and conform to any conditions as recited by the AC voltage regulating electronic switch in claim 1 , is the AC voltage regulating electronic switch.
[0070] Briefly, the AC voltage regulating electronic switch is formed by connecting semiconductor device in series or in parallel. In principle, there are various series parallel methods. No matter which method, as long as the switch is formed by semiconductor devices, based on superposition principle of waveform, and connected to the tertiary winding of the series voltage regulating transformer as defined in claim 2 (or primary winding of the series transformer) in series or in parallel, or applied to the primary or secondary windings of any kind of the transformers, and has functions of voltage regulation, or AC switch, the transformer resolve problems of non-continuous voltage waveform, voltage regulation, large harmonics, high-speed regulation of reactance of the transformer, replacement of devices or components in circuitries (which means removing or adding), which is the AC voltage regulating electronic switch.
[0071] The above switch is combined with the measuring and control device. The measuring and control device consists of an input signal, a measurement portion, a logic portion, a execution portion, an output signal, a tuning value portion and other portions, detects the current, voltage, impedance and other various indicators of the system, the AC voltage regulating electronic switch is controlled in accordance with a compiled program so as to automatically control the transient impedance transformer, and the load may be regulated. The measuring and control device may not be provided, and the measurement is finished by manual operation. FIG. 9 is a schematic diagram showing the principle of a measuring and control device.
[0072] The solution of series voltage regulating transformer: the series voltage regulating transformer as defined in the present patent is characterized in that it generically consists of two types of transformers. One is a main transformer (referred as main transformer for short, the transformers with split windings or series transformer, and it can include a plurality of main transformers), the other is a series type of transformer (called the series transformer for short, the trans former with split windings or series transformer, and it can include a plurality of series transformers).
[0073] Regardless of whether the voltage regulation winding arranged on the main transformer is required or not by the two transformers to supply power to the primary side of the series transformer, the transformer is referred to as the extended series voltage regulating transformer, and generally called the series voltage regulating transformers, as long as the same secondary windings are connected in series, the voltage of the secondary winding of the main transformer is constant (or adjustable), the voltage of the secondary winding of the series transformer is adjustable so that the voltage of the two secondary winding, which are connected in series, is changed, so as to change the combined voltage of the secondary winding of the main and series transformers, thereby regulating voltage together with loads. The range of application thereof is extended to all the field of transformers, and wherein the structure of the secondary winding can employ any structures of transformer windings.
[0074] When the secondary winding of the main transformer of the series voltage regulating transformer is cancelled, the transformer in which one end of the secondary winding thereof directly connected to the power grid (or power source), and the other end is connected to another power grid (or load or power source) is referred to as the series transformer voltage regulation auto transformer, in which the power grid (or power source) serves as a secondary winding of the main transformer, and generally referred to as the series voltage regulating transformer.
[0075] When the primary and secondary windings of the main transformer of the series voltage regulating transformer are cancelled, the primary winding of the series transformer is powered by the control power source of the AC voltage regulator, one end of the secondary winding of the series transformer is connected to the other power grid, and the other end is connected to another loaded series voltage regulating transformer, which is a series voltage regulating transformer using the power source as the main transformer.
[0076] Two same secondary windings of the series voltage regulating transformer are connected in series to form a single phase second winding of the series voltage regulating transformer (two in-phase secondary windings can employ a splayed coil structure (the structure is showed in FIG. 10 ), and the two windings can also employ any structures for the transformer coils, and then can be connected end to end, which is called the secondary winding or secondary side of the series voltage regulating transformer). When three phases are required, the secondary winding of the series voltage regulating transformer can be designed as any connecting combinations (comprising an extended triangle).
[0077] The primary winding and secondary winding of the series transformer employing an auto transformer type is referred to as an auto series transformer series voltage regulating transformer, and also referred to as the series voltage regulating transformer herein. The primary winding and secondary winding of the main transformer employing an auto transformer type is referred to as an auto main transformer series voltage regulation transformer, and also referred to as the series voltage regulating transformer herein. The main transformer supplying power to the series transformer in a way of auto transformer (or voltage regulating transformer) is referred to as a power supplying series voltage regulating auto transformer, but is referred to as the series voltage regulating transformer, which can be used mixedly.
[0078] A transformer belongs to transformers with split windings regardless of the number of split windings and the number of transformers of main transformer or series transformer, and a transformer belongs to series transformer regardless of the number of the windings of transformers connected in series and the split transformer, or the series transformer and split transformer can be used mixedly.
[0079] Any transformer in which the secondary side of the transformer is connected in a way of the voltage regulation principle of the series voltage regulating transformer or a voltage is synthesized by two or more variable or constant or adjustable voltage, and regardless how many transformer connected to the secondary side in series (including connection to power grid and power source), is the series voltage regulating transformer type as defined by the present patent.
[0080] Any transformer employing transient impedance regulation technology to suppress short circuit or other emergencies or any conventional series voltage regulating transformer employing high-speed voltage regulation function is also the series voltage regulating transformer as defined by the present patent.
[0081] The series voltage regulating transformer (the structure is showed in FIG. 11 ) generally consists of a primary winding, a secondary winding, and a tertiary side winding or referred as a voltage regulation winding, and can consist of a primary winding, a tertiary side winding or referred as voltage regulation winding. The series transformer consists of a primary winding (sometimes may be referred as the tertiary side winding), a secondary winding, or various windings are split or the transformers are split, as long as the winding supplies power to the primary winding of the series transformer, regardless whether it is arranged on the main transformer or on one or more transformer, the winding can be referred to as the tertiary side winding.
[0082] The formula for the combined voltage of the secondary voltage of the series voltage regulating transformer is recited as U=U 1 ±U 2 (wherein, U represents for output voltage, U 1 represents for the secondary voltage of the main transformer, and U 2 represents for the secondary voltage of the series transformer), the range of voltage regulation is 0-100%.
[0083] The AC voltage regulating electronic switch has either a high-speed stepless voltage regulation function or a high-speed stepped voltage regulation function, and the series voltage regulating transformer when applied to the stepless voltage regulation system is referred to as a voltage regulator.
[0084] The two in-phase secondary windings of the series voltage regulating transformer are connected in series to form a single phase. When three phases are required, the secondary winding of the series voltage regulating transformer can be designed as any connecting combinations comprising an extended triangle, and an extended triangle connection group structure, which has significant effects when the above technology is applied to the prior transformer remolded according to the present technology.
[0085] The feature of the series voltage regulating transformer can be other transformer type, such as, two or three or four limbs voltage regulating transformer with by-pass limb, front regulating transformer and other transformers can have the same function.
[0086] Currently, as the series voltage regulating transformer are applied to AC voltage regulating electronic switches, the usage and functions of the series voltage regulating transformer are largely extended, in view of this circumstance, the present patent proposes a new form of transformer, referred to as a extended series voltage regulating transformer, (also called series voltage regulating transformer for short), which is a supplement and perfection to conventional series voltage regulating transformers in order to meet different requirements.
[0087] Safe solution for suppressing sudden short circuit and maintaining system stability: the transient impedance technology of the present invention is characterized in that (that is, the transient impedance regulation technology, visually, is referred to as a transformer secondary voltage high-speed regulating technology): the transient impedance technology is the transient impedance regulation technology, and a technology of using the high-speed regulator function of the AC voltage regulating electronic switch, when short circuit or other extreme cases occur at the secondary side, the AC voltage regulating electronic switch regulates the secondary voltage of the transformer in a high speed to regulate the reactance voltage drop of the transformer upward or downward so as to maintain the secondary system stable under any emergencies. The transient impedance technology of the present invention mainly employs the AC voltage regulating electronic switch to control the secondary voltage of the series voltage regulating transformer to increase or decrease in a high speed, even makes the polarities of the two in-phase secondary windings opposite so as to form the inductance coils connected in series with opposite polarities, and makes the secondary winding of the transformer immediately become a reactance coil. By regulating the voltage of the secondary winding of the series transformer, the reactance voltage drop of the transient impedance transformer is regulated to a predetermined level in a high speed, in principle. The reactance voltage drop of the transformer can be lowered to almost 100% in theory, and the reactance voltage of the control transformer make the system possible to become a predetermined level in case of emergency, or make the voltage become close to 0, but not equal to 0 (when regulating the voltage to a level next higher than 0 by stepped regulation, stepless voltage regulation can be used for making the secondary voltage close to 0, but not equal to 0), make the short-circuit current under control, but not interrupting the current, thereby maintaining the secondary system stable under any emergencies, and make common transformer or even low-impedance transformer become a reactance-adjustable reactor instantaneously, which is very important for protecting many power equipments, such as, a high voltage power grid and electric furnace smelting.
[0088] The time standard for high-speed regulation: the shortest time within which the transformer or other power equipments and all the system consisting of them with such voltage class and capacities shall be capable to withstand under sudden short circuit and other emergencies as specified by international standards.
[0089] Technical solution of the transient impedance transformer: the transient impedance transformer is characterized in that: the transient impedance transformer generally consists of an AC voltage regulating electronic switch, a series voltage regulating transformer (it can include a transformer switch as well). In the application of high voltage or ultra-high voltage power grid or low-voltage and high-current system or other resistive, resistive-inductive, and resistive-capacitive load systems requiring step up the reactance instantaneously or stabilizing voltage in a high speed, the reactance voltage drop of the transformer may be regulated to a predetermined or reasonable level in a high speed by using the transient impedance technology of the present invention. The transformer may become a high-impedance transformer in a high speed, that is, under a normal condition, and the transformer is a common transformer, or even a low-impedance transformer in aspects of impedance, loss and the like. When a sudden short circuit or other extreme cases occur, the common transformer becomes a high-impedance transformer or ultra-high impedance transformer instantaneously, thereby ensuring the short-circuit current of the system under the rated current or any level, and when the emergencies are eliminated, the transformer may be restored to a common transformer instantaneously. This kind of transformer is referred to as the transient impedance transformer. the transformer can be classified into a transient impedance power transformer, a transient impedance special transformer, a transient impedance voltage regulator, a transient impedance power transformer and the like based on the technical field of application, and the transformer may be applicable to safety protection of various systems.
[0090] Technical solution of the high voltage circuitry breaker: the technical advantages of the transient impedance transformer tertiary side disconnection technology is that the low-voltage tertiary side disconnection portion is used for replacing primary side disconnection, thereby achieving partial replacement of the high voltage circuitry breaker by a cheap and long-life low-voltage circuitry breaker. The principle is that another basic winding is added to the main transformer, and is connected to the regulating windings, a load circuitry breaker is provided between the basic winding and the primary winding of the series transformer, and a short circuit switch is provided at the secondary side, when someone wants to cut off the loading current, the tertiary side circuitry breaker is disconnected, at the same time, the secondary side short circuit switch is closed, as the secondary side is shorted out, the low voltage of the main transformer is wholly applied to the low-voltage windings of the series transformer, and as the high voltage windings of the series transformer are open, the series transformer is under a condition of idle running with the low-voltage windings supplying power thereto. Only no-load current flows through the low-voltage winding. Obviously, the main transformer is under on-load condition, and at this time, the secondary load is under a no electric current, voltage state. The wiring scheme is showed in FIG. 12 .
[0091] Technical solutions of the transient impedance power transformer: the transient impedance power transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer, and the AC voltage regulating electronic switch is connected to the tertiary side of the series voltage regulating transformer, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, the secondary windings of the main transformer and series transformer of the series voltage regulating transformer are connected to the second power grid or other power loads, and a transient impedance power transformer with split windings, a transient impedance step up power auto transformer, a transient impedance step up power auto transformer with split windings, a high-speed voltage regulation step down power auto transformer, a high-speed voltage regulation step down power auto transformer with split windings, and the like are derived from the transient impedance power transformer.
[0092] The transient impedance power transformer is mainly applied to high voltage or ultra-high voltage power grid for power transmission and power grid reactive power control as well as high-speed voltage regulation, safety protection, and reactive compensation of secondary side, and may control the system with intelligent control by the transformer, achieve voltage stability control, control the imbalance of each phase load in a high speed, exempt the transformer from maintenance, adjust the capacity of the transformer.
[0093] The transient impedance power transformer with split windings is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer. In the first transient impedance power transformer with split windings, the secondary winding of the main series transformer of the series voltage regulating transformer is split into two secondary windings, and in the second transient impedance power transformer, the series transformer is divided into two transformers, which are referred to as a secondary winding ( 1 ), and a secondary winding ( 2 ), when the first power grid, the second power grid (electric power load) and the third power grid (electric power load) are required to be connected, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, the secondary winding ( 1 ) is connected to the second power grid (electric power load), the second winding ( 2 ) is connected to the third power grid (electric power load). If the second power grid (electric power load) and the third power grid (electric power load) need voltage regulation respectively, the second split solution may be used, i.e., the series transformer is divided into two transformers, and then the voltage regulation winding is split into two windings, at this time, two AC voltage regulating electronic switches are required to be connected to the two voltage regulation windings of the series voltage regulating transformer, the primary windings of the two series transformer are powered by the two voltage regulation windings of the main transformer. By regulating different switches, the voltages of the second power grid (electric power load) and the third power grid (electric power load) are regulated respectively. Here, the transient impedance transformer is referred to as the transient impedance power transformer with split windings. As the secondary winding of the series transformer of the series voltage regulating transformer is divided into two secondary windings, when the series transformer is divided into two transformers, as the transient impedance technology can be applied to the two secondary windings respectively, a power grid (an electric power load) will be less influenced if the other power (the other electric power) fails.
[0094] The transient impedance step up power auto transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer.
[0095] The secondary winding of the main transformer is cancelled, and the AC voltage regulating electronic switch is connected at the tertiary side of the series voltage regulating transformer. When the first power grid (at lower voltage) and the second power grid are required to be connected to boost the voltage, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, and the secondary winding of the series voltage regulating transformer is connected between the first power grid and the second power grid, to regulate the voltage of the second power grid.
[0096] The transient impedance step up power auto transformer with split windings is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer. The secondary winding of the main transformer is cancelled, the secondary winding of the series transformer is split into two secondary windings, or the series transformer is divided into two transformers. Here, the secondary windings of the series transformer are referred to as a secondary winding ( 1 ), and a secondary winding ( 2 ). When the first power grid (lower voltage), the second power grid and the third power grid are required to be connected, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, the secondary winding ( 1 ) is connected between the first power grid and the second power grid, the second winding ( 2 ) is connected between the first power grid and the third power grid. If the second power grid and the third power grid need voltage regulation respectively, the second split solution may be used, i.e., the series transformer is divided into two transformers, and then the voltage regulation winding is split into two windings. At this time, two AC voltage regulating electronic switches are required to be connected to the two voltage regulation windings of the series voltage regulating transformer. The primary windings of the two series transformer are powered by the two voltage regulation windings of the main transformer. By regulating different switches, the voltages of the second power grid and the third power grid are regulated respectively. Here, the transient impedance transformer is referred to as the transient impedance step up power auto transformer with split windings. As the secondary winding of the series transformer of the series voltage regulating transformer is divided into two secondary windings, when the series transformer is divided into two transformers, as the transient impedance technology can be applied to the two secondary windings respectively, a power grid will be less influenced if the other power fails. In this solution, the power grid with lower voltage is used as the secondary winding of the main transformer.
[0097] The high-speed voltage regulation step down power auto transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer, the secondary winding of the main transformer is cancelled, the AC voltage regulating electronic switch is connected at the tertiary side of the series voltage regulating transformer. When the first power grid (at higher voltage) and the second power grid (electric power load) are required to be connected to step down voltage, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, the first power grid and the second power grid (electric power load) are connected by the secondary winding of the series transformer, and the first power grid is used as the secondary winding of the main transformer of the series voltage regulating transformer, to regulate the voltage of the second power grid (electric power load).
[0098] The high-speed voltage regulation step down power auto transformer with split windings is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer. The secondary winding of the main transformer is cancelled, and the secondary winding of the series transformer of the series voltage regulating transformer is split into two secondary windings, or the series transformer is divided into two transformers, which are referred to as a secondary winding ( 1 ), and a secondary winding ( 2 ). When the first power grid (higher voltage), the second power grid (electric power load) and the third power grid (electric power load) are required to be connected, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, the secondary winding ( 1 ) is connected between the second power grid (electric power load) and the first power grid, the second winding ( 2 ) is connected between the third power grid (electric power load) and the first power grid. If the second power grid (electric power load) and the third power grid (electric power load) need voltage regulation respectively, the series transformer may be divided into two transformers, and then the voltage regulation winding is split into two windings. At this time, two AC voltage regulating electronic switches are required to be connected to the two voltage regulation windings of the series voltage regulating transformer. The primary windings of the two series transformer are powered by the two voltage regulation windings of the main transformer, respectively. By regulating different switches, the voltages of the second power grid (electric power load) and the third power grid (electric power load) are regulated respectively. Here, the transformer is referred to as the high-speed voltage regulation step down power auto transformer with split windings.
[0099] The solution of transient impedance special transformer: the transformer typically generally consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer (may include a transformer switch). The AC voltage regulating electronic switch is connected to the tertiary side of the series voltage regulating transformer, the primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid or power source, the secondary windings of the main transformer and series transformer of the series voltage regulating transformer are connected to an electric power load. A high-speed voltage regulation special auto transformer is derived from the transient impedance special transformer, and a series of special transformer, such as, a transient impedance converting transformer, a high-speed voltage regulation converter auto transformer, a transient impedance furnace transformer, a high-speed voltage regulation furnace auto transformer, a transient impedance traction transformer, a transient impedance voltage-stabilizing and capacity regulation traction transformer and the like are derived from the transient impedance special transformer;
[0100] The high-speed voltage regulation special auto transformer is characterized in that: (as showed in FIG. 13 ) the transformer generally consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer (may include a transformer switch), the AC voltage regulating electronic switch is connected at the tertiary side of the series voltage regulating transformer, and the secondary winding of the main transformer is cancelled. When the electric power load is required to be connected to power grids to step up/down the voltage, the primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid, and the power grid and the electric power load are connected by the secondary winding of the series transformer. The power grid is used as the secondary winding of the main transformer of the series voltage regulating transformer, to step up/down the voltage of the electric power load.
[0101] The solution of transient impedance converting transformer: the transient impedance converting transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer (may include a transformer switch). And the AC voltage regulating electronic switch is connected to the tertiary side of the series voltage regulating transformer, and the primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid or power source. The secondary windings of the main transformer and series transformer of the series voltage regulating transformer are connected to an electric power load. The description of a split windings or multi-pulse converting transformer is omitted.
[0102] The high-speed voltage regulation step down converting auto transformer is characterized in that: the transformer generally consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer (may include a transformer switch). The AC voltage regulating electronic switch is connected at the tertiary side of the series voltage regulating transformer, and the secondary winding of the main transformer is cancelled. When the electric power load is required to be connected to power grids to step up/down the voltage, the primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid, and the power grid and the electric power load are connected by the secondary winding of the series transformer. The power grid is used as the secondary winding of the main transformer of the series voltage regulating transformer, to regulate the voltage of the electric power load. The description of a multi-pulse converting transformer with split windings is omitted.
[0103] The solution of transient impedance furnace transformer the transient impedance furnace transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer (may include a transformer switch). The AC voltage regulating electronic switch is connected to the tertiary side of the series voltage regulating transformer, and the primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid or power source. The secondary windings of the main transformer and series transformer of the series voltage regulating transformer are connected to an electric power load.
[0104] The high-speed voltage regulation furnace transformer is characterized in that: the high-speed voltage regulation furnace transformer generally consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer (may include a transformer switch). The AC voltage regulating electronic switch is connected at the tertiary side of the series voltage regulating transformer, and the secondary winding of the main transformer is cancelled. When the electric power load is required to be connected to power grids to step up/down the voltage, the primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid, and the power grid and the electric power load are connected by the secondary winding of the series transformer. The power grid is used as the secondary winding of the main transformer of the series voltage regulating transformer, to step up/down the voltage of the electric power load.
[0105] The solution of transient impedance traction transformer: the transient impedance traction transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer. The AC voltage regulating electronic switch is connected to the tertiary side of the series voltage regulating transformer to achieve high-speed loaded and stepped voltage regulation. Take a group formed by connecting YN and dl 1 , the primary winding of the main transformer of the series voltage regulating transformer is connected to the high-voltage power grid, the secondary windings of the main transformer and series transformer of the series voltage regulating transformer are connected to form a structure of d11 which is connected to a railway traction transmission line in a traction changed YN, d11 structure.
[0106] When the traction transformer belongs to other groups such as YN, d11, d5 connection group, V, V0 structures with two connected single-phase transformer, a LeBlanc connection transformer, Wood bridge transformer structure, deformed Wood bridge transformer structure, deformed YN, d11 transformer, deformed YN, d11, d5 transformer and the like are usable by changing in this way.
[0107] Technical solution of the transient impedance voltage regulator: the transient impedance voltage regulator is characterized in that: the transformer consists of an AC voltage regulating electronic switch and a series voltage regulating transformer (may include a transformer switch). The voltage of the tertiary side of the AC voltage regulating electronic switch is regulated in a stepped or stepless manner in high speed, the primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid, and the secondary winding formed by the main transformer and the series transformer of the series voltage regulating transformer are connected to a resistance, resistance-inductance or resistance-capacitance load. A transient impedance step up auto regulator, or a high-speed voltage regulation step down auto transformer is derived from the transient impedance voltage regulator. The AC voltage regulating electronic switch has functions of high-speed stepless voltage regulation and high-speed stepped voltage regulation. When they are combined, the output voltage waveform can be infinitely close to a sine wave. The transformer when applied to the stepless voltage regulation system is referred to as the voltage regulator.
[0108] The transient impedance step up auto transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch and a series voltage regulating transformer. The primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid, and the secondary winding of the main transformer is cancelled, the voltage of the tertiary side is regulated in a stepped or stepless manner in a high speed by using the AC voltage regulating electronic switch. The power grid (or power source) and the electric power load are connected by the secondary winding of the series transformer, the power grid (or power source) is used as the secondary winding of the main transformer of the series voltage regulating transformer, to regulate the voltage of the resistance, resistance-inductance or resistance-capacitance electric power load.
[0109] The high-speed voltage regulation step down auto transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch and a series voltage regulating transformer (may include a transformer switch). The primary winding of the main transformer of the series voltage regulating transformer is connected to the power grid, and the secondary winding of the main transformer is cancelled. The voltage of the tertiary side of the AC voltage regulating electronic switch is regulated in a stepped or stepless manner in a high speed, the power grid (or power source) and the electric power load are connected by the secondary winding of the series transformer. The power grid (or power source) is used as the secondary winding of the main transformer of the series voltage regulating transformer, to regulate the voltage of the resistance, resistance-inductance or resistance-capacitance electric power load.
[0110] Technical solution of the transient impedance power source transformer: the transient impedance power source transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch and a series voltage regulating transformer (may include a transformer switch). The voltage of the tertiary side of the AC voltage regulating electronic switch is regulated in a stepped manner in a high speed. The primary winding of the main transformer of the series voltage regulating transformer is connected to the power source, and the secondary winding formed by the main transformer and the series transformer of the series voltage regulating transformer are connected to a resistance, resistance-inductance or resistance-capacitance load, a high-speed voltage regulating power source auto transformer is derived from the transient impedance power source transformer.
[0111] The transient impedance step up power source auto transformer is characterized in that: the transformer consists of an AC voltage regulating electronic switch and a series voltage regulating transformer (may include a transformer switch). The primary winding of the main transformer of the series voltage regulating transformer is connected to the power source, and the secondary winding of the main transformer is cancelled. The voltage of the tertiary side of the AC voltage regulating electronic switch is regulated in a stepped or stepless manner in a high speed. The power source and the electric power load are connected by the secondary winding of the series transformer. The power source is used as the secondary winding of the main transformer of the series voltage regulating transformer, to regulate the voltage of the resistance, resistance-inductance or resistance-capacitance electric power load.
[0112] The high-speed voltage regulation step down power source auto transformer and the high-speed voltage regulation step down auto transformer are characterized in that: the transformer consists of an AC voltage regulating electronic switch, and a series voltage regulating transformer (may include a transformer switch), the primary winding of the main transformer of the series voltage regulating transformer is connected to the power source (or power grid), the secondary winding of the main transformer is cancelled. The voltage of the tertiary side is regulated in a stepped or stepless manner in a high speed by using the AC voltage regulating electronic switch. The power grid is powered by the secondary winding of the series voltage regulating transformer, to regulate the voltage of the resistance, resistance-inductance or resistance-capacitance electric power load.
[0113] Technical solution of the high-speed voltage regulating transformer: the high-speed voltage regulating transformer consists of an AC voltage regulating electronic switch and any types of transformers. The AC voltage regulation switch acts on the primary side of the transformer, and the transformer uses the AC voltage regulating electronic switch as a loaded voltage regulation switch. Such a transformer is referred to as a high-speed voltage regulating transformer. But at the present, the transformer may only utilized on low-voltage and low-capacity transformers due to performance of semiconductor components.
[0114] The technical solution of power grid connection technology type of a transient impedance transformer: the power grid connection method type of a transient impedance transformer is characterized in that: the transient impedance transformer constituted by an AC voltage regulating electronic switch and a series voltage regulating transformer, and the power grid connection technology. The AC voltage regulating electronic switches are connected to the tertiary side of the series voltage regulating transformer. The primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, and the secondary windings of the main transformer and series transformer of the series voltage regulating transformer are connected to the second power grid. And a power grid connection method type of a transient impedance power transformer with split windings, a power grid connection method type of a transient impedance step up auto transformer, and a power grid connection method type of a transient impedance step up auto transformer, and the like are derived from the power grid connection method type of a transient impedance power transformer.
[0115] The power grid connection method type of a transient impedance power transformer with split windings is characterized in that: the secondary windings of the main transformer of the series voltage regulating transformer is split into two windings (the first type of transient impedance power transformer with split windings), or the series transformer is divided into two transformers (the second type of transient impedance power transformer with split windings), which are referred to as a secondary winding ( 1 ), and a secondary winding ( 2 ). When the first power grid, the second power grid and the third power grid are required to be connected, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, the secondary winding ( 1 ) is connected to the second power grid, the second winding ( 2 ) is connected to the third power grid. If the second power grid and the third power grid need voltage regulation respectively, the series transformer is divided into two transformers, and then the voltage regulation winding is split into two windings. At this time, two AC voltage regulating electronic switches are required to be connected to the two voltage regulation windings of the series voltage regulating transformer, respectively. The primary windings of the series transformer are powered by the two voltage regulation windings of the main transformer. By regulating different switches, the voltages of the second power grid and the third power grid are regulated respectively. Here, the transient impedance transformer is referred to as the split transient impedance power transformer. As the secondary winding of the series transformer of the series voltage regulating transformer is divided into two secondary windings, when the series transformer is divided into two transformers, as the transient impedance technology can be applied to the two secondary windings respectively, a power grid will be less influenced if the other power fails.
[0116] The power grid connection method type of a transient impedance step up auto transformer are characterized in that: it is applied to a step up power grid system, and consists of an AC voltage regulating electronic switch and a series voltage regulating transformer ( FIG. 14 ). The secondary winding of the main transformer is cancelled, and the AC voltage regulating electronic switch is connected at the tertiary side of the series voltage regulating transformer. When the first power grid (at lower voltage) and the second power grid are required to be connected to step up the voltage, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, the first power grid and the second power grid are connected by the secondary winding of the series transformer. The first power grid acts as the secondary winding of the main transformer of the series voltage regulating transformer to regulate the voltage of the second power grid.
[0117] The power grid connection method type of transient impedance step up auto transformer with split windings is characterized in that: when applied to a step up power grid system, the transformer consists of an AC voltage regulating electronic switch and a series voltage regulating transformer. The secondary winding of the main transformer is cancelled, and the secondary winding of the series transformer of the series voltage regulating transformer is split into two secondary windings, or the series transformer is divided into two transformers, which are referred to as a secondary winding ( 1 ), and a secondary winding ( 2 ). When the first power grid (lower voltage), the second power grid and the third power grid are required to be connected, the primary winding of the main transformer of the series voltage regulating transformer is connected to the first power grid, the secondary winding ( 1 ) is connected between the second power grid and the first power grid, and the second winding ( 2 ) is connected between the third power grid and the first power grid. If the second power grid and the third power grid need voltage regulation respectively, the series transformer may be divided into two transformers, and then the voltage regulation winding is divided into two windings. At this time, two AC voltage regulating electronic switches are required to be connected to the two voltage regulation windings of the series voltage regulating transformer. The primary windings of the series transformer are powered by the two voltage regulation windings of the main transformer. By regulating different switches, the voltages of the second power grid and the third power grid are regulated respectively. Here, the transient impedance transformer is referred to as the transient impedance step up power auto transformer with split windings. As the secondary winding of the series transformer of the series voltage regulating transformer is divided into two secondary windings, when the series transformer is divided into two transformers, as the transient impedance technology can be applied to the two secondary windings respectively, a power grid will be less influenced if the other power fails.
[0118] The power grid connection method type of a high-speed voltage regulation step down auto transformer is characterized in that: it has the same structure to that of the power grid connection method type of a transient impedance step up auto transformer, but it is applied to a power grid step down connecting system.
[0119] The power grid connection method type of a high-speed voltage regulation step down auto transformer with split windings is characterized in that: it has the same connection method to that of the power grid connection method type of a transient impedance step up auto transformer with split windings, but it is applied to a power grid step down connecting system.
[0120] The technical solution for connection technology of reactive compensation devices: the reactive compensation devices connected in series or parallel to the end port of the secondary side (constant voltage end) of the main transformer of the series voltage regulating transformer is characterized in that (its location is showed in FIG. 12 ): when the present invention is required to be applied to a voltage stabilizing system, a voltage regulation system, a high voltage power grid system, and when the reactive compensation devices are required to be connected to achieve reactive compensation, the reactive compensation devices can be connected in series or parallel to the end port of the secondary outgoing wire of the main transformer of the series voltage regulating transformer.
[0121] The reactive compensation devices connected in series or parallel to basic winding at tertiary side (the tertiary side may be disconnected) of the main transformer of the series voltage regulating transformer, characterized in that (its location is showed in FIG. 12 ): when the present invention is required to be applied to a voltage stabilizing system, a voltage regulation system, a high voltage power grid system, and when the reactive compensation device is required to be connected in series or parallel to achieve reactive compensation, the reactive compensation device can be connected in series or parallel to basic winding at tertiary side (the tertiary side may be disconnected) of the main transformer of the series voltage regulating transformer.
[0122] The reactive compensation device is characterized in that it can be formed as a single-phase or three-phase structure by capacitors (or paralleling reactors), and use mechanically or thyristor to control the switching function. It can also be a static reactive compensation device (SVC), and other reactive compensation methods are not described in details.
ADVANTAGEOUS EFFECTS
[0123] The new AC voltage regulator has advantageous effects that: the new AC voltage regulator is the foundation of AC voltage regulating electronic switches, and it is one of the simplest AC voltage regulating electronic switch. As compared with the output waveform of conventional AC voltage regulators, the waveform output by the AC voltage regulator of the present invention is relatively in close to sine wave, achieving lowest effect on the device. Thus, in resistive, resistive-inductance, and resistive-capacitive AC load systems, the application can achieve voltage smoothly stepless regulation in high speed, and the range of continuous voltage regulation is 0-100%, which has advantages of readily achieving facility automation, high power factor, low power loss, small harmonics, without voltage interrupted region, and continuous current. The new AC voltage regulator can be applied in high voltage classes and large capacity, and can achieve stepless voltage regulation and stepped voltage regulation, but it should be applied to a series circuitry with more than one voltage regulating transformer (or voltage regulating power source) connected with more than one transformer (power grid, or power source). The application of the new AC voltage regulator breaks through the limits on voltage classes and capacities of conventional AC voltage regulator, and extends the application thereof to high voltage and ultra-high voltage systems.
[0124] The AC voltage regulating electronic switch has advantages that: it resolves the problems that conventional contactor switches are easy to generate arc, incapable of stepless voltage regulation, incapable of response in a high speed, high maintenance cost, cumbersome volume, complex structure, high accident rate, and excessive costs in split-phase voltage regulation. The AC voltage regulating electronic switch (it is preferred to eliminate capacitor discharge when the current of the voltage regulator circuitries is crossing the zero point) has functions of reversing change-over voltage regulating, linear regulation, coarse-fine regulation, and can achieve stepless voltage regulation, and stepped voltage regulation, or arbitrarily switching between stepped voltage regulation and stepless voltage regulation in a high speed. It can be applied to low-voltage and high-current systems and achieve high-speed response, and can be embodied as intelligent control, no electric arc, corrosion resistance and lower costs. As for application in dry type transformers, it has great significance to be embodied as a switch without electric arc and noise which can be controlled in a high speed and is corrosion resistant. The AC voltage regulating electronic switch may be applied to small and medium size transformers as well as giant transformer and ultra-high voltage transformer.
[0125] The advantageous effects of the series voltage regulating transformer: the total capacity of the whole series voltage regulating transformer may be controlled by only controlling the capacity of the series transformer by the AC voltage regulating electronic switch, and the output voltage of the total capacity of the whole series voltage regulating transformer may be changed by changing the voltage of series transformer. Even if the range of voltage regulation is 100%, the capacity of the series transformer is only half of the total capacity of the transformer, and in principle, the voltage and current of the voltage regulation winding may be combined arbitrarily. That is, the voltage and current of the AC voltage regulating transformer are free to choose, which is convenient for choosing a safe and cheap AC voltage regulator. Secondly, as the series voltage regulating transformer consists of a main transformer and a series transformer, in high, especially, ultra-high systems, the capacity of the transformer may be divided into two parts, one part for the ultra-high transformer, and the other part is for lower voltage transformer. As the voltage class of the lower voltage transformer part is greatly lowered, the manufacturing costs are saved. Thirdly, the series transformer part adopts variable magnetic flux voltage regulation, and may change the capacity of the transformer.
[0126] The advantageous effects of the transient impedance technology: the secondary voltage of the series voltage regulating transformer is controlled by using the AC voltage regulating electronic switch, or by arranging the polarities of two in-phase secondary windings to be opposite, the coil is changed into an inductance coil with two windings which are connected in series and have opposite polarities. The secondary side winding of the transformer is changed into a reactance coil instantly, and by regulating the voltage of the secondary winding of the series transformer, the reactance voltage drop of the transient impedance transformer is regulated to a predetermined level in a high speed. In principle, the reactance voltage drop of the system may be close to 100%.
[0127] By controlling the reactance voltage of the transformer, the reactance of the system will tend to a predetermined level in emergency, or the secondary voltage becomes close to 0, but not equal to 0 (when regulating the voltage to a level next higher than 0 by stepped regulation, stepless voltage regulation can be used for making the secondary voltage close to 0, but not equal to 0), make the short-circuit current under control, but not interrupting the current, thereby maintaining the secondary system stable under any emergencies
[0128] The advantageous effects of the transient impedance transformer: the transient impedance technology and high-speed voltage regulation technology according to the present invention may be applied to high voltage or ultra-high voltage power grid power transmission and power grid reactive power control as well as high-speed voltage regulation, safety protection, energy conservation and safety protection of AC/DC smelting systems, energy conservation and safety protection of DC electrolysis systems, and safety protection of electric traction locomotives, and reactive compensation of secondary or tertiary side, and may control the system with intelligent control by the transformer, achieve voltage stability control, control the load imbalance of each phase in a high speed, achieve high-speed smooth stepless voltage regulation as well as high-speed stepped and high-speed stepless voltage regulation, may exempt the transformer from maintenance, adjust the capacity of the transformer, and can be applied to circumstances requiring fire protection. It is the greatest advantage of the transient impedance transformer to replace the primary side disconnection in prior art by tertiary side disconnection in high voltage or ultra-high voltage power grid.
[0129] The advantageous effects of the transient impedance power transformer in high voltage or ultra-high voltage power grid: the application of the transient impedance technology and high-speed voltage regulation technology according to the present invention in power grid provides important guarantee for power grid safety, keeps the electric power system stable in any emergencies, and meanwhile, the reactive power of the system is greatly reduced by the operation of low-impedance transformer in the power grid, and the transmission capacity and transmission distance of the AC power grid is increased. The economical efficiency as well as energy consumption of power transmission is improved. Save floor space for transmission corridors and floor space for transformer substation. The problem of chain reaction in case of accidence in high-voltage power grid may be prevented. It facilitated to network topographies and simplifies the structure of the power grid, and can replace the primary side disconnection by tertiary side switch part. The problem of stability and reliability in high voltage and ultra-high power transmission systems may be resolved. The costs of the transformer are saved by replacing Cu by Al. By regulating the transformer in a high speed, the power grid may be controlled safely, efficiently, synchronously and intelligently. The transient impedance technology can be applied to the two secondary windings respectively, thus a power grid (electric power load) will be less influenced when the other power (the other electric power load) fails. Reactive compensation may be applied to tertiary side, so as to save costs greatly. By achieving “current tipping” in a high speed, the requirements on accuracy, speedability and frequent regulation of current control by power system are met.
[0130] The advantageous effects of application of transient impedance converting transformer in high voltage DC power transmission system are: lower transmission line costs, lower power loss per year, and saving energy and reducing consumption. As the application of transient impedance technology and high-speed voltage regulation technology according to the present invention in the power grid, the problems of system stability and high-speed regulation are solved, and it is possible to achieve nonsynchronous interconnection of the power grid. The short-circuit current is limited by a converting transformer. By regulating the transformer in a high speed, the power grid may be controlled efficiently and intelligently, in a high speed, and reliably. There is no capacitor charging current. Floor space of the corridors is saved. The converter device has lower price, and generate weaker harmonic influence, and the capacity of the filter is lowered. By endowing the converting transformer with phase controlling function and high-speed regulation function of the converter device, the converter device may be embodied as a semi-controlled converter device or the thyristor is replaced by a diode directly, alleviate overheat of the capacitor and generator, and attenuate interference of unstable converter control on communication systems. The converter device expends less reactive power, and may conduct reactive compensation in place at secondary side or tertiary side of the converting transformer (the compensation solution is described hereafter). A part of functions of the DC high voltage circuitry breaker is achieved by the converting transformer. Sub-synchronous oscillation of the electric power system and the like are suppressed. The control on bridge in DC power transmission protection is changed into the control on transformer. Split-phase voltage regulation and shunt voltage regulation may be applied, i.e., in a multi-terminal power supply system, various systems may be regulated in voltage in a high speed, and in capacity in a high speed respectively. When a method of splitting series transformer is used for controlling a certain supply terminal in a sudden short circuit or other emergencies case, the influence on other supply terminals is very weak. Reactive compensation may be applied to tertiary side, so as to save costs greatly. The application of the transient impedance technology and high-speed voltage regulation technology according to the present invention in power grid provides important guarantee for power grid safety, keeps the electric power system stable in any emergencies.
[0131] The advantageous effects of application of the transient impedance converting transformer in the rectification system: as the transient impedance technology and high-speed voltage regulation technology, high-speed stepless voltage regulation technology according to the present invention applied to the system, the existing average current control scheme may be replaced by constant current control scheme, and the fine regulation of reactors may be replaced. As for each phase of the transformer, the voltages of various units may be finely regulated, and thus the currents among various parallel rectifier units, as well as three phases, are balanced. The problems of high-speed voltage regulation in loaded switches, and loaded switches incapable of voltage regulation in high frequency are solved, i.e., even if the range of voltage regulation is large, the high-speed response of the switches may synchronize with the time when the electrolytic current changes. The rectifying device is cheap, generate weak harmonic influence. By endowing the rectification transformer with phase controlling function and high-speed voltage regulation function of the converter, the rectification device may be embodied as a semi-controlled converter device or the thyristor is replaced by a diode directly. The rectifying device is fast in voltage regulation, and may achieve split-phase voltage regulation. In three-phase short circuit, the rectifying device may operate very fast, and make the impedance of the transformer increase, thereby ensuring the stability of the system. The rectifying device may achieve saving energy and reducing consumption. The rectifier transformer may control the system with intelligent control efficiently in a high speed. The application of the transient impedance technology and high-speed voltage regulation technology according to the present invention in power grid provides important guarantee for system safety, keeps the system stable in any emergencies.
[0132] The advantageous effects of application of the transient impedance furnace transformer in the AC/DC electric furnace smelting system: as the transient impedance technology and high-speed voltage regulation technology, high-speed stepless voltage regulation technology according to the present invention applied to the system, voltage regulation and current regulation in furnace of electric-arc furnace and submerged arc furnace system may be achieved without electrodes regulation. In three-phase short circuit situation, the rectifying device may operate very fast, and make the impedance of the system increase, thereby ensuring the stability of the system. The rectifying device has short response time. The rectifying device saves energy and reduces consumption. By using split-phase voltage regulation, imbalance in three-phase power can be resolved. The rectifying device may adjust capacity, generate weak harmonic influence, and compensate filter at secondary side or tertiary side in a reactive compensation manner, thereby reduce ultra harmonics. The furnace transformer may control the system with intelligent control safely and efficiently in a high speed. The three-phase system voltage (electrode voltage) may be symmetrical, thereby reducing third harmonic, stabilizing melting power, eliminating reactive current flowing between electrodes, and decreasing power consumption of the furnace. The application of the transient impedance technology and high-speed voltage regulation technology according to the present invention in power grid provides important guarantee for system safety, keeps the system stable in any emergencies.
[0133] The advantageous effects of application of the present invention in the DC traction, AC traction or AC/DC traction systems: as the transient impedance technology and high-speed voltage regulation technology according to the present invention applied to the system, as for each phase of the transformer, the voltages of various units may be finely regulated, and thus the currents among various parallel rectifier units, as well as three phases, are balanced, and especially, in split-phase voltage regulation, only the structure of the series transformer, not the main transformer, is changed. As the range of voltage regulation of the traction transformer is small, the capacity of the series transformer is not large, and the voltage class is 27.5 KV, there is little influence on costs. The high-speed response of the AC voltage regulating electronic switch may synchronize with the time when the load current changes. The rectifying device is cheap, generate weak harmonic influence. By endowing the rectification transformer with phase controlling function and high-speed regulation function of the converter, the rectification device may be embodied as a semi-controlled converter device or the thyristor is replaced by a diode directly. In a certain range, the rectifying device may adjust capacity, increase capacity, and stabilize voltage in a high speed. In three-phase short circuit, the rectifying device may operate very fast, and make the impedance of the transformer increase, thereby ensuring the stability of the system. The rectifying device may achieve saving energy and reducing consumption. The rectifier transformer may control the system with traction control efficiently in a high speed.
[0134] The advantageous effects of application of the present invention in the system requiring stepless voltage regulation: as the transient impedance technology and high-speed voltage regulation technology, high-speed stepless voltage regulation technology according to the present invention applied to the system, the range of voltage regulation of the voltage regulator may be 0 to 100%, the capacity and voltage class may be the same as that of the existing transformer. The stepless voltage regulation has great breakthrough in capacity, voltage classes, waveform deviation factor and other aspects, and has great influence on the industry which has great requirements on stepless voltage regulation devices, such as, vacuum furnace, scientific experiment and the like.
[0135] The advantageous effects of application of the present invention in power source system: as for high, precise and advanced loads, safe, high-speed, synchronized and intelligent control may be possible.
[0136] The advantageous effects of application of the present invention in the reactive compensation system: in a scheme that the low-voltage or tertiary side is directly connected to the reactive compensation device in parallel, the effect of saving energy and reducing consumption is the best in all the schemes. It is an urgent needed technology to connecting the reactive compensation device with low-voltage device in parallel in a system with variable secondary voltage. In tertiary side compensation in a high voltage or ultra-high voltage system, the high voltage reactive compensation device may be replaced by a low-voltage reactive compensation device, so that the costs of the reactive compensation device are greatly decreased, and its reliability is greatly improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0137] FIG. 1 is a schematic diagram showing the principle of a new AC voltage regulator.
[0138] FIG. 2 is a schematic diagram showing the principle of a linear regulating AC voltage regulating electronic switch.
[0139] FIG. 3 is a schematic diagram showing the principle of a reversing change-over AC voltage regulating electronic switch.
[0140] FIG. 4 is a schematic diagram showing the principle of a coarse-fine regulating AC voltage regulating electronic switch.
[0141] FIG. 5 is a schematic diagram showing the principle of an intermediate regulating AC voltage regulating electronic switch.
[0142] FIG. 6 is a schematic diagram showing the principle of an intermediate regulating AC voltage regulating electronic switch.
[0143] FIG. 7 is a schematic diagram showing the principle of an end portion regulating AC voltage regulating electronic switch.
[0144] FIG. 8 is a schematic diagram showing the principle of a neutral point regulating AC voltage regulating electronic switch.
[0145] FIG. 9 is a schematic diagram showing the principle of a measuring and control device.
[0146] FIG. 10 is a schematic diagram showing the principle of a splayed coil structure.
[0147] FIG. 11 is a schematic diagram showing the principle of a single phase series voltage regulating transformer (one of which is showed, the rest are omitted).
[0148] FIG. 12 is a structure diagram showing the principle of tertiary side disconnection (the schematic diagram of location of the two compensation method, only one of which is need in compensation).
[0149] FIG. 13 is a schematic diagram showing the principle of a high-speed voltage regulation special auto transformer.
[0150] FIG. 14 is a schematic diagram showing the principle of a power grid connection method type of a transient impedance step up auto transformer.
[0151] FIG. 15 is a schematic diagram showing the principle of a series voltage regulating transformer phase controlled by an AC voltage regulator.
[0152] FIG. 16 is a schematic diagram showing the principle of a transient impedance furnace transformer.
[0153] FIG. 17 is a vectogram showing the current before compensation.
[0154] FIG. 18 is a vectogram showing the current after compensation.
[0155] Wherein: 1 . constant voltage power source (or sine wave power source); 2 . AC voltage regulator; 3 . primary winding of a new AC voltage regulator; 4 . secondary winding of a new AC voltage regulator; 5 . basic coil; 6 . voltage regulation coil; 7 . AC voltage regulating electronic switch; 8 . reversing change-over AC voltage regulating electronic switch; 9 . coarse regulating AC voltage regulating electronic switch; 10 . fine regulating AC voltage regulating electronic switch; 11 . structure of secondary winding of main transformer of series voltage regulating transformer of splayed coil; 12 . structure of secondary winding of series transformer of series voltage regulating transformer of splayed coil; 13 . series voltage regulating transformer voltage regulation coil; 14 . primary coil of the main transformer of the series voltage regulating transformer; 15 . secondary coil of the main transformer of the series voltage regulating transformer; 16 . portions not showed by coils; 17 . primary coil of the series transformer of the series voltage regulating transformer; 18 . secondary coil of the series transformer of the series voltage regulating transformer; 19 . power grid; 20 . load; 21 . power grid; 22 . schematic diagram showing locations for reactive compensation; 23 . basic winding for tertiary side disconnection; 24 . short circuit switch; 25 . tertiary side load circuitry breaker.
[0156] The above figures are illustrated in single phase, and the three phases is in a similar way. In principle, other connection methods and connection positions of the AC voltage regulator may be combined with the connection method of the transformer arbitrarily, which are not illustrated wholly.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Example 1
[0157] In the present solution, the AC voltage regulating electronic switch is not used, but a new AC voltage regulator is used, which is aimed at showing the capability of voltage regulation of the AC voltage regulator under extreme cases. A furnace, resistance-inductive load, is provided, when the distance from the electrode to the burden surface is determined, the maximal and minimal output voltages of the series voltage regulating transformer is required to be between 1 and 0.7, respectively.
[0158] A furnace transformer, three phases, is provided, and a series voltage regulating transformer, with range of voltage regulation of 30% and positive voltage regulation, is also provided, the main transformer and the series transformer are of an Yd11 connection group. The output constant voltage at lower voltage of the main transformer is U 1 =0.7, and the highest output voltage at lower voltage of the series transformer is U 2 =0.3. The high voltage and current of the series transformer can be combined arbitrarily, as long as the capacity thereof is equal to the capacity of the series transformer.
[0159] An AC voltage regulator is provided, a three-phase AC voltage regulator is connected in a manner of Y, the voltage of the semiconductor is defined as the phase voltage of the tertiary side system multiplied by a correlation coefficient as defined in its specification, the current effective value is 2 or 3 times of the tertiary side current of the series voltage regulating transformer (determined by total impedances), the delay angle of the thyristors is defined as α, the conduction angle of the thyristors is defined as θ, and the impedance angle of the system is defined as δ, and is activated by a broad pulse or pulse trains. The principle of the single-phase electrical wiring is showed in FIG. 15 (there is no reversing change-over switch in the present example), and the three-phase wiring graph is combined as Y and d11, the principle thereof is not illustrated herein.
[0160] When the system needs the maximal voltage, the control angle of the thyristor α≦δ, the output voltage of low voltage side of the transformer is U=U 1 +U 2 =0.7+0.3=1. When the system needs the lowest voltage, the control angle of the thyristor α=180°, i.e., U 2 =0, and the output voltage of low voltage side of the transformer U=U 1 =0.7. When the system needs other voltage, the control angle of the thyristor α=0, δ≦θ≦180°, and the output voltage of low voltage side of the transformer U=0.7˜1.
Example 2
[0161] A furnace transformer with range of voltage regulation of 40%, reversing change-over voltage regulating, Yd11 connection group, and a series voltage regulating transformer are provided. The secondary winding of the main transformer is connected, in parallel, to the capacitor group to adjust the power factor. Before compensation, cos φ=0.8, it is required that after compensation, cos φ=0.95. The principle of electrical wiring is showed by the combination form of the low-voltage winding and the reactive compensation device, as showed in FIG. 16 . U 21 and U 22 are secondary voltages of the main transformer, and series transformer, respectively, and the leakage reactance of the transformer is omitted. FIG. 17 is a vectogram showing the current before compensation. Before compensation, the power factor is defined as cos φ=0.8, sin φ=0.6, and meanwhile, the working current of the furnace I L =1. The active component of the working current is I R =0.8. The idle component of the working current is I Q =0.6. Both the currents flowing through the secondary winding of the main transformer and the series transformer are working current I L of the furnace. FIG. 18 is a vectogram showing the current after compensation. As the compensation (capacitance) current only flow through the secondary winding of the main transformer, it is assumed that the vector angle between the magnitude of the current of the secondary winding of the main transformer after compensation and its voltage U 21 will be changed.
[0162] It is assumed that the working current of the furnace after compensation is still I L =1, and the power factor of the secondary winding of the main transformer after compensation is 0.95.
[0163] The current in the secondary winding of the main transformer is changed to I 21 =0.842. The current flowing through the compensation capacitor is I c =0.3374. The secondary capacity of the main transformer after compensation is SN 21 =0.842 (it is assumed that the secondary voltage of the main transformer is U 21 =1). The decreased value of the secondary capacity of the main transformer after compensation is ΔSN 21 = 0 . 158 . The capacity of the required compensation capacitor should be S c =0.3374.
[0164] The electromagnetic capacity required by the secondary winding of the main transformer after compensation is about 84.2% of that before, and thus the capacity of the primary winding of the main transformer is decreased correspondingly. As the range of voltage regulation is 40%, and may be of a reversing change-over form, the capacity of the transformer before compensation is SN 1 .
[0165] SN 1 —capacity of the transformer before compensation. SN 11 —capacity of the main transformer before compensation is 0.8 SN 1 . SN 12 capacity of the series transformer before compensation is 0.2 SN 1 . SN 1 =SN 11 +SN 12 =0.8 SN 1 +0.2 SN 1 . The capacity of the transformer after compensation is SN 2 the capacity of the transformer after compensation. SN 21 —the capacity of the main transformer after compensation. SN 22 —the capacity of the series transformer after compensation.
[0000] SN 2 =SN 21 +SN 22 =0.8 SN 1 ×0.842+0.2 SN 1 =0.8736 SN 1
[0166] It can be seen that, the capacity of the whole device after compensation is improved by about 12.5%, i.e., the active power is improved.
Example 3
[0167] A furnace transformer with range of voltage regulation of 40%, reversing change-over voltage regulating, Yd11 connection group, and a series voltage regulating transformer are provided. The low voltage of the main transformer is 0.8, the low voltage of the series transformer is 0˜0.2, the combined voltage of the main and series transformers is 0.8±(0˜0.2), with 21 levels of voltage regulation, each of which is 0.02, the capacity of the main transformer is 0.4˜1, and the tolerance of each level of the main transformer is 0.03. It is assumed that the ratio of transformation is 1, and the resistance values of the two windings of the low-voltage main and series transformers are the same. It is assumed that the working current of the furnace after compensation is still I L =1, and the current of the secondary winding of the main transformer is I 21 =0.842, and the no-load loss is about of 15% of the load loss.
[0168] As showed in Example 2: loss of the transformer Pk is
[0000] Pk =(0.842 I L ) 2 ×0.8× R +( I L ) 2 ×0.2× R =0.767( I L ) 2 ×R
[0169] That is, the energy conservation and consumption reduction of the load of the transformer is about 23%.
[0170] As the no-load loss is about 15% of the load loss. The total loss ratio of the transformer after and before the regulation of the power factor is: (0.767 I L ) 2 R+0.15(I L ) 2 R)/1.15(I L ) 2 R=0.797(I L ) 2 R. That is, the total energy conservation and consumption reduction of the transformer is about 20%.
INDUSTRIAL UTILITY
[0171] The application of the transient impedance technology and high-speed voltage regulation technology, high-speed stepless voltage regulation technology according to the present invention in a high voltage or ultra-high voltage AC-DC power transmissions system, an AC/DC furnace smelting system, an electrochemically electrolytic industry system, a electric power locomotive traction system, a reactive compensation system, and a high-power stepless voltage regulation is beneficial to safety protection and high efficiency synchronous intelligent control of the associated system.
[0172] When the present invention is applied to resistive, resistive-inductive, and resistive-capacitive load systems requiring stable control, or requiring capacity regulation of the transformer, or requiring high-speed control of characteristics of each phase unbalanced load and other characteristics, the transient impedance transformer may be used to control its feature in a high speed.
[0173] The present invention may be used to improve the stability and reliability of the high voltage or ultra-high voltage power system, reduce system short circuit capacity, reduce equipment investment, reduce voltage fluctuation and flickering, the high voltage circuitry breaker may be replaced by the tertiary side disconnection function, and the transformer has obvious effects of regulating system impedance in a high speed and improve the power factor of the system per se.
[0174] The stepless voltage regulation has great breakthrough in capacity, voltage classes, waveform deviation factor and other aspects, and has great influence on the industry which has great requirements on stepless voltage regulation devices, such as, vacuum furnace, scientific experiment and the like.
[0175] The stepless voltage regulation may be applied to fields of industrial and agricultural production, scientific experiment, communication and transportation, telecommunication transmission, national defense, health care, power transmission. So to speak, the transient impedance transformer plays a role in various industry of national economy. | 4y
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FIELD OF THE INVENTION
The invention relates to improvements in immunoassays for polycyclic aromatic hydrocarbons analytes.
BACKGROUND
Polycyclic aromatic hydrocarbons (PAHs) are a group of compounds composed of two or more fused rings. The U.S. Environmental Protection Agency has identified 16 unsubstituted PAHs, each containing from two to six fused rings, as priority pollutants: naphthalene, acenaphthalene, phenanthrene, anthracene, fluorene, acenaphthylene, benzo a!anthracene, pyrene, fluoranthene, chrysene, benzo b!fluoranthene, benzo k!fluoranthene, benzo a!pyrene, dibenzo a,h!anthracene, indeno 1,2,3-cd!pyrene and benzo g,h,i!perylene.
A rapidly growing technology for measuring contamination by such compounds in water and other substances is the immunoassay, an assay wherein antibodies with high specificity for particular PAHs play a key role. Nevertheless, the standards used to calibrate such immunoassays frequently are a problem because of their deterioration with time of storage. Such instability affects the value of commercial immunoassay kits, wherein a period of months can elapse between the time the standard solutions are made by the manufacturer and the time the standard solutions are actually used.
S. B. Friedman et al., U.S. Pat. No. 5,449,611, identified phenanthrene as a useful standard in an immunoassay directed at phenanthrene and certain other PAHs, anthracene, fluorene, benzo(a)anthracene, chrysene, and fluoranthene. Those other PAHs were also identified as potential standards.
K. Meisenecker et al., Analytical Methods and Instrumentation, vol. 2, pp. 114-118 (1993), identified 4-(1-pyrenyl)butyric acid as a useful standard in an immunoassay directed at pyrene and certain other PAHs.
A. Roda et al., (Environmental Technology, Vol. 12, pp. 1027-1035 (1991) and Analytica Chimica Acta Vol. 298, pp. 53-64 (1994)) used benzo(a)pyrene in an immunoassay directed at unknown amounts of benzo(a)pyrene and certain other PAH's in tap water, river water, and other water sources.
P. T. J. Scheepers et al. (Fresnius J. Anal. Chem., vol. 351 pp 660-669 (1995) and Toxicology Letters, vol. 72, pp. 191-198 (1994)) used 1-aminopyrene in an immunoassay directed at unknown amounts of 1-aminopyrene and certain other PAHs in urine samples.
M.-P. Marco et al., (J. Org. Chem., vol. 58, pp. 7548-7556 (1993) and Chem. Res. Toxicol., vol. 6, pp. 284-293 (1993)) identified NaphMA ((N-acetyl-S-(1,2-dihydro-1-hydroxy-2-naphthyl)cysteine) and (N-acetyl-S-(1,2-dihydro-2-hydroxy-2-naphthyl)cysteine)), which are mercapturic acid conjugates of naphthalene as useful standards in an immunoassay for NaphMA and certain other PAHs in urine samples.
N. Y. Kado and E. T. Wei (J. Natl. Cancer Inst., vol. 61, pp. 221-225) identified benzo(alpha)pyrene as a useful standard in an immunoassay for benzo(alpha)pyrene.
BRIEF SUMMARY OF THE INVENTION
The present invention is an immunoassay directed at polyaromatic hydrocarbons wherein the improvement in the immunoassay is the use of certain compounds as standards that are not only reactive in the immunoassay but also can be used to create assay calibration solutions of superior stability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. B/Bo's of phenanthrene and phenanthrene-9-carboxaldehyde as a function of their time of storage at -20° C.
FIG. 2. B/Bo's of phenanthrene and phenanthrene-9-carboxaldehyde as a function of their time of storage at 4° C.
FIG. 3. B/Bo's of phenanthrene and phenanthrene-9-carboxaldehyde as a function of their time of storage at room temperature (about 20°-25° C.).
FIG. 4. B/Bo's of phenanthrene and phenanthrene-9-carboxaldehyde as a function of their time of storage at 37° C.
FIG. 5. B/Bo's of phenanthrene and phenanthrene-9-carboxaldehyde as a function of their time of storage at 50° C.
FIG. 6. B/Bo of phenanthrene as a function of its concentration.
DESCRIPTION OF THE INVENTION
In a general aspect, the invention is an immunoassay for an analyte (which analyte may be one of several analytes being tested for in the immunoassay), said immunoassay a process that comprises the steps of:
1) reacting a sample with an antibody preparation, said sample comprising an unknown amount of analyte, said antibody reactive against said analyte,
2) reacting a known amount of standard with an antibody preparation of the same specificity as that used in step (1), it being required that the standard is a compound that is immunoreactive with the antibody preparation,
3) calculating the amount or an upper or lower limit to the amount of analyte present in the sample used in step (1),
wherein the analyte is a compound that comprises at least two fused benzene rings, (and, if the analyte consists of rings in addition to the two fused benzene rings, then preferably there are not more than six rings, and each of the additional rings is either a six atom-ring, such as benzene, or a five atom-ring such as cyclopentane, the atoms of the additional rings being selected from carbon, oxygen, nitrogen, and sulfur),
wherein a benzene ring in the analyte may be substituted at one or more of its six carbon atoms,
wherein any substituent on said benzene ring that is not I, Cl, Br, OH, --CH 3 , or --NO 2 , has a backbone chain that does not have more than six atoms,
wherein either the standard is a compound with the structure ##STR1## wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 , are substituents,
wherein one or two of said substituents are not H (i.e., not hydrogen) and the other substituents are H, and a substituent that is not H is either OH, COH (i.e., carboxaldehyde), CH 2 OH, CH 2 (CH 2 ) x OH, CO 2 H, NH 2 , CN, SO 3 H, NO 2 , or ##STR2## wherein the leftmost carbon is the point of attachment to the phenanthrene moiety (a substituent that is not H is preferably either OH, COH, CH 2 OH, or CH 2 (CH 2 ) x OH),
or the standard is a compound with a structure ##STR3## wherein x is an integer between 1 and 12 (preferably between 1 and 6).
The positions on the phenanthrene moiety are numbered in the following manner: ##STR4##
Examples of standards usable in the present invention are:
phenanthrene-9-carboxaldehyde,
2-aminophenanthrene,
3-aminophenanthrene,
4-aminophenanthrene,
9-aminophenanthrene,
9,10-diaminophenanthrene,
3,4-dihydroxyphenanthrene,
1-hydroxyphenanthrene,
2-hydroxyphenanthrene,
2-nitrophenanthrene,
3-nitrophenanthrene,
9-nitrophenanthrene,
1-phenanthrene carboxylic acid,
2-phenanthrene carboxylic acid,
3-phenanthrene carboxylic acid,
3-phenanthronitrile,
9-phenanthrene carboxylic acid,
3-phenanthrene carboxylic acid,
2-phenanthrene sulfonic acid,
3-phenanthrene sulfonic acid,
9-phenanthrene sulfonic acid,
5 phenanthrene quinone,
gamma-oxo-2-phenanthrenebutyric acid,
9-cyanophenanthrene, and
4-phenanthrene methanol.
In a particular embodiment, step (3) of the immunoassay above comprises three steps, 3A, 3B, and 3C:
3A) quantitating the amount of the antibody preparation that reacted with the sample in step (1),
3B) quantitating the amount of the antibody preparation that reacted with the known amount of standard in step (2), and
3C) utilizing the amounts quantitated in steps (3A) and (3B) and the known amount in step (2) to calculate the amount or an upper or lower limit to the amount of analyte present in the sample used in step (1).
In a particular embodiment, the immunoassay of the invention comprises reacting an antibody preparation with the analyte, said antibody preparation prepared by using an immunogen that comprises both anthracene and chrysene linked to a carrier (preferably a protein) or carriers.
Preferably the analyte has a 50% B/Bo that is not more than four times the 50% B/Bo of phenanthrene and not less than one fifth the 50% B/Bo of phenanthrene.
Most preferably the analyte is selected from the group:
phenanthrene,
fluoranthene,
benzo a!pyrene,
pyrene,
chrysene,
anthracene,
indeno 1,2,3-cd!pyrene,
1,2-benzoanthracene,
fluorene, and
benzo(b)fluoranthene.
The immunoassay is particularly useful when the analyte is part of a mixture selected from the group, creosote, diesel fuel, fuel oil (1, 2, 3, 4, 5, 6), coal tar and home heating oil.
In a preferred embodiment of the invention, the immunoassay is one wherein the standard is a substantially pure preparation of a single compound. However, the standard may, for example, be a mixture of one or more substantially pure compounds, said mixture constructed by mixing together portions of substantially pure preparation of said compounds.
A substantially pure preparation of a compound is one in which substantially all of the compounds have the same structure. A substantially pure preparation is therefore different from home heating oil or other mixtures of compounds.
The analyte is the compound being tested for.
The immunoassay of this invention is an assay for an analyte that may be one of several analytes detectable in the assay. The fact that the immunoassay can test for more than one analyte at the same time is because of the crossreactivity of the antibody used in the assay. In Example 2, below, a number of PAHs will be seen to have reactivity to the antibody used in the immunoassay. (Such cross-reactivity occurs in PAH immunoassays in general, not just the one exemplified herein.) Therefore, if the nature of the analyte in the sample is unknown, then for each possible analyte one can only assign an upper limit to the concentration of that analyte. Alternatively, for example, if the color (or other response) generated in a competitive immunoassay is greater than the amount generated by a standard then the assay provides a lower limit (that of the standard) to the amount of analyte. For many purposes, however, such information is sufficient to determine the extent and degree of contamination, to delineate pollutant plumes in ground water, to monitor well placement, and for preliminary identification and quantitation of pollutants.
A highly preferred standard is phenanthrene-9-carboxaldehyde, which is commercially available from Aldrich Chemical Company, Milwaukee, Wis. and Chem Service, West Chester, Pa.
The standards chosen for superior stability are ones expected to show both cross-reactivity with the antibody and good solubility in the co-solvents used to store them.
The immunoassays to which the present invention is applicable include: (1) Competition assays where the analyte competes with a detectable conjugate (e.g., as used in the Examples, an antibody-reactive moiety linked to an enzyme that can catalyze a reaction generating a colored compound) for binding sites provided by an antibody and detection is accomplished by measuring the decrease in the amount of detectable conjugate bound to the antibodies; (2) non-competition assays, where the analyte does not have to compete for such binding sites and the antibody is labelled with a detectable label; (3) sandwich assays, where one anti-analyte antibody acts as a bridge to bind the analyte to a solid phase, and detection is accomplished with a detectably-labelled second anti-analyte antibody that is allowed to attach the solid phase-bound analyte; or (4) any other immunoassay format. Indeed the term "immunoassay" is intended here in a very general sense and is any assay in which an antibody specific for an analyte of interest is used. Nevertheless, for the smallest analytes, sandwich assays may be difficult because of the need for two antibody binding sites.
The antibodies may be polyclonal or monoclonal. The use of hybridomas to create monoclonal antibodies is well known in the art. The fact that polyclonal antibodies against a compound can be created is an indicator that a monoclonal antibody against that compound can be created.
Detectable labels include enzymatic, fluorescent, radioactive, and chemiluminescent labels. The labels may be linked directly to other molecules of interest, such as antibodies, or indirectly by streptavidin-biotin linkages or other linkages. The labels may be bound directly to the antibodies or conjugates, or alternatively, be generated from substrates by enzymes attached to antibodies or substrates.
PREPARATION AND STRUCTURE OF THE IMMUNOGEN USED TO MAKE THE ANTIBODIES USED IN THE EXAMPLES
2-Succinamidoanthracene was synthesized as follows: 2-aminoanthracene was reacted with succinic anhydride in dioxane at 90° C. for 3 hours. On cooling to room temperature, the crystals formed were collected by suction filtration. The product was 2-succinamidoanthracene.
6-succinamidochrysene was synthesized as follows: 6-aminochrysene was reacted with succinic anhydride in dioxane-DMF (4:1) at 60°-70° C. for 4 hours. Water was then added and the solution allowed to stand at room temperature (about 20° C.) overnight. The solid obtained was collected by suction filtration. The product was 6-succinamidochrysene.
The ligand (0.6 mmole), either 2-succinamido anthracene or 6-succinamido chrysene in 10 mL of dry dimethylformamide ("DMF"), was treated with 2.4 mL of 0.25M triethylamine. The solution was cooled in ice-water, then 2.4 mL of 0.25M iso-butyl chloroformate was added and after 10 min the reaction solution was removed from the ice-water bath. After a total of 30 min of reaction time, the solution was added dropwise to a stirred and ice-cold solution of 300 mg carrier protein dissolved in 45 mL of 0.2M sodium borate, pH 8.7 and 30 mL of DMF. Cooling was maintained in an ice-water bath. The addition of the activated ligand required about 10 min. One hr after the complete addition, the solution was removed from the ice-water bath and stirred at room temperature another 2 hr. Dialysis was carried out against 0.1M sodium borate, pH 8.7, and then against two changes of water, all at 4° C. The product was freeze dried.
PREPARATION OF THE ANTIBODIES USED IN THE EXAMPLES
The immunogens were injected into rabbits and the antibodies were prepared as follows: The immunogen was dissolved or suspended in sterile saline to a concentration of 4 mg/ml. It was mixed with an equal amount of Freund's complete adjuvant and then emulsified. On Day 1, a total of 0.5 ml of the emulsion was injected into the hip muscle of the rabbit and a control bleed was done. On Day 20, the back of the animal was shaved and, in 6-8 sites, a total of 0.5 ml of emulsion was injected. On Day 30, a test bleed was done. On day 45, the immunization of Day 20 was repeated. On Day 55, a test bleed was done.
The immunization described for Day 20 is repeated at 30-day intervals using Freund's incomplete adjuvant. The interval is lengthened if antibody production was inadequate or the animal was distressed.
The animal was bled 7-10 days after immunization (30-50 ml). Bleeds were then screened for cross-reactivity to the various PAHs and selected bleeds from the anthracene and chrysene immunized rabbits were pooled to obtain a pool of rabbit anti-PAH antisera with broad specificity against PAHs.
PREPARATION OF THE ENZYME CONJUGATE USED IN THE EXAMPLES
The anthracene ligand, 2-succinamido anthracene (10 mg), was dissolved in 0.5 mL DMF and placed in an ice-bath. Tributylamine (80 μL), followed by isobutylchloroformate (40 μL) were added to the ligand solution. Stirring for 30 minutes at 8°-12° C. followed. The reaction mixture was then centrifuged to remove any precipitates. Added (124 μL) of the anhydride formed to 500 μL of a 3 mg/mL HRP (horse radish peroxidase) solution in carbonate buffer, pH 9.0, and stirred overnight at 4° C. The reaction mixture was then centrifuged and the supernatant purified through a Sephadex G-25 column using PBS, pH 5.0 (phosphate buffered saline, 25 mM phosphate, 150 mM sodium chloride, pH 5.0) as the mobile phase.
PREPARATION OF THE ANTIBODY-LINKED MAGNETIC PARTICLES
Attachment of the rabbit anti-PAH antibodies to magnetic particles was done as follows: One mL of a 50 mg/ml suspension of BioMag 4100 amine-terminated particles (Perseptive Diagnostic, Cambridge, Mass.) was activated with 5% (v/v) glutaraldehyde in 2 mL of 0.01M MES buffer, pH 6 (MES is 2-N-morpholine)ethanesulfonic Acid) for 3 hours. Unreacted glutaraldehyde was removed by washing four times with 5 ml of 0.01M MES buffer. Goat anti-rabbit IgG was diluted to an antibody concentration of 5 mg/mL and 1 mL was reacted with the activated magnetic particles by shaking for 16 hours. A 1M glycine solution was then used to quench any unreacted sites for 30 minutes. The particles were washed four times with 5 ml of Tris buffered saline with 0.1% bovine serum albumin (BSA), pH 7.4 and diluted in Tris buffered saline with 0.1% gelatin, pH 7.4 to achieve an iron concentration of 12-15 mg/ml. Rabbit anti-PAH antisera was then added at a 1:30,000 dilution and incubated for at least 30 minutes to allow coupling.
ASSAY PROCEDURE USED IN THE EXAMPLES
The sample to be tested was added, along with the enzyme conjugate, to a disposable test tube followed by the addition of paramagnetic particles with analyte-specific antibodies attached. At the end of an incubation period, a magnetic field was applied to hold the paramagnetic particles (with analyte and enzyme-conjugate bound to the antibodies on the particles, in proportion to their original concentration in the tube) in the tube and allow the unbound reagents to be decanted. After decanting, the particles were washed with Washing Solution.
The presence of analyte was detected by adding the enzyme substrate (hydrogen peroxide) and the chromogen (3,3'5,5'-tetramethylbenzidine). The enzyme-conjugate bound to the anti-analyte antibody catalyzes the conversion of the substrate/chromogen mixture to a colored product. After an incubation period, the reaction was stopped and stabilized by the addition of acid. Since the conjugate was in competition with the unlabeled analyte for the antibody sites, the color developed was inversely proportional to the concentration of analyte in the sample.
The anti-analyte antibody was a rabbit antibody covalently bound to paramagnetic particles, which were suspended in 150 mM Tris, 150 mM NaCl, 1 mM EDTA, 0.1% Gelatin, with 15 ppm active Proclin (manufactured by Rohm and Haas, purchased from Supelco), pH 7.4.
The enzyme-conjugate was in 25 mM sodium acetate, 150 mM NaCl, 4 mM DNS, 0.1 mM Luminol, 0.1% Gelatin with 15 ppm active Proclin, pH 5.0.
Each standard, calibrated to have an immunoreactivity equivalent to specific total phenanthrene concentrations, was in 25 mM sodium acetate, 150 mM NaCl, 0.1% Gelatin, with 15 ppm active Proclin containing 25% methanol, pH 5.0.
A solution containing 25% methanol can be made, for example, by adding 25 ml of methanol to 75 ml of an aqueous solution containing the other ingredients needed to make the desired final solution.
The Diluent/Zero Standard was 25 mM sodium acetate, 150 mM NaCl, 0.1% Gelatin, with 15 ppm active Proclin containing 25% methanol, pH 5.0 but without detectable analyte.
The Color Solution used in the Examples was obtained as a 3,3',5,5'-tetramethylbenzidine/peroxide system from Kirkegaard and Perry Laboratories (Gaithersburg, Md.).
The Stopping Solution was a solution of sulfuric acid (0.5%).
The Washing Solution was deionized water with 0.05% Triton X-100 with 15 ppm active Proclin.
Test tubes were polystyrene tubes.
Reagents were stored at 2°-8° C., not frozen.
A photometer was used to absorb the absorbance at 450 nm.
All reagents were allowed to come to room temperature and the antibody-coupled paramagnetic particles were mixed thoroughly just prior to pipetting into the assay.
Foam formation was avoided during vortexing.
The magnetic separation rack consisted of two parts: an upper rack which securely held the test tubes and a lower separator which contained the magnets used to attract the antibody-coupled paramagnetic particles. During incubations, the upper rack was removed from the lower separator so that the paramagnetic particles remained suspended during the incubation. For separation steps, the rack and the separator were combined to pull the paramagnetic particles to the sides of the tubes. The rack was decanted by inverting it away from the operator using a smooth turning action so that the liquid flowed consistently along only one side of the test tube. While still inverted, the rack was placed on an absorbent pad and allowed to drain. The rack was lifted replaced gently onto the pad several times to insure complete removal of the liquid from the rim of the tube.
The total time required for pipetting the magnetic particles was kept to two minutes or less.
The assay was done as follows:
1. 250 μl of either standard or control was added to each tube.
2. 250 μl of enzyme conjugate was added to each tube.
3. The antibody-coupled paramagnetic particles were mixed thoroughly and 500 ul of them were added to each tube (The stock solution was diluted to obtain a concentration of 12-15 mg iron/ml in 150 mM Tris, 150 mM NaCl, 1 mM EDTA, 0.1% Gelatin with 15 ppm Proclin, pH 7.4, and 500 ul was added to each tube).
4. Tubes were vortexed for 1 to 2 seconds minimizing foaming.
5. Tubes were incubated for 30 min at room temperature (15°-30° C.).
6. Tubes in the magnetic rack were placed over a magnetic base for two minutes.
7. The tubes were decanted and gently blotted briefly in a consistent manner.
8. One ml of Washing Solution was added to each tube, the tubes are vortexed for 1-2 seconds, and the tubes were allowed to remain in the separation rack for two minutes.
9. The tubes were decanted and gently blotted briefly in a consistent manner.
10. Steps 8 and 9 were repeated an additional time.
11. The rack was removed from the separator and 500 μl of Color Solution was added to each tube.
12. Vortexing was done for 1 to 2 seconds minimizing foaming.
13. Incubation was done for 20 minutes at room temperature.
14. 500 μl of Stopping Solution was added to each tube.
15. The results were read at 450 nm within 15 minutes after adding the Stopping Solution.
It is recommended that, in general, precision pipets capable of delivering 250 ul and 500 μl, and a 1.0 ml repeating pipet be used; that reagents are added directly to the bottom of the tube while avoiding contact between the reagents and the pipet tip; that clean pipets be used for each sample; and that contact between reagent droplets on the tubes and pipet tips be avoided. To minimize loss of volatile compounds, the sample, conjugate and particle addition steps are performed in as timely a fashion as possible.
A Thermolyne Maxi Mix, Scientific Industries Vortex Genie, or equivalent vortex mixer may be used.
Data can, if desired, be analyzed by a commercially available data storer and analyzer, such as the Ohmicron RPA-I Analyzer available from Ohmicron, Newtown, Pa. 18940. Such automated analyzers are used to make direct optical readings and use a microprocessor to convert optical readings to sample concentrations by comparing the results to those obtained with calibration curves.
USE OF THE ASSAY IN THE FIELD
For use in the field, the sample to be tested for analyte concentration is water or diluted soil extract. Water samples are collected in glass containers with Teflon caps and diluted 3:1 with methanol (3 parts water and 1 part methanol). Soil samples may be analyzed by extracting them with calcium chloride in 100% methanol and then diluting them 1:50 in Diluent.
Samples containing gross particulate matter are filtered (e.g., with 0.2 μm Anotop® 25 Plus, Whatman, Inc.) to remove particles.
If the analyte concentration of a sample exceeds 50 ppb of phenanthrene or its immunoreactive equivalent, the sample is subject to repeat testing using a diluted sample. Prior to assay, a ten-fold or greater dilution of the sample is recommended with an appropriate amount of Diluent/Zero Standard and mixing thoroughly.
Although not used in the Examples, a Control sample is recommended for routine use of the immunoassay. The Control, calibrated to have an immunoreactivity equivalent to a concentration of approximately 25 ppb phenanthrene, is in 25 mM acetate, 150 mM NaCl, 0.1% Gelatin, 25% methanol, with 15 ppm active Proclin, pH 5.0. The Control sample can be used to determine whether the assay is providing the correct value for analyte concentration.
A standard curve is constructed by plotting the % B/B o for each standard on vertical logit (Y) axis versus the corresponding analyte concentration on a horizontal algorithmic (X) axis. The % B/B o for controls and sample will then yield levels in ppb of analyte by interpolation using the standard curve.
EXAMPLES
Example 1
Study of Standard Stability
Standards were prepared by weighing 100 +/-1 mg of phenanthrene and dissolving it in 10.0 mL of DMF (dimethylformamide). This 10 mg/mL solution was diluted 1.0 mL into 100 mL methanol for a 100 μg/ml solution. The 100 μg/mL solution was then diluted 1.0 mL into 100 mL of Diluent (25 mM sodium acetate, 150 mM NaCl, 0.1% Gelatin, 25% methanol, 15 ppm Proclin) to provide a 1 μg/mL solution. Standards were prepared from the 1 μg/mL solution volumetrically at 2, 10, and 50 ppb by dilution with diluent.
Phenanthrene has a 50% B/Bo of 16.5 ppb and phenanthrene-9-carboxaldehyde has a 50% B/Bo of 13.0 ppb. Phenanthrene-9-carboxaldehyde solutions were prepared by first preparing a 10 mg/mL solution of that compound in DMF. This 10 mg/mL solution was then diluted 1.0 mL into 100 mL methanol for a 100 μg/mL solution. The 100 μg/mL solution was then diluted 1.0 mL into 100 mL of diluent to provide a 1 μg/ml solution from which standards were prepared at 1, 7.5 and 50 ppb of phenanthrene-9-carboxaldehyde by dilution with Diluent.
Stability studies were conducted by aliquoting prepared standards (0, 2, 10 and 50 ppb for phenanthrene and 0, 1, 7.5 and 50 ppb for phenanthrene-9-carboxaldehyde) into 5 mL glass vials at a volume of 2.5 mL. The vials were then capped with Teflon coated caps and crimped. The vials were then separated into five groups. Each group was then placed at a different temperature (-20° C., 2°-8° C., 20°-25° C., 37° C. and 50° C.) in an upright position. Standards were tested for B/Bo at specified intervals by assaying each standard level in duplicate for each temperature. The results were then graphed as a function of time (x) versus B/Bo(y) by temperature level. (See FIGS. 1-5) (B/Bo is the absorbance at 450 nm observed for phenanthrene or phenanthrene-9-carboxaldehye at the specified concentration divided by the absorbance using diluent/zero standard instead of either phenanthrene or phenanthrene-9-carboxaldehyde.)
The results show that the B/Bo of phenanthrene-9-carboxaldehyde shows less change as a function of time of storage than the B/Bo of phenanthrene does. The superior stability of the phenanthrene-9-carboxaldehyde solutions becomes more marked as the temperature of storage is increased.
In FIG. 2. for example, there was an apparent 25 percent increase in the B/Bo of the phenanthrene after 200 days of storage at 4° C. Because, as illustrated in Example 3, there is not a linear relationship between B/Bo and concentration of a standard (or analyte), a 25% error in B/Bo will result in considerably more than a 25% error in the analyte concentration determined by the immunoassay.
Example 2
Cross-reactivity Studies
The cross-reactivity, of the antibodies used in the assay, for various hydrocarbons was tested and the results expressed both as 50% B/Bo and as least detectable dose (LDD) which is estimated as the dose needed to generate a B/B o of 90%. (If the mean absorbance value for the standard is 0.5 times the mean absorbance value for the Diluent/Zero Standard then the % B/B o is 50% and the concentration of standard used is the 50% B/B o concentration. A B/Bo of 90% means B equals 0.9 times B o ). The results are tabulated in Table 1:
TABLE 1______________________________________Cross-reactivity Studies LDD 50% B/Bocompound (ppb) (ppb)______________________________________phenanthrene 0.70 16.5fluoranthene 0.32 4.7benzo(a)pyrene 0.50 6.9pyrene 0.20 7.7chrysene 0.40 7.8anthracene 0.54 11.0indeno(1,2,3-c,d)pyrene 0.78 27.21,2 benzoanthracene 0.77 28.4fluorene 1.65 35.2benzo(b)fluoranthene 0.91 54.2benzo(k)fluoranthene 0.77 524______________________________________
Example 3
Calculation of 50% B/B o
An example of a curve plotting the % B/B o for a standard on vertical logit (Y) axis versus the corresponding analyte concentration on a horizontal algorithmic (X) axis is shown in FIG. 6. The curve is for phenanthrene. The value for 50% B/B o is 16.5 ppb.
Example 4
Four environmental water sources (two ground waters and two municipal waters) were each spiked with four different amounts of phenanthrene then, using phenanthrene-9-carboxaldehyde as a standard, each sample was analyzed with the immunoassay for phenanthrene as if the phenanthrene concentration was unknown. For each amount of spiked phenanthrene, the Mean of the phenanthrene value obtained with the immunoassay for the four samples was calculated, as was the standard deviation (S.D.) and the % recovery. The results are shown in Table 2.
TABLE 2______________________________________Recovery StudiesPhenanthrene Mean S.D. %Added (ppb) (ppb) (ppb) Recovery______________________________________+5.0 5.09 0.58 102+7.5 8.13 0.56 108+20.0 21.46 2.47 107+40.0 40.91 2.99 102______________________________________ | 4y
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/183,627, filed Jul. 15, 2011, which is a continuation of U.S. patent application Ser. No. 10/428,566, filed May 2, 2003, which issued as U.S. Pat. No. 8,023,475 on Sep. 20, 2011, which claims priority from U.S. Provisional Application No. 60/378,901, filed on May 6, 2002, the contents of which are hereby incorporated by reference herein.
FIELD OF INVENTION
[0002] The present invention relates to the field of wireless communications. More specifically, the present invention relates to the optimization of power resources of wireless devices within wireless communications systems.
BACKGROUND
[0003] The more often a battery operated device, such as a wireless transmit/receive unit (WTRU), looks for possible data being sent to it, the more power the device consumes. In networks and devices that support not only telephony, but also data transmission, the manner in which the devices look for messages from the network varies, depending on whether the device is looking for incoming phone calls or incoming data transmissions.
[0004] With respect to telephony, users are accustomed to terrestrial networks wherein a ringing sound is heard almost immediately after a particular telephone number is dialed. To meet this expectation in wireless environments, a WTRU must frequently scan the network to minimize the delay in establishing a connection as perceived by a person placing a phone call. That is, the WTRU must frequently scan the network for incoming calls to minimize the time between when the network sends a calling signal or message and when the receiving WTRU actually checks for the calling signal.
[0005] This arrangement is quite suitable for telephony, but is inefficient for data transmission. With respect to data transmission, the strict requirements necessary for ensuring a near-instantaneous response to a call are not required. Longer delays are generally tolerated when transmitting data to WTRUs such as pagers and similar devices, for example. However, it is generally expected, that such devices respond to a message indicating that there is an incoming data transmission “in real time.” Therefore, the network must also be scanned rather frequently in some cases when dealing with data transmission, but even in such situations the frequency with which the network must be scanned is less then when dealing with telephony.
[0006] The amount of delay that is acceptable varies according to the type of data being transmitted and user preference. For example, longer delays are tolerated where information is infrequently updated, such as traffic or weather data. In the case of a pager, a reasonable response time could be evaluated in terms of an anticipated time delay for the user to respond to a paged message. In the case of multiple network transmissions (i.e. stock quotes, sport scores, etc.), some users want information occasionally updated so that they may have longer battery life. Other users have less concern for battery life and simply want data updated rapidly. Examples of users wishing frequent updates would be people desiring immediate information updates and people whose WTRU is connected to an external power supply. In the case of stock quotes, for example, there are casual watchers, and those who desire immediate notification of changes. Thus, if the user would expect to respond to a message quickly, the response time should ideally be fairly quick, but still much greater than the necessary response time for a WTRU becoming aware of an incoming telephone call.
[0007] It would therefore be desirable to have a method and system for efficiently supporting data transmissions as well as telephony.
SUMMARY
[0008] A wireless network permits WTRUs to operate in a quiescent mode of operation according to a synchronization schedule. Synchronization information is provided to the WTRUs to inform them of when they may be in a quiescent mode and when they need to wake up and retrieve data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is diagram showing a wireless communication network.
[0010] FIG. 2 is a data diagram showing a frame structure used in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] According to the present invention, synchronization information is provided to wireless transmit/receive units (WTRUs) to inform them of when they may be in a quiescent mode (i.e. when they may be asleep) and when they need to wake up and retrieve data. For purposes of describing the invention, a WTRU may have a transmit-only, a receive-only or a transmit-and-receive capability. That is, a WTRU may be any type of device capable of receiving and/or transmitting data in a wireless environment.
[0012] Referring now to FIG. 1 , a representation of a network is shown wherein one or more base stations 21 communicate with a plurality of WTRUs, such as WTRU 22 which will be referred to when describing the invention. The WTRU 22 , as explained, can be any of a number of devices supported by the network. Examples include user equipment (UE), cellphone, pager, Blackberry (TM) device, computer with a modem connection or any other device that is capable of operating in a wireless environment. The base station 21 is controlled by a radio network controller (RNC) 25 which performs various network supervisory and communications functions. The base station 21 includes signal processing circuitry 31 and an RF stage 32 , which includes a transmit function. Signals from the base station 21 are transmitted to the WTRUs within its cell or transmission area, as represented by antennas 33 , 34 . The WTRU 22 has an RF stage 37 and a signal processing stage 38 . A receive function is provided by the WTRU's RF stage 37 in order to receive signals transmitted by the base station 21 . In the case of two-way devices, the RF stages 32 and 37 have both transmit and receive functions, permitting the WTRU 22 to transmit data in an uplink and receive data in a downlink. While transmitting requires significantly greater power than receiving, issues of quiescent operation primarily affect the downlink, so the receiver function of the WTRU 22 is significant.
[0013] In accordance with the present invention, the WTRU 22 uses its signal processing circuitry 38 in order to control when the RF stage 37 is receiving signals from the base station 21 . This allows the operation of the receive function of the WTRU 22 to be active primarily during times when signals are expected to include data intended for that particular WTRU 22 . During at least some of the time when signals are not intended for that particular WTRU 22 , the WTRU goes quiescent, meaning that most reception and signal processing by the WTRU 22 is turned off.
[0014] Regardless of the manner in which data is being transmitted from the network, the WTRUs are preferably synchronized so that they may wake up and go sleep to maximize battery life and satisfy user preferences. The synchronization information provided to the WTRUs is provided in accordance with the manner in which data is being delivered from the network. That is, regardless of the manner in which data is being transmitted from the network, synchronization information is provided to WTRUs so that they are aware of when they need to be awake and when they may go to sleep.
[0015] As known to those skilled in the art, data may be provided from the network to WTRUs in a variety of ways, as desired. In one embodiment, data may be transmitted in the form of scheduled transmissions. In this case, the network transmits various types of broadcast or multicast data on a known schedule that is tightly synchronized to a time frame known by both the transmitting WTRU and the receiving WTRU(s). The WTRUs can then synchronize their wake-ups to search occurrences when data may or will be transmitted. To implement this embodiment in 3 rd generation cellular networks, scheduling information can either be provided by a common control channel such as the Broadcast Common Control Channel (BCCH) signaling or a Dedicated Control Channel (DCCH) signaling. Where BCCH signaling is used, scheduling (i.e. synchronization) information may be signaled for all broadcast and multicast services. If DCCH signaling is used, only scheduling of services that are specific to a receiving WTRU will be signaled.
[0016] In another embodiment, data may be transmitted in the form of multiple network transmissions. That is, as mentioned, some users want information updated only occasionally in favor of longer battery life whereas others want data updated rapidly without regard for battery life. Therefore, in this embodiment, data is transmitted (even where there is no data change) at a rate that is consistent with a user's preference for the frequency of updates versus battery life. By transmitting data at a rapid by synchronized pace (i.e. the highest available rate desired by a user) and repeating the transmissions even when there is no data change, individual receiving WTRUs can wake up and search for data at different time intervals, according to user preference. This satisfies the needs of both groups of users (as well as those in between) by providing an adjustable degree of settings.
[0017] Since the amount of delay that is acceptable varies according to the particular user application, it is likely that any tradeoff between delay and power consumption would have different optimums for different users. Therefore latency (i.e. delay time) may be optimized based on usage, as low latency conflicts with low power consumption. This becomes particularly significant during times when the WTRU is not in active use.
[0018] To implement this embodiment in 3 rd generation cellular networks, once a receiving WTRU is aware of scheduled broadcast or multicast transmissions, the receiving WTRU can then acquire the service (i.e. the scheduled broadcast or multicast transmissions) transmitted on either the Forward Access Channel (FACH) or the Downlink Shared Channel (DSCH) on an as needed basis. The network will transmit the broadcast or multicast data in either Radio Link Control Transparent or Unacknowledged Mode, which allows the receiving WTRU to determine if reception is needed autonomously without requiring interaction or causing errors to be perceived in the network.
[0019] A modification to the embodiment where multiple network transmissions are provided is to transmit only until certain WTRUs in the network's range acknowledge receipt. This modification has the advantage of terminating the transmission when it is no longer necessary while also providing some robustness to the transmission of the information for appropriately enabled devices. This modification has the disadvantage of requiring uplink transmissions from WTRUs and may not be suitable for a large number of WTRUs. With respect to implementation in 3 rd generation cellular networks, there are several network acknowledgement alternatives. For example, where there is a single receiving WTRU, Radio Link Control Acknowledged mode provides an automatic repeat request mechanism for assured delivery. When there are multiple receiving WTRUs, layer 3 acknowledgements can either by provided by Radio Resource Control signaling within the Access Stratum, or by transparent data transfer of Non Access Stratum signaling.
[0020] In another embodiment, the network simply transmits the fact that there is a message awaiting delivery. That is, rather then sending the message all the time, in some instances it is more efficient to just notify the WTRUs that a message for them exists. In 3 rd generation cellular networks the availability of the message is identified by a common control channel, such as the BCCH. Those WTRUs that want the message will then request its transmission from the network. The request for the message may either be for the particular message or registration with the multicast service for reception of one or more messages associated with that service. This approach is suitable when only a small number of WTRUs are expected to request the actual message, while many WTRUs may want the actual ability to do so. This situation may arise, for example, where there is only limited information in the initial transmission informing WTRUs of a message's existence. In 3 rd generation cellular networks, the receiving WTRU will generate a request for the service with either layer Access Stratum or Non Access Stratum signaling. The network will then either signal broadcast scheduling information or establish a dedicated radio bearer for transmission of the service. That is, the network with knowledge of the number of WTRUs requesting the message or service of multiple messages determines the most efficient method of transmission. If there is a large number of recipients, scheduling of information will be signaled on a common control channel. This information will identify a common channel such as the FACH or DSCH, and the time of transmission for reception of the service. If there is a small number of WTRUs requesting the message or service a dedicated channel will be established to each requesting or registered WTRU associated with this message or service.
[0021] Referring now to FIG. 2 , a signal frame diagram including a sequence of transmissions transmitted by a base station to multiple WTRUs is shown. As mentioned, the delivery of transmissions is synchronized so that messages directed to a particular WTRU or group of WTRUs associated with that message or service is delivered when that particular WTRU or group of WTRUs associated with that message or service is awake looking for data. To accomplish this, in one embodiment, the transmissions are divided into frames 54 wherein seventy two (72) frames 54 make up a superframe, as shown in FIG. 2 . For simplicity in describing the invention, portions of two superframes 51 , 52 are shown. It should be noted, however, that superframes 51 , 52 are part of a repeating series of superframes, each having seventy two (72) frames. It should also be noted that a superframe having 72 frames is provided purely by way of example, as other multiframe sequences are possible.
[0022] The frames 54 are divided into time slots 56 , as shown in an expanded view 71 E of frame 71 . The time slots 56 within each frame, such as frame 71 , include transmission packets designated, for example, zero (0) through (14). Each time slot 56 may include data intended for one or more devices. By way of example, slot 6 includes data for WTRU 101 and slot 12 includes data for WTRUs 102 and 103 .
[0023] WTRUs 101 through 103 preferably synchronize their reception so that they are able to receive data during their respective allocated time period. The use of fixed time periods for data reception means that, once a WTRU is provided with its synchronization information (i.e. information related to the particular time sequence of signals intended for that WTRU), the WTRU may synchronize with that time sequence and remain asleep (i.e. quiescent) for a portion of a superframe. This results in reduced power consumption because a WTRU in a quiescent state has most or all of its RF reception circuits turned off. The WTRU, preferably, has most of its signal processing circuits turned off as well. In this embodiment, the reduction in power consumption approximately corresponds to the number of frames that are ignored.
[0024] Once synchronized, WTRUs 101 through 103 wake up only in their respective slot, radio frame or multiframe associated with the particular interleaving period known as the transmission time interval (TTI). From the network perspective, for each superframe, the network will wait for frame 71 , slot 6 before transmitting data to WTRU 101 .
[0025] It should be noted that WTRUs may wake up at other times (i.e. other than their designated slots), if needed. For example, it may be necessary to wake up for certain common signals. Additionally, the network and WTRUs may be adapted so that a special “wake up” signal is transmitted from the network to a particular WTRU or group of WTRUs where it is necessary for the WTRU(s) to wake up and receive data outside of their designated slot.
[0026] It should be noted that the division of transmissions into superframes, frames, and slots may be varied as desired. For example, in the discussion above, it is assumed that a WTRU will wake up at least every superframe and look for data in at least one slot of at least one frame. However, as mentioned, data transmissions may be provided to users as desired so as to satisfy user preferences for battery life and frequency of data renewal. Therefore, the timing of a particular synchronization scheme may similarly be varied. By way of example, it is possible to create a synchronization schedule between network data delivery and a WTRU's receipt thereof wherein more than one superframe passes between WTRU wake up periods within which a WTRU wakes up and looks for a message at its assigned frame and slot.
[0027] While the present invention has been described in terms of the preferred embodiment, other variations which are within the scope of the invention as outlined in the claims below will be apparent to those skilled in the art. | 4y
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This application is a continuation of Ser. No. 07/869,517 filed Apr. 16, 1992 now U.S. Pat. No. 5,825,060.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to integrated circuits, and more specifically to a method for fabricating polycrystalline silicon resistor structures therein.
2. Description of the Prior Art
CMOS SRAMs often use a four transistor cell design having resistive load devices. This design is used in order to save chip layout area over the traditional six transistor cell design. Two N-channel transistors are used to form a cross-coupled latch, while two additional N-channel transistors are used to provide access to the cell for reading and writing data. Two load devices are connected between the N-channel transistors in the latch and the power supply.
In the prior art, the resistive load devices are formed after formation of the transistors. After the transistors have been formed, a dielectric layer is deposited and contact openings are formed to the substrate. A second polycrystalline silicon layer is deposited and lightly doped N-type to achieve a resistivity in the range of 10 6 to 10 13 ohms/square. This blanket implant determines the load resistor value. The resistivity of the load resistors must be low enough to supply ample current to compensate for transistor leakages, but high enough to allow for sufficient standby currents for proper device operation under adverse conditions.
Resistance of the polycrystalline silicon load structures is a function of four variables. These are: the grain structure of the polycrystalline silicon used to form the resistor structure, the impurity levels used to dope the polycrystalline silicon; the cross-sectional area of the resistive device; and the length of the device. Impurity levels and polycrystalline silicon grain structure can be controlled only to limits determined by the process technology being used. If cross-sectional area of the structure could be reduced, length of the load resistor could also be reduced to preserve a given resistance for a small overall structure.
It would be desirable to provide a polycrystalline silicon resistor structure, and a method for fabricating same, which resulted in resistor structures having a reduced cross-sectional area. It would further be desirable for such a method to be compatible with existing process technologies.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a polycrystalline silicon resistor structure, and method for making same, having a reduced cross-sectional area.
It is a further object of the present invention to provide such a structure and method which is compatible with current process technologies.
It is another object of the present invention to provide such a structure and method which adds a minimal amount of complexity to the process flow used to fabricate the device.
Therefore, according to the present invention, a method for fabricating polycrystalline silicon resistor structures includes steps directed to the provision of a polycrystalline silicon structure having a decreased width. In one embodiment, sidewall spacers are used to narrow a region in which the polycrystalline silicon resistors are formed. In an alternative embodiment, polycrystalline silicon resistors are formed as sidewall structures in a resistor region. Use of either technique provides a reduced cross-section for the resistor structures, allowing shorter resistors to be used, or providing increased resistance for longer resistors.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, and further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIGS. 1-4 illustrate the formation of polycrystalline silicon resistor structures according to a first preferred embodiment of the present invention;
FIG. 5 illustrates the formation of polycrystalline silicon resistor structures according to a second preferred embodiment;
FIG. 6 is a planned view of a resistor formed according to the technique described in connection with FIGS. 1-4; and
FIG. 7 illustrates resistive structures formed according to the technique described in connection with FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process steps and structures described below do not form a complete process flow for manufacturing integrated circuits. The present invention can be practiced in conjunction with integrated circuit fabrication techniques currently used in the art, and only so much of the commonly practiced process steps are included as are necessary for an understanding of the present invention. The figures representing cross-sections of portions of an integrated circuit during fabrication are not drawn to scale, but instead are drawn so as to illustrate the important features of the invention.
Referring to FIG. 1, integrated circuit devices are formed in a substrate 10. Field oxide regions 12, 14 separate and define active areas within the substrate 10. Polycrystalline silicon signal line 16 is used to conduct signals on the device. Signal line 16 is separated from the substrate 10 by gate oxide layer 18. Sidewall oxide spacers 20 are formed on either side of the signal line 16 as known in the art.
Although the cross-sectional view through signal line 16 shows the same structure as a field effect transistor, signal line 16 can be a non-gate signal line which is utilized in a shared contact region. Signal line 16 will be so used as will be described further below. Active regions 22, 24 function as the source/drain regions of the field effect device if polycrystalline silicon signal line 16 actually functions as a field effect gate. In a shared contact layout, the active areas 22, 24 may actually be connected out of the plane of the drawing, so that the signal line 16 does not function as a gate.
Polycrystalline silicon signal line 26 rests on field oxide region 14. Oxide sidewall spacers 28 are formed thereon at the same time as sidewall spacers 20.
Processing to form the elements just described is conventional as known in the art. After formation of the transistor structures, dielectric layer 30 is deposited over the surface of the integrated circuit device. This layer 30 is preferably LPCVD/APCVD/LTO silicon dioxide followed by a deposited layer of LPCVD silicon nitride as known in the art. Other insulating layers may be used if desired.
After formation of dielectric layer 30, insulating layer 32 is deposited over the surface of the device. Layer 32 is preferably a dielectric which can be easily planarized. Layer 32 may be, for example, BPSG which is deposited and heated to reflow as known in the art. If BPSG is used, the reflow is preferably performed in an ambient atmosphere including steam. The reflow cycle, or other planarization step, results in a nearly planar surface as shown in FIG. 1.
Referring to FIG. 2, an insulating layer 34 is deposited over the surface of the device. Insulating layer 34 is preferably an LPCVD silicon nitride layer deposited to a depth of approximately 2000-4000 angstroms. Nitride layer 34 is then patterned and etched to define a region 36 in which polycrystalline silicon resistors are to be formed.
Another insulating layer (not shown) is deposited over the surface of the chip, and anisotropically etched without masking to form sidewall spacers 38 within the resistor region 36. The insulating layer used to form the spacers 38 is preferably an LPCVD/LTO silicon oxide layer. The oxide layer is deposited to a thickness which results in the width of the oxide regions 38 resulting as desired. As known in the art, the width of the spacers 38 is approximately equal to the thickness of the oxide layer from which they are formed. Thus, for example, if a 0.2 micron opening is desired between the spacers 38, and the region 36 is one micron wide, the oxide layer used to produce spacers 38 is deposited to a depth of approximately 4000 angstroms.
After formation of the sidewall spacers 38, contacts are opened to the substrate 10 and other underlying features through insulating layers 30, 32, 34. As examples of the types of contacts which may be formed, contact opening 40 makes contact with active region 22 within a substrate 10. Contact opening 42 makes contact with both the polycrystalline silicon signal line 16 and active region 24. The contact to be formed in opening 42 is part of a shared contact region. Contact opening 44 is opened simply to allow contact to underlying polycrystalline silicon line 26.
Referring to FIG. 3, a layer of polycrystalline silicon 40 is deposited over the device. Layer 40 is preferably deposited to a depth of approximately 500 to 1500 angstroms. A blanket impurity implant is then made to control the resistivity of the polycrystalline silicon resistors to be fabricated in region 36. If N-type resistors are to be formed, an N - implant is made.
Referring to FIG. 4, the polycrystalline silicon layer 46 is patterned and etched to remove it except in the desired contact regions 40, 42, 44 and interconnect regions as desired. This results in various polycrystalline silicon contact structures 48 as shown. The layer 40 is etched to completely clear it, which can be accomplished by etching until the end point is reached as known in the art, and continuing the etch for a period of time approximately ten percent beyond reaching the end point. Such an over etch insures that undesired polycrystalline silicon regions do not remain behind.
During etching of the polycrystalline silicon layer 46, resistor region 36 is left unmasked. This causes the polycrystalline silicon overlying such region 36 to be etched away. However, due to the depth of the region 36, some material remains in the region between the sidewall spacers 38. This polycrystalline silicon region 50 provides the resistor desired for use in the device. As will be apparent to those skilled in the art, the cross-sectional area of resistor 50 is much smaller than a resistor which fills the resistor region 36.
A masked N + implant can then be made to reduce the resistivity of the polycrystalline silicon contacts and interconnect 48. Remaining fabrication steps for the device, such as formation of further polycrystalline silicon and metal interconnect layers, is completed in a conventional manner. To a great extent, the device is already planarized due to the planarization of insulating layer 32, so that further planarization steps may be minimized or not required.
Referring to FIG. 5, an alternative technique for fabricating small cross-section polycrystalline silicon resistor structures is shown. The technique used is very similar to that described in connection with FIGS. 1-4. The difference is that the deposition of the oxide layer, and anisotropic etching thereof to form sidewall spacers 38, is not performed. Instead, when polycrystalline silicon layer 40 is deposited over the device, it extends across the entire width of resistor region 36. When the polycrystalline silicon is anisotropically etched to form contact and interconnect regions 48, sidewall polycrystalline silicon regions 52 are formed within the resistor region 36. These regions 52 are separated by region 54 in much the same manner that sidewall oxide regions 38 were separated as described in connection with FIG. 2. The width of the polycrystalline silicon resistors 52 is controlled by the depth to which polycrystalline silicon layer 46 is deposited. The height of the resistor regions 52 is controlled by the depth to which the nitride layer 34 is deposited. Decreasing the depth of nitride layer 34, or the thickness of polycrystalline silicon layer 46, results in resistor regions 52 having a smaller cross-sectional area.
Further processing of the device after the stage shown in FIG. 5 is completed in a conventional manner as described above in connection with FIG. 4.
FIG. 6 illustrates a plan view of a polycrystalline silicon resistor formed according to the techniques described in connection with FIGS. 1-4. Polycrystalline silicon contacts 60 connect to signal lines 62. Lines 64 indicate the boundaries of the resistor region 36. Polycrystalline silicon resistor 66 connects the contacts 60.
As can be seen, the cross-sectional area of the polycrystalline silicon resistor 66 is greatly reduced from that which would normally be formed connecting contact regions 60. This allows a much higher valued resistor to be formed, or a shorter resistor to be used. Use of shorter resistor 66 allows the contacts 60 to be placed closer together, if desired, thereby reducing the overall layout area required for circuit structures such as 4-transistor SRAM cells.
FIG. 7 is a plan view of a device constructed according to the method described in connection with FIG. 5. Contact regions 70 are connected to signal lines 72. Polycrystalline silicon resistors 74 connect the contact regions 70. Since the resistors are formed on both sidewalls of the resistor region 36, two parallel resistors 74 are formed. The twin resistor structures 74 shown in FIG. 7 have the same advantages as the single structure 66 shown in FIG. 6, and can be fabricated with a lesser number of process steps.
The resistor structures described above provide polycrystalline silicon resistor structures which have a reduced width, and thus a reduced cross-sectional area. Use of such resistor structures in circuits such as CMOS SRAM cells allows the use of shorter resistors for a given required resistance. This can lead to smaller cell layout areas, and increased device density on an integrated circuit chip.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | 4y
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FIELD OF THE INVENTION
This invention relates to valves and is primarily concerned with valves which can be incorporated into evaporative air conditioning systems to enable those systems to dry out during periods of non-use, thereby substantially obviating the proliferation of microorganisms which commonly occurs in the base region of such systems, particularly in the water reservoir.
BACKGROUND OF THE INVENTION
Stringent health requirements govern the legal operation of evaporative air conditioners to ensure that public health standards are not violated. One requirement is a minimum three monthly cleaning of the drainage system. However, it is found in practice, particularly in hot climates and when the air conditioner is not in frequent use, significant microorganism populations can still grow in the water reservoir of the air conditioner in the period between cleaning.
In order to address this problem, and the general problem of having the base of the air conditioner permanently wet which leads to corrosion and other deterioration of the system, dump valves of various construction have been proposed to be incorporated in the water reservoir. Such dump valves are typically designed to release the water from the reservoir at regular intervals or when the air conditioner is turned off. Unfortunately however, there are problems associated with these dump valves which means that they do not fully meet the requirements for which they were designed. For instance, a common problem is that they are fitted to a typical waste outlet having a rim which prevents the last few milliliters of water from draining from the reservoir. Such a small quantity of water having a large surface area, is an ideal growth medium for microorganisms. Another problem is due to the manner in which the dump valve operates. Usually, operation is controlled by a 240 volt power source--which can be dangerous for maintenance personnel due to the presence of water--which closes off the outlet after the air conditioner has been turned off and the reservoir has been drained, thereby preventing the escape of any latent excess water draining into the reservoir or the draining of water which collects in the reservoir when it rains.
OBJECT OF THE INVENTION
It is therefore an object of the present invention to provide an improved dump valve which obviates or at least minimizes the aforementioned disadvantages and/or provides a viable alternative to existing dump valves.
SUMMARY OF THE INVENTION
According to the present invention there is provided an hydraulic valve having a housing with closed and open structured portions in which a plunger is adapted for reciprocal movement; said closed portion incorporating an hydraulic fluid inlet and an hydraulic fluid outlet; said open structured portion incorporating a plug seat and plug stem; said plunger incorporating a sealing member on an end which reciprocates in the closed portion and a plug on the end which reciprocates in the open structured portion, there being provided spring means which normally bias the sealing member towards the inlet to prevent fluid communication between the inlet and the outlet; the construction and arrangement being such that when pressurized hydraulic fluid is passed through the inlet, it impacts upon the sealing member moving the plunger through the open structured portion of the housing to seat the plug on the plug seat, simultaneously bringing the inlet and outlet into fluid communication with one another.
Although the valve has been defined in terms of an hydraulic valve, that is, a valve for use with all manner of fluids, the primary use for which it has been developed is with water in evaporative air conditioners. The following description will therefore be restricted to such an embodiment in order to facilitate the understanding of the invention. It should always be borne in mind, however, that the invention has wider ramifications and is applicable to valves used in other contexts and with other fluids.
DESCRIPTION OF PREFERRED EMBODIMENTS
The hydraulic valve of the present invention is preferably used in association with a dual functioning water operated solenoid valve of the type which is the subject of Australian Patent Application No. PL 9114 to co-inventor L. Kittlety which comprises inlet and outlet solenoids operable through a transformer on a 24 volt power supply. The combined dual operating solenoid valve and hydraulic valve constitute the main componentry of the water maintenance and water removal system in a typical evaporative air conditioner. Here the componentry is tied into the pumping cycle of the air conditioner.
The hydraulic valve is fitted into the reservoir at the base of the air conditioner by mounting the plug seat level with the floor of the reservoir, with the plug stem extending through the floor and the housing extending upwardly from the floor. The dual operating solenoid valve is connected to the inlet in the housing and to a standard mains pressure water supply.
In operation, turning the air conditioner on, activates the electrical circuitry which opens the inlet solenoid of the dual functioning solenoid valve and closes the outlet solenoid, enabling a measured quantity of water to flow through the hydraulic valve to the air conditioner reservoir. There is a two minute delay on the pump start-up. Also, an optional shut-down timer for longer running period is provided. The water is recirculated in the evaporative air conditioner through the cooling pads and back to the reservoir. Top-up water is admitted as required by level sensing with a float valve or the like in the reservoir which is connected to the hydraulic valve.
During the on-cycle of the pump, the hydraulic valve maintains the plug in firm seating engagement with the outlet in the reservoir due to the pressure of water within its housing. However, as soon as the pump is turned off, i.e. when the air conditioner is switched off, the inlet solenoid valve shuts off water to the hydraulic valve, and the outlet solenoid opens to atmosphere, reducing the water pressure in the housing, and the spring means can then raise the plug from its seat allowing the water in the reservoir to discharge through the plug hole. Further, since the plug seat is level with the surface of the reservoir base, all water is thoroughly drained from the reservoir. Such drainage also occurs if it happens to rain as any water which washes down through the air conditioner pads will collect in the water reservoir and then run straight through the waste water outlet, allowing the air conditioner to dry out as soon as the rain ceases. The rainwater also serves to clean the pad.
The hydraulic valve housing can be constructed from typical valve materials, that is brass, stainless steel or like alloys, or durable plastics materials such as polyvinylchloride, polyethylene, polypropylene and the like. The latter materials are particularly preferred from a cost consideration as they can be used to economically injection mould the housing.
The plunger and sealing member can be constructed from the same materials as the housing, but may comprise a different selection of materials to that of the housing. Once again, they are preferably plastics materials. The sealing member will typically include plastics or rubber seals such as 0-rings or the like to prevent the passage of water past the sealing member.
The plug is preferably fabricated from a resilient material such as a cross-linked rubber to ensure good sealing contact with the outlet.
The hydraulic valve housing may comprise single or multiple components. Preferably, it comprises two components which are connected together by a complimentary screw thread on each component. One component which is typically the closed portion is suitably substantially cylindrical in construction and accommodates the sealing member. This portion also incorporates the inlet and outlet. The other component, which is typically the open structured portion, has a mid-regional cylindrical cage structure which acts as a guide for the plunger and the attached plug as well as the opening through which the waste water from the air conditioner discharges, and a cylindrical plug stem preferably formed integrally therewith which is adapted to extend beneath the water reservoir of the evaporative air conditioner.
The inlet in the closed cylindrical housing is suitably located in the end wall thereof and the outlet is suitably located in the side wall at a distance spaced from the inlet which is comparable to the distance by which the plug moves between it's seated and it's fully unseated locations.
Known spring means can be utilized for biasing the sealing member on the plunger towards the inlet in the housing. Such spring means may comprise a helical coil spring of non-corrosive material, such as high tensile stainless steel, which seats between a ledge in the end section of the closed portion and an internal cavity in the sealing member.
The sealing member can have any structure which meets the desired result, i.e. of providing a fluid tight seal but still being reciprocally moveable in the housing. It's configuration will be determined by the shape and internal dimensions of the closed portion of the housing. Typically, the housing has a cylindrical shape as mentioned above and the sealing member will thus usually also be cylindrical in shape.
DESCRIPTION OF DRAWINGS
Preferred embodiments of the invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a vertical cross-sectional view of an hydraulic valve according to the present invention in one configuration with an associated dual acting solenoid valve shown in phantom;
FIG. 2 is a view similar to FIG. 1 showing the valve in another configuration but without the solenoid; and
FIG. 3 is a schematic representation of an evaporative air conditioner incorporating the hydraulic valve depicted in FIGS. 1 and 2.
In all the drawings, like reference numerals refer to like parts.
Referring firstly to FIGS. 1 and 2, the hydraulic valve comprises a closed housing portion 1 and an open structured housing portion 2 with an internal plunger 3 which reciprocates between the two. The closed housing portion 1 is injection moulded from high density polyethylene polymer and has a cylindrical configuration with a water inlet 4 in the top end wall 4' and a water outlet 5 in a cylindrical side wall 6.
The open structured housing portion 2, which is also injection moulded from high density polyethylene polymer, is connected to closed housing portion 1 by a screw-threaded connection comprising an externally threaded shank 7 integrally formed on the end of portion 2 and an internally threaded recess 8 formed on the lower end of portion 1. The open structured housing portion 2 includes a cage section 9 which includes a narrow opening 10 for guiding the reciprocal movement of the plunger 3, and a plug stem 11 depending from a plug base 12. The plug stem 11 may be externally threaded if need be for ready screw connection to standard waste plumbing fixtures. The cage section 9 is open to the exterior except for a minimum number of supports connecting an upper wall 13 with the plug base 12. The plug base 12 is tapered at its periphery 14 to enable levelling with the base surface of the water receptacle of an evaporative air conditioner, thereby ensuring that there is no lip which would prevent all water from draining from the receptacle.
The plunger 3 comprises a stem 15, with an integrally formed enlarged head or sealing member 16 moulded from high density polyethylene polymer. The base of the plunger has a polybutadiene rubber plug 16a fitted to it which is adapted for sealing contact with the plug base 12 as shown in FIG. 2. The sealing member 16 has three rubber O-rings 17, 18, 19 fitted in grooves around its perimeter to provide a seal with the side wall 6 of the housing.
A stainless steel helical spring 20 is fitted into the sealing member and is restrained by the upper wall 13 of the open structured portion.
FIG. 2 shows the state of the valve when the valve is in the "off" mode, that is, when there is no water pushing on the sealing member 16. It will be observed that in this state, the helical spring 20 biases the plug 16a away from the plug seat, thereby allowing water in the reservoir to drain through the open-cage structure of the portion 2 with minimal restriction to the water flow.
FIG. 1 shows the valve in the "on" mode, that is when the inlet water has been turned on and water has been admitted to the valve through the inlet 4. The water pressure is sufficient to overcome the force of the helical spring 20 and push the sealing member 16 and plunger downwardly so that fluid communication is provided between the inlet 4 and outlet 5. Simultaneously the plug 16a is seated on the plug seat preventing the outflow of water through the caged structure.
FIG. 3 is a schematic view showing the hydraulic valve 30 fitted to an evaporative air conditioner 31. The valve is fitted to stand perpendicular in the base of the water reservoir 32, with the plug stem 11 projecting therethrough. A dual acting solenoid valve 33 is provided for controlling the flow of water into the hydraulic valve and opens into the housing inlet 4. The solenoid valve 33 is connected in electrical sequence to the pump circuitry 34 and to a 24 volt transformer 35. The amount of water in the reservoir is sensed by float 36 which connects to the outlet 5 of the hydraulic valve. When the float 36 drops below a pre-set level, top up water is admitted into the reservoir.
In operation, when the evaporative air conditioner is turned on, an inlet solenoid of the dual acting solenoid 33 opens, admitting water to the hydraulic valve 10. Simultaneously, an outlet or pressure relief solenoid closes, shutting off the interior of the hydraulic valve to the atmosphere. The water pushes the plunger down, opening the communication between the inlet and outlet of the valve housing, and simultaneously sealing the water outlet with the plug. After a pre-determined amount of water has been admitted, as sensed by the float valve, the admission of further water into the reservoir is halted. The pump 37 then commences pumping the water into the cooling pads where air is blown for circulation through an associated evaporative air conditioning system. As water is drawn from the system, the float valve lowers until a point is reached where the float valve can let in replacement water to top up the reservoir.
When the air conditioning unit is turned off, the inlet solenoid valve closes so that no more water can enter the hydraulic valve. Simultaneously, the outlet solenoid opens, venting the interior of the hydraulic valve to the atmosphere. The plunger then rises under the force exerted by the coil spring, closing off the outlet 5 and simultaneously raising the plug 16a from its seat to permit water in the reservoir to drain away.
The arrangement thus described overcomes the problems of prior art systems by permitting complete drainage of the reservoir when the air conditioner is switched off. Furthermore, in view of the fact that the outlet from the reservoir remains open after turning off, any latent water in the air conditioner is still able to drain away, leaving a completely dry reservoir, thus reducing the potential for microorganism growth to be reduced to zero for all practical purposes. The installation meets AS3666 when the RT system is fitted. The system uses available water pressure to keep the valve closed, not electric. | 4y
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BACKGROUND OF THE INVENTION
[0001] A. Field of the Invention
[0002] The present invention relates to methods and apparatus for forming in a three-dimensional image space two-dimensional views of an object. More particularly, the invention relates to a method and apparatus for remotely measuring and recording the position and orientation of an ultrasonic imaging transducer while each of a plurality of two-dimensional image slices is obtained of an internal biological feature by the transducer, and assembling in a three-dimensional space accurately oriented scaled and proportioned views of the slices, thereby facilitating three-dimensional visualization of the feature.
[0003] B. Description of Background Art
[0004] Acquiring and viewing of two-dimensional ultrasound images has long been a useful non-invasive, non-destructive test method which yields valuable information enabling the visualization of otherwise invisible structures, in diverse fields such as medicine and materials inspection. For example, ultrasonic imaging is routinely used to acquire plan-view images of a fetus within the mother's womb, or of the otherwise invisible honeycomb cell structure in metal panels, so constructed to provide a high rigidity/strength-to-weight ratio. However, a problem exists with existing ultrasonic imaging techniques, particularly when these technologies are used to form images of irregularly shaped objects, including internal biological features (IBF's) such as a fetus. Thus, a three-dimensional visualization of an IBF oftentimes must be performed in real-time by a doctor or other healthcare professional who is acting as an ultrasonographer while a sequence of ultrasound scans are made on a patient. To form any ultrasonic image or sonogram of an IBF or other such feature, an ultrasonic imaging wand which contains an ultrasonic energy transducer is used. In a transmit mode, the transducer is electrically energized to transmit a fan-shaped scanning beam of ultrasonic energy; in a receive mode, the transducer receives ultrasonic signals reflected from an object and converts the ultrasonic signals to electrical signals which are used to form an image of the object on a monitor screen. The reflected signals received by the transducer are displayed on the screen in a two-dimensional pattern corresponding to the scanned beam of ultrasonic energy emitted by the transducer when the transducer is operated in the transmit mode, the brightness or color of displayed image elements or pixels on the screen being proportional to the strength of the received signals.
[0005] To form a three-dimensional visualization of an IBF or other feature of interest, a sequence of two-dimensional views or sonograms are made by varying the orientation and/or location of the ultrasound wand relative to the feature, thus causing the transmitted and received ultrasound beams to “slice” the feature at different angles and/or locations. Such “on-the-fly” visualizations of the three-dimensional shape of a feature, made from a sequence of two-dimensional image slices, is problematic for a number of reasons. For one thing, it requires a substantial degree of skill and experience to perform meaningful visualization. Moreover, the procedure requires that the wand be repositioned or panned continuously in the area of interest for time periods which may be discomforting to a patient. Also, there is no practical way to preserve on-the-fly mental visualizations of an IBF. Therefore, although it is possible to record and preserve individual sonograms, it is usually impractical if not impossible for the ultrasonographer to recreate three-dimensional views of results of an examination at a later date, or to transmit 3-D views to a different healthcare professional for his or her review.
[0006] There are existing machines which are capable of tracking the position and orientation of an ultrasonic imaging wand and associating the instantaneous position of the wand with the ultrasound image acquired at that time. However, such machines are extremely expensive and do not afford a capability for retrofitting to existing ultrasound machines.
[0007] In U.S. Pat. No. 5,967,979, issued Oct. 19, 1999, the present inventor, Geoffrey L. Taylor, disclosed with Grant D. Derksen a Method And Apparatus For Photogrammetric Assessment Of Biological Tissue. In that patent, a remote wound assessment method and apparatus was disclosed in which an oblique photographic image is made of a surface wound and a target object such as a plate containing a rectangular image and placed near the wound. Using a novel method of determining vanishing points where a photographic image of parallel lines on the target object intersect, coordinate transformations are calculated which map the oblique image of the rectangle into a normal image thereof. Using the same coordinate transformations, an oblique image of a wound adjacent to the target plate is mapped into a normal, i.e., perpendicular view thereof, allowing precise determination of the true size and outline shape of wound features. The '979 patent also disclosed an enhancement of the novel planar feature mapping method and apparatus with three-dimensional feature mapping. Thus, according to the method, two separate images of a wound and target plate are formed by moving the camera to two different locations which provide two different oblique views from which three-dimensional topographical features of a wound surface may be measured. Although the method and apparatus disclosed in the '979 patent have proved to be highly successful in evaluating surface features of biological tissue, the problem of conveniently forming three-dimensional views of internal biological features has been heretofore unsolved, motivating the present invention.
OBJECTS OF THE INVENTION
[0008] An object of the present invention is to provide a method and apparatus for forming from a plurality of two-dimensional image slices of an object a three-dimensional representation of the image slices.
[0009] Another object of the invention is to provide a method and apparatus for forming from a plurality of relatively thin image scans which intersect an object at different angles and/or from different vantage points a three-dimensional representation of the image slices, thus facilitating visualization of the object, including heights of various features of the object.
[0010] Another object of the invention is to provide a method and apparatus for forming from a plurality of thin image scans which intersect an object at different heights a three-dimensional representation of the image slices, thereby enabling visualization of the object including heights of various features of the object.
[0011] Another object of the invention is to provide a method and apparatus for remotely measuring in a three-dimensional coordinate space locations and orientations of a sensor used to gather data.
[0012] Another object of the invention is to provide a method and apparatus for remotely measuring the location and orientation of an ultrasonic transducer used to form ultrasound images whereby the location and orientation of features imaged by the transducer may be precisely reconstructed in a three-dimensional coordinate space.
[0013] Another object of the invention is to provide a method and apparatus which photogrammetrically monitors a target plate attached to an ultrasonic imaging transducer wand, as the wand is moved relative to an object of interest, and which performs coordinate transformations of a sequence of oblique images of the target plate to thereby map a sequence of relatively thin, quasi two-dimensional ultrasound image scans of an object obtained by the transducer wand at various orientations relative to the object into a sequence of object feature images of correct relative size, shape and location within a three-dimensional coordinate system, from which a three-dimensional visualization of the object is constructed.
[0014] Another object of the invention is to provide a method and apparatus for photogrammetrically monitoring ultrasonic image-forming scans of internal biological features, in which a target plate attached to a scanning ultrasonic transducer wand is photographically monitored to thereby determine and record the precise location and orientation of the wand during each of a sequence of scans, coordinate transformations of each oblique wand and target plate image performed to obtain a sequence of normal view images of the target plate, and, using the oblique-to-normal view transformations of target plate images, a sequence of ultrasonically formed scanned images or sonograms are assembled into a composite three-dimensional view from which internal biological features may be visualized.
[0015] Various other objects and advantages of the present invention, and its most novel features, will become apparent to those skilled in the art by perusing the accompanying specification, drawings and claims.
[0016] It is to be understood that although the invention disclosed herein is fully capable of achieving the objects and providing the advantages described, the characteristics of the invention described herein are merely illustrative of the preferred embodiments. Accordingly, I do not intend that the scope of my exclusive rights and privileges in the invention be limited to details of the embodiments described. I do intend that equivalents, adaptations and modifications of the invention reasonably inferable from the description contained herein be included within the scope of the invention as defined by the appended claims.
SUMMARY OF THE INVENTION
[0017] Briefly stated, the present invention comprehends a method and apparatus for photogrammetrically monitoring the position and orientation coordinates of a sensor being used to acquire a sequence of sensor images of an object, performing a first coordinate transformation to correctly orient the sensor images, and constructing a three-dimensional representation of the correctly oriented sensor images, thereby permitting three-dimensional visualization of the object.
[0018] According to the present invention, an optical imaging and recording instrument such as a video camera, camcorder or digital camera is used to form a sequence of photographic images, at arbitrary, typically oblique angles, of a target plate attached to an ultrasonic transducer wand while a sequence of ultrasound image scans is being made of an object of interest, e.g., a fetus within the mother's womb. During this step, a separate recorded image of the target plate and ultrasound wand is associated with each ultrasound image scan, which is typically a relatively thin, quasi two-dimensional “slice” of the object. A sequence of two-dimensional ultrasound image slices is formed by changing the orientation and/or location of the ultrasound wand for each scan, thus obtaining different ultrasound views of the object.
[0019] According to the present invention, the target plate has visual features of known dimensions which permit measurement of its distance from, and orientation with respect to a fixed monitoring device such as a video camera which may be temporarily secured to a fixed structure such as a bed on which a patient is lying. For example, the target plate may contain at least one pair of lines that intersect at a known angle, and preferably contains two pairs of parallel lines that are mutually perpendicular, forming a rectangle. When photographed at an arbitrary oblique angle, the image of the target rectangle is in general a quadrilateral. A coordinate transformation and image mapping method is then used to map the intersecting lines of an arbitrary image such as a quadrilateral into the rectangular “real world” shape of the target plate. A preferred method of performing the coordinate transformation and image mapping is that disclosed in U.S. Pat. No. 5,967,979. Using the same coordinate transformation which is used to map an oblique view of the image plate into a normal view thereof, the distance of the wand from the video camera, and its angular orientation with respect to the camera, may be precisely determined for each ultrasound image scan performed by the wand. Also, since the scan pattern of ultrasonic energy emitted by the wand bears a fixed relationship to the wand, precisely determining the position and orientation of the wand precisely determines the location and orientation of each ultrasound image slice relative to a patient and object of interest. The novel method and apparatus according to the present invention utilizes that information to calculate a coordinate transformation matrix which is then used to construct a three-dimensional image representation of the sequence of two-dimensional image slices, utilizing the orientation and position of each slice relative to a fixed reference frame. This three-dimensional image representation of sensor image slices enables an object scanned by the sensor to be visualized in three dimensions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a block diagram of an apparatus for photogrammetric orientation of ultrasound images according to the present invention.
[0021] [0021]FIG. 2 is a partially diagrammatic perspective view of an image acquisition portion of an apparatus for photogrammetric orientation of ultrasound images according to the present invention.
[0022] [0022]FIG. 3 is a simplified flow chart showing operation of the present invention.
[0023] [0023]FIG. 4 is a diagrammatic perspective view showing the orientation of a target plate affixed to an ultrasound imaging wand, the beam pattern of imaging energy emitted by the wand, and an idealized object scanned by the beam at a first position and orientation to form a first sonogram consisting of a first two-dimensional image slice of the object.
[0024] [0024]FIG. 5 is a plan view of the first sonogram obtained as shown in FIG. 4.
[0025] [0025]FIG. 6 is a perspective view in which the first sonogram comprising a two-dimensional object image slice obtained as shown in FIG. 4, has been properly oriented, shaped and sized with respect to a fixed reference frame by the same coordinate transformation used to form a normal view of the target plate.
[0026] [0026]FIG. 7 is a view similar to that of FIG. 4, but showing the wand and target plate of FIG. 4 oriented to obtain a second two-dimensional image slice of the object.
[0027] [0027]FIG. 8 is a plan view of the second sonogram obtained as shown in FIG. 7.
[0028] [0028]FIG. 9 is a view similar to that of FIG. 6, but showing a transformed image of the second two-dimensional image slice added thereto.
[0029] [0029]FIG. 10 is a view similar to that of FIG. 4, but showing the wand and target plate of FIG. 4 oriented to obtain a third two-dimensional image slice of the object.
[0030] [0030]FIG. 11 is a plan view of the third sonogram obtained as shown in FIG. 10.
[0031] [0031]FIG. 12 is a view similar to that of FIG. 6, but showing a transformed image of the third two-dimensional image slice added thereto.
[0032] [0032]FIG. 13A is a perspective view showing a partial image of the object of FIG. 4, in which the partial image is properly oriented, shaped and sized relative to a fixed reference frame.
[0033] [0033]FIG. 13B is a perspective view showing a complete image of the object of FIG. 4, in which the image is properly oriented, shaped and sized relative to a fixed reference frame.
[0034] [0034]FIG. 14 is a perspective view showing an ultrasonic imaging transducer wand and target plate according to the present invention, located in a first position and orientation on the abdomen of a patient.
[0035] [0035]FIG. 15 is a photographic view of a CRT screen showing an ultrasound image slice obtained with the arrangement shown in FIG. 14.
[0036] [0036]FIG. 16 is a view similar to that of FIG. 14, but showing the wand at a second position and orientation.
[0037] [0037]FIG. 17 is a view similar to that of FIG. 15, but showing a CRT display for the ultrasound image slice obtained with the ultrasound wand located as shown in FIG. 16.
[0038] [0038]FIG. 18 is a view similar to that of FIG. 14, but showing the wand at a third position and orientation.
[0039] [0039]FIG. 19 is a view similar to that of FIG. 15, but showing the CRT display for an ultrasound image slice obtained with the ultrasound wand located as shown in FIG. 18.
[0040] [0040]FIG. 20 is a view similar to that of FIG. 14, but showing the wand at a fourth position and orientation.
[0041] [0041]FIG. 21 is a view similar to that of FIG. 15, but showing a CRT display for an ultrasound image slice obtained with the ultrasound wand located as shown in FIG. 20.
[0042] [0042]FIG. 22 is a diagrammatic view showing the coordinate system of a target plate/ultrasound wand, and that of a camera used to image the target plate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] FIGS. 1 - 22 illustrate an apparatus and methods according to the present invention for photogrammetrically orienting two-dimensional ultrasound image slices of an object into a three-dimensional view of the image slices, thereby enabling three-dimensional visualization of the object.
[0044] Referring first to FIGS. 1 and 2, an apparatus 30 for photogrammetric orientation of ultrasound images according to the present invention may be seen to include an image acquisition apparatus 50 . As shown in FIG. 2, image acquisition apparatus 50 according to the present invention includes a visual imaging device 51 which is capable of recording a sequence of optical images. Thus, imaging device 51 may be a still photographic film camera such as a 35 mm camera or film motion picture camera. Preferably, however, imaging device 51 is of a type which produces real-time electronic representations of an optical image, rather than one such as a film camera which requires photographic processing of film and subsequent electro optical scanning of film images to obtain electronic images. Thus, imaging device 51 is preferably a digital camera or camcorder. Alternatively, imaging device 51 may consist of a video camera that outputs an electronic image signal which is recorded on an external electronic memory such as a computer hard disk, floppy disk, or the like.
[0045] Referring still to FIG. 2, it may be seen that imaging device 51 is used to form an image 52 at the focal plane 53 of the device. As shown in FIG. 2, imaging device 51 is fixed with respect to a stationary object, such as a hospital bed (not shown), and has a field of view which encompasses an ultrasonic imaging transducer wand 54 located in proximity to a subject such as a patient lying on a hospital bed. Wand 54 has affixed thereto a target plate 55 which has contrasting visual features of a predetermined size and shape. In the example embodiment of image acquisition apparatus 50 shown in FIG. 2, ultrasonic imaging transducer wand 54 has a bulbous shape similar to that of an egg cleaved along a vertically disposed medial plane parallel to the long axis of the egg to form a flat front surface 56 . This type of transducer emits an ultrasonic energy beam which is directed in a generally conically-shaped scan pattern having a triangular trace in a plane generally perpendicular to front surface 56 of the transducer, and produces a similarly shaped ultrasound image field pattern, as shown in FIGS. 4 and 5.
[0046] Referring still to FIG. 2, it may be seen that target plate 55 , which is preferably mounted flush with and parallel to front face 56 of ultrasonic transducer wand 54 , has a generally rectangular, preferably square shape, and has a rectangular central area 57 concentric with the perimeter 58 of the target plate. Central area 57 of target plate 56 is preferably of a different color or darkness than the remainder of the target plate. Thus, as shown in FIG. 2, central area 57 of target plate 55 may be of a light color, such as while, while the remainder of the target plate may be of a darker color, such as black.
[0047] Referring still to FIG. 2, it may be seen that apparatus 30 includes an ultrasonic imaging apparatus 58 which is connected by an electrical cable 59 to ultrasonic imaging transducer wand 54 . Ultrasonic imaging apparatus 58 is of a conventional type, such as a General Electric brand LOGI Q 500 model number. The construction and function of typical ultrasonic imaging apparatus of this type is described in Havlice and Taenzer, “Medical Ultrasonic Imaging: An Overview of Principles and Instrumentation,” Proc. IEEE, Vol. 67 , pp. 6200-641 , April 1979.
[0048] Ultrasonic imaging apparatus 58 contains electronic circuitry for producing electrical signals of ultrasonic frequency which drive a piezoelectric or magnetostrictive ultrasonic transducer in wand 54 , and cause the transducer to emit a beam of energy directed to an object of interest, such as a fetus or other Internal Biological Feature (IBF). Typically, the ultrasonic energy beam emitted by the transducer in wand 54 is mechanically or electronically scanned to form a generally fan-shaped pattern, i.e., in the shape of a truncated isosceles triangle with the vertex located at the transducer, as shown in FIGS. 2, 4 and 5 . This type of scan format is referred to as a sector scan. During a period when ultrasonic drive energy to the transducer within transducer wand 54 , is interrupted, the transducer functions in a receive mode, converting ultrasound signals reflected from an IBF into electrical information signals. The latter are used to form an image 60 of a region scanned, the image being displayed on the screen of a LCD, CRT or other display device monitor 61 .
[0049] Image 60 appears on monitor 61 within an active display area 60 A shaped similarly to the scan pattern of the ultrasonic energy beam transmitted by transducer wand 54 . In this display, referred to as a B-scan or brightness mode scan, the angular coordinate position of an object feature in the scanned image field 60 A is indicated by the angular position of radial display lines corresponding to the instantaneous directions of an ultrasonic energy beam emitted by the transducer. Radial coordinate positions of an object from the common vertex of ultrasound energy beam scan lines, which intersect at the transducer, are determined by measuring the time delay between the emission of an ultrasonic energy pulse, and a return signal reflected from a feature and received by the transducer. The radial coordinates of object features in display area 60 A of monitor 61 are displayed at a proportional distance from the vertex of the display area, and the strength of the reflected signals are indicated by modulating the brightness of display pixels. Ultrasound imaging apparatus 58 also includes electronic memory means 62 for storing a sequence of ultrasound images 60 , referred to as monograms.
[0050] Referring now to FIG. 1, it may be seen that apparatus 30 according to the present invention includes components functionally interconnected with visual image acquisition apparatus 50 and ultrasonic imaging apparatus 58 shown in FIG. 2 and described above, to perform a photogrammetric orientation of ultrasound images according to the method of the present invention.
[0051] As shown in FIG. 1, apparatus 30 includes a computer 64 . As will be described in greater detail below, computer 64 is utilized to precisely determine the instantaneous location and orientation of ultrasonic imaging wand 54 relative to a fixed imaging device 51 for each two-dimensional image slice or sonogram in a sequence of sonograms obtained by changing the orientation and/or location of the wand relative to an Internal Biological Feature (IBF) or other feature of interest. This step is performed by forming an oblique view image of target plate 55 with imaging device 51 , and transforming and scaling the oblique image into a correctly scaled normal view image of the target plate using the method described in detail in U.S. Pat. No. 5,967,979, the entire disclosure of which is hereby incorporated by reference into the present specification.
[0052] Since target plate 55 is fixed to ultrasound scanning wand 54 , precisely determining the orientation and location of target plate 55 precisely determines the orientation and location of the ultrasound scanning wand. Therefore, the method described in the '979 patent enables determination of the precise orientation of the scanned ultrasound energy beam relative to a feature of interest, and therefore the location and orientation of sonogram slices obtained of the feature. According to the present invention, the precise orientation and location of each sonogram slice relative to a fixed coordinate reference frame, e.g., one in which a patient and imaging device 51 are fixed, is used to construct an assembly of correctly scaled and oriented three-dimensional views of ultrasound image slices of the object, using software such as VOXELVIEW, version 1.0, obtainable from Vital Images, Inc., 3300 Penbrook Avenue North, Plymouth, Minn. 55447, or IDL, version 3, also obtainable direction from Vital Images. This enables the object to be visualized in three dimensions.
[0053] Referring still to FIG. 1, it may be seen that apparatus 30 according to the present invention includes means for inputting into computer 64 electronic image signals of wand 54 and target plate 55 obtained by imaging device 51 , the computer being used to compute instantaneous normal view images of the target plate and wand. Apparatus 30 also includes means for inputting into computer 64 a sequence of electronic image frames, one for each sonogram that represents a two-dimensional image slice of an internal biological features.
[0054] As shown in FIG. 1, apparatus 30 includes a first, visual image frame grabber 65 which converts each visual image signal 66 obtained by optical imaging device 51 into a separate frame of image data for each of a sequence of images. Operation of visual image frame grabber 65 is controlled by a system control electronic module 67 , which issues a command signal, timing signal, and frame identification signal when it is desired to capture and store a particular image frame input to the frame grabber by optical imaging device 51 . Each optical image frame thus captured and stored is electronically identified with a sonogram obtained simultaneously with the optical image of transducer wand 54 and target plate 55 , thus recording the precise orientation and location of the wand during the sonogram scan. Frame capture command signals may be issued at predetermined times by system control module 67 , or manually by an external command instruction issued by the ultrasonographer. Although system control module 67 is shown in FIG. 1 to be separate from computer 64 , functions of the system control module could of course be performed by the computer with appropriate interface electronics and software, as will be understood by those skilled in the art.
[0055] As shown in dashed lines in FIG. 1, imaging device 51 could optionally be replaced by a photographic still camera 51 A. In this case, a separate photographic film image 52 A is made of ultrasonic wand 54 and target plate 55 for each sonogram obtained using the wand. The exposed film must then be processed in a conventional manner to develop the latent photographic images on the film, the developed film images scanned using an optical scanner 68 and an analog-to-digital (A/D) converter 69 used to convert the analog two-dimensional film image into a digital image, which is input into computer 64 in place of electronic images output from frame grabber 65 . However, because of the difficulty of synchronizing real-time sonograms with subsequently processed photographic film image, electronic imaging by video camera 51 is a preferred method. Alternatively, camera 51 A could be a digital camera, in which case scanner 68 and A/D converter 69 would be replaced by a digital memory means such as a flash memory card.
[0056] Referring still to FIG. 1, it may be seen that apparatus 30 includes a second, ultrasound image from grabber 75 which converts electronic ultrasound image signals 60 E corresponding to sonograms 60 obtained by ultrasonic imaging apparatus 58 into a separate frame of image data for each of a sequence of sonograms showing separate image slices of an internal biological feature. Each ultrasound image frame 60 E corresponding to a separate sonogram 60 is stored electronically along with a timing code and identification code that associates each sonogram with an optical image frame of the transducer wand 54 and target plate obtained simultaneously with the particular sonogram.
[0057] As described above computer 64 of apparatus 30 performs on each optical image 66 of wand 54 and target plate 55 a coordinate transformation which determines the precise orientation and location of the wand at the time a sonogram 60 associated with the optical image is formed. Since the ultrasonic fan beam emitted by transducer wand 54 to form a sonogram image bears a fixed geometric relationship to the transducer, determining the precise location and orientation of the wand determines the exact trajectory of the image-forming beam relative to a fixed reference frame. In a typical example embodiment of the present invention, an ultrasound beam 76 is emitted in a plane perpendicular to front face 56 of the transducer wand, with the vertex of the beam located behind the front face and centered on a longitudinally disposed, vertical medial plane of the wand, as shown in FIG. 2.
[0058] Construction of a three-dimensional assembly of two-dimensional sonograms taken at different orientations of ultrasound beam 76 is performed by apparatus 30 in the following manner.
[0059] Referring again to FIG. 1, it may be seen that transformed normal view images 77 of ultrasound wand 54 and target plate 55 are input to a computer 78 , which may be part of computer 64 . The transformed normal view images are used to indicate the relative spacing between ultrasound wand 54 and an object of interest, and the orientation of the wand relative to the object, for each sonogram obtained of the object. Using this information, computer 78 constructs in a three-dimensional image space 79 three-dimensional images of a sequence of two-dimensional sonogram image slices, in the manner shown in the following example.
[0060] Referring now to FIG. 4, a solid cone A is shown as an example object of interest to be visualized using the method and apparatus 30 according to the present invention. As shown in the example of FIG. 4, cone A, which could as well be a fetus or other internal biological feature of interest to an ultrasonographer, is scanned by a beam 76 emitted by ultrasound wand 54 having a first location and orientation to form a first sonogram. The position and orientation of the want relative to cone A during the first scan are determined by calculating the size and orientation of visual features on target plate 55 , using the coordinate transformation described in U.S. Pat. No. 5,967,979 and cited above. As shown in FIG. 4, the orientation of front face 56 of transducer wand 54 is parallel to the central, vertically orientated axis B of cone A. With this arrangement, ultrasound image beam 76 lies in a horizontal plane which intersects cone A a short distance below the vertex C of the cone. Thus, a first sonogram of cone A, as shown in FIG. 5, consists essentially of a circular area having a first diameter, d 1 . Using the VOXELVIEW reconstruction software described above, a first image slice is therefore reconstructed which is a circle of a first diameter, D 1 , scaled in a ratio K to d 1 , and in a three-dimensional image space 79 , shown in FIG. 6, a perspective view of circle D 1 , is constructed.
[0061] Next, as shown in FIG. 7 of the present example, ultrasonic imaging wand 54 is relocated to a second position, e.g., a position lower than that shown in FIG. 4, and the wand tilted obliquely upwards with respect to its orientation shown in FIG. 4. At this second location and orientation, a second sonogram is made of cone A, with fan beam 76 of wand 54 intersecting the cone at an oblique angle. Thus, as shown in FIG. 8, a second sonogram of cone A consists essentially of an elliptically shaped area having a major axis e, and a minor axis f. Using the VOXELVIEW reconstruction software, a reconstruction of the second sonogram image slice in three-dimensional image space 79 , as shown in FIG. 9, is therefore an ellipse having a major axis E, and a minor axis F that are scaled in the same ratio K used to scale each sonogram into three-dimensional image space 79 .
[0062] [0062]FIG. 10 of the present example shows ultrasonic imaging want 54 oriented to a third position intermediate in height between positions 1 and 2 shown in FIGS. 4 and 7, but inclined obliquely downward from a horizontal plane. At this third location, a third sonogram is made of cone A, with fan beam 76 of wand 54 intersecting the surface D and base E of the cone at an oblique angle. Thus, as shown in FIG. 11, a third sonogram of cone A consists essentially of a semi-elliptical area having a major axis g, and a truncating chord h. Using the VOXELVIEW reconstruction software, a reconstruction of the third sonogram slice in three-dimensional image space 79 as shown in FIG. 12, is therefore a semi-ellipse having a major axis G, and a truncating chord H, that are scaled in the ratio K used to scale each sonogram into three-dimensional space 79 .
[0063] [0063]FIG. 13A shows a three-dimensional image space 79 in which the transforms of sonogram images shown in the example FIGS. 4 - 12 have been assembled together in a properly arranged and scaled and oriented relationship. FIG. 13B shows a surface 80 which is constructed using the rendering portion of the VOXELVIEW program, visually, for example, by mentally extending a plurality of directrix lines 81 through the perimeters of a stack of substantially planar image transforms. As shown in FIG. 13B, surface 80 formed by directrix lines 81 defines a conical transferred image object A, having an altitude B 1 and a base E 1 which is a correctly scaled and proportioned representation of the object cone scanned by ultrasound fan beam 76 .
[0064] Referring now to FIGS. 14 - 21 , it may be seen how apparatus 30 according to the present invention is used to form a three-dimensional visualization of an actual object of interest using the method shown in FIGS. 4 - 13 and described above. Thus, as shown in FIG. 14, ultrasonic imaging wand 54 is located in a first position and at a first orientation relative to the abdomen J of a patient K. At this first position and orientation of transducer wand 54 , a first sonogram 82 - 1 , shown in FIG. 15, is obtained of an internal biological feature (IBF) such as a fetus L.
[0065] In an exactly similar manner, additional sonograms 82 - 2 through 82 - 4 are obtained of fetus L, as shown in FIGS. 16 - 231 . Using the transformation method described above, a three-dimensional representation of fetus 80 L is then visually constructed in image space 79 . Three-dimensional images 80 , such as that of fetus 80 L may be displayed on a system monitor 83 , and electronically stored for future access.
[0066] The process used to position the ultrasound image slices in 3D space to thereby enable three-dimensional visualization of an object scanned by an ultrasound beam is described in somewhat greater detail below:
[0067] Background:
[0068] There is understood to be a coordinate system, XYZ, based on the camera's point of view, with the following characteristics:
[0069] the viewpoint (or ‘eye’) is at (O,O,O) 0
[0070] the camera is looking in the negative-Z direction
[0071] the positive-X axis extends to the right of the camera's view
[0072] the positive-Y axis extends to upward in the camera's view
[0073] There is also a coordinate system, xyz, for each ultrasound frame based on the target rectangle attached to the ultrasound wand, with the following characteristics (assuming that the wand is pointing downward as we look at the target plate with its Y-axis pointing to:
[0074] the origin (O,O,O) t is the lower left corner of the target rectangle
[0075] the positive-x axis extends to the right along the bottom edge of the rectangle
[0076] the positive-y axis extends upward along the left edge of the rectangle
[0077] the positive-z axis extends perpendicular to the target rectangle, toward us
[0078] Within a target's coordinate system, each image pixel's location can be calculated, knowing the following:
[0079] xyz position of the top-center point of the acquired image (given in cm as, for example, (u.0,−3.0,−1.0))
[0080] size of a pixel in x and y direction (for example, each equal to 0.025 cm)
[0081] The method of the present invention utilizes placement of the pixel data from each frame into a single 3-D space based on the camera's view. This requires transformation from each target's coordinate system to the camera's coordinate system.
[0082] A 4×4 transformation matrix may be used to represent any combination of the translation, rotation and scaling of a 3-dimensional coordinate system. Thus, the matrix describes translation of the origin, rotation of xyz axes to another orientation, and optionally, change in scale (although re-scaling is not required in this application). Any number of separate translation and rotation steps can be combined into a single transformation matrix, which will contain the result of all steps performed in sequence.
[0083] In the present application, each ultrasound frame provides the following:
[0084] grayscale image from ultrasound imaging system
[0085] target rectangle measurement data from vision system; i.e., position, aim, rotation
[0086] Procedure:
[0087] The target-to-camera coordinate system transformation matrix is calculated for an ultrasound frame from the position, aim and rotation values for the frame. The image pixel data for this frame is then transformed into the camera's coordinate system by multiplying each pixel's xyz location in the target's coordinate system by this transformation matrix.
[0088] Referring now to FIG. 22, the 4×4 target-to-camera transformation matrix can be determined from these given values:
[0089] p 3-element floating-point vector (xyz) T giving the position of the camera in the target's coordinate system.
[0090] a 3-element floating-point vector (xyz) giving the position of a point directly ahead of the camera in the target's coordinate system (this defines the -Z-axis of the camera's coordinate system).
[0091] r A floating-point scalar giving the angle between bottom edge of the photograph and the line where the plane of the photograph intersects the plane of the target plate. (In radians.)
[0092] To generate the transformation matrix, the camera coordinate system axis vectors XYZ C are calculated with respect to the target coordinate system with axes XYZ T :
[0093] Z-axis:
[0094] Z has a direction from point a to point p (opposite the aim vector).
[0095] X-axis:
[0096] The direction L is calculated; i.e., the direction of the line of intersection of the xy plane and the XY plane (Z).
[0097] XY plane:
[0098] L is equal to the cross product of the normal to the xy plane (z) and the normal to XY plane (Z).
[0099] Vector L is rotated by R radians on the XY plane:
[0100] Rotations qy and x around y are then calculated to bring vector Z to point along z-axis
[0101] Vector L is rotated by R radians on the xy plane.
[0102] Opposite rotations −qy and −qx are applied to bring rotated vector L to point within the XY plane, giving final X vector.
[0103] Y-axis:
[0104] Vectors X and Z and the right-hand rule, give vector Y.
[0105] X and Z are combined together, and rotations iz, iy, ix (around z,y,x) needed to bring them to match x and z calculated.
[0106] The transform of rotations rz, ry, rx is calculated
[0107] Point −P is transformed to calculate the target origin point in camera coordinate system
[0108] The translation of that point is added to the transform to complete the matrix
[0109] Having calculated the transformation matrix, each pixel point is multiplied by this matrix to determine its position in camera space. | 4y
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This a continuation-in-part of application Ser. No. 896,880 filed Aug. 15, 1986, now abandoned.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a machine that simulates a human boxer by throwing punches at a user and receiving punches thrown by the user in return.
The need for continued aerobic exercise is essential in order to maintain cardiovascular fitness and muscle tone and to prevent weight gain. Those whose normal activities do not provide sufficient exercise to meet these needs must engage in a regular exercise program which does. However, home exercises are by nature repetitive and thus quickly become boring for most people. As a result, it becomes difficult to continue with a home exercise program and many people fail to exercise on a regular basis even after having spent a considerable sum for equipment which facilitates the process.
The present invention provides an exercise device which not only permits the user to achieve a high level of aerobic activity but does so in a manner which most people find entertaining, and which by its very nature motivates people to continue its use on a regular basis.
This is accomplished by providing a machine which looks like a boxer and throws punches repeatedly when in operation and which can be punched by the user in return, without injury to either the machine or the user. The user must continue to remain in motion when using the machine or be hit. Furthermore, stepping away from the machine is psychologically difficult, since doing so is an admission that the machine has won. Therefore, the user will be driven to continue exercising with the machine once started, and competetive instinct will cause the user to continue to use the machine on a regular basis. By varying the speed at which the punches are thrown and the frequency at which they are repeated, the machine can be adjusted to accommodate people with a wide variety of exercise capability and boxing skill thereby allowing it to be used by almost anyone.
The machine comprises a pair of simulated arms one of which is attached to each end of a shoulder assembly by rotatable joints. The arms are divided into upper and lower portions which are joined together through hinged joints. The upper portion is a four-bar parallelogram linkage, with the extremities of both long bars having independent joints. Thus if one of these joints is moved away from the other joint the upper and lower arm portions rotate away from each other and become more horizontal and the arm is extended. On the other hand if the two joints are moved together the arm portions rotate toward one another and the arm is retracted.
Relative movement of the joints is achieved by the shoulder assembly which they are attached to having two links, one which swings upon shoulder rotation and one which remains stationary. The two shoulder links are approximately the same length but the stationary link has articulated end portions. The ends of the swinging link, which is located forwardly of the stationary link, are attached to the forward joints of the upper arm portions, and the ends of the stationary link are attached to the rearward joints of the upper arm portions. When one end of the swinging link is rotated forward the articulated end of the stationary link follows it but does not move as far forward. Thus, as one side of the shoulder is moved forward the rearward joint moves toward the forward joint and the arm is extended. As a result the device duplicates a normal punching action by simultaneously moving the arm forward at the shoulder as it is extended.
The stationary shoulder link is attached to a fixed support which is carried in an upright position by means of a base. In a first embodiment of the invention the base comprises tanks which are filled with water or sand to provide the weight necessary to stabilize the device and absorb a portion of the energy resulting from the machine throwing or receiving a punch. In a second embodiment of the invention, the base comprises an articulated support having a dampening cylinder which absorbs the punching energy. The swinging shoulder link is attached to a rotating support which is coaxial with the fixed support and which rotates relative to it. A motor, having a first sprocket driven by it, is attached to the fixed support and a second sprocket is attached to the rotating support co-planar with the first sprocket. A belt, having cleats which engage the sprockets, rotatably interconnects them. Thus, the shoulders swing clockwise, looking from above, when the motor is rotated in one direction, to extend the left arm and retract the right arm, and counter-clockwise when the motor is rotated in the other direction, to extend the right arm and retract the left arm.
A controller, which can be activated by either a microprocessor or manual controls, operates the motor in the proper direction and at the desired speed. The microprocessor also can be programmed to make the machine throw combinations of punches in predetermined patterns in order to simulate an actual boxer.
Located on the rotating support, below the shoulder, is a series of thin oblong hoops which simulate the boxer's ribs. The ribs, as well as the arms, are made of an ultrahigh molecular weight polyethylene and thus are strong enough to withstand a high impact without breaking and yet flexible enough not to injure the user, even when a punch makes direct contact. A simulated fist is located at the extremities of each arm and a simulated head is placed on top of the fixed support. The entire device is covered with a foam wrap, which, along with the flexibility of the ribs, allows users to hit the machine without injuring themselves.
Accordingly, it is a principal object of the present invention to provide an exercise machine which can throw punches and which can receive punches in return.
It is a further object of the present invention to provide such a machine in which the arms move forward and extend simultaneously when a punch is being thrown.
It is a further object of the present invention to provide such a machine which can be programmed to throw a prearranged series of punches or can be manually controlled to throw individual punches upon command.
The foregoing and other objectives, features and advantages of the present invention will be more readily understood upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, partially broken away to show hidden detail, of a boxing machine embodying the features of the present invention, with one of its arms being shown in an extended position in dashed line.
FIG. 2 is a front elevational view of the boxing machine.
FIG. 3 is a plan view of the boxing machine.
FIG. 4 is a plan view of the boxing machine with the shoulder rotated.
FIG. 5 is a view of the boxing machine fully wrapped.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, the boxing machine of the present invention is carried by an upright support 10 comprising a fixed portion 12, which generally is as long as the machine is tall, and a rotating portion 14, which is shorter than the fixed portion and is rotatably mounted on it. The fixed portion 12 is cylindrical in the embodiment illustrated, and itsupper end 12a is angled forwardly. A platform 16, attached to the fixed portion 12 immediately below the bottom of the rotating portion 14, contains a thrust bearing 18 which positions the rotating portion longitudinally on the fixed portion and permits it to rotate relative thereto. An electric motor 20, which is mounted on the platform 16, has a first sprocket 21 attached to its output shaft 22. A second sprocket 23, which has a considerably larger diameter than the first sprocket 21, is attached to the rotating portion of the support. A continuous belt 24, having cleats formed in its inner surface, fits around the first and second sprockets and rotatably joins them. Limit switches 25 located on the platform 16 prevent rotation of the rotating portion relative to the fixed portion beyond predetermined limits. Thus, the rotating portion rotates clockwise relative to the fixed portion when the motor is run in one direction and counterclockwise when the motor is reversed.
Attached to the fixed portion 12 of the support 10 are several simulated ribs 26. The ribs are in the form of oval hoops and are made from an ultrahigh molecular weight polyethylene. Thus, they are flexible enough to easily be deflected when hit and yet will not break. In addition, the deflection of the ribs when they are hit, absorbs a portion of the energy of a punch and thus helps prevent the machine from being tipped over. The size of the ribs varies progressively along the support with the top one having a larger hoop size than the bottom one.
Attached to the upper end of the rotating portion of the support are a pairof simulated arms 28 which can be moved between a retracted or cocked position (solid line position in FIG. 1 and an extended or punching position (dashed line position in FIG. 1). In order to achieve this movement, the arms are divided into upper portions 30, which are rotatableabout first hinged joints 32, and lower portions 34 which are rotatably attached to the upper portions by means of second hinged joints 35. The arms preferably are constructed from the same material that the ribs are.
In order to facilitate movement between the retracted and extended positions, the upper arm portions 30 comprise four-bar parallelogram linkages, and the first hinged joints 32 comprises forward pivots 36, which are located at the ends of one of the longer bars 30a of the linkages and rearward pivots 38, which are located at the ends of the other longer bars 30b of the linkages. The inner portions of the lower arms 34 comprises one of the shorter bars of the parallelogram linkage andthe linkage is arranged such that when the forward and rearward pivots 36 and 38 are moved apart the upper and lower arms rotate away from one another and become more horizontal, and when the forward and rearward pivots are moved together the upper and lower arms rotate toward one another and become more vertical.
This relative movement of the forward and rearward pivots is accomplished by means of a simulated shoulder 40, which is best seen in FIGS. 3 and 4. The shoulder comprises a swinging link 41 which is attached to the rotating portion 14 of the support 10, and a stationary link 42 which is attached to the fixed portion 12 of the support. The ends of the swinging link 41 carry the forward pivots 36, and the ends of the stationary link carry the rearward pivots 38. The stationary and swinging links have approximately the same length, however, the outer portions 42a of the stationary link are articulated with respect to the center portion 42b. Asa result, while both the forward and rearward pivots 36 and 38 in an arm are moved forward when the side of the shoulder attached to that arm is rotated forwardly, the rearward pivot is not moved as far forward as the forward pivot, due to the rotation of the outer portion 42a of the stationary link, FIG. 4. As a result, when the shoulder is rotated the armattached to the side which is moved forward is extended and the arm attached to the side which is moved rearward is retracted giving a naturalpunching action with the shoulder rotating forwardly simultaneously with the extension of the arm.
Referring to FIG. 5, a simulated head 44 is mounted on top of the fixed support portion 12, and simulated gloved fists 46 are mounted at the extremities of the lower arm portions. The entire device is then wrapped with a foam skin to give it a human appearance. The machine is held in an upright position by means of a base which snugly receives the lower extremity of the fixed support.
In a first embodiment of the invention, shown in FIGS. 1-4, the base comprises a series of resilient tanks 48 which mechanically interconnect to form an integral unit. The tanks are hollow in order to receive sand orwater to provide the necessary weight in use without being overly heavy when being transported. In addition, the sand or water will permit the base to be deflected when the machine throws a punch or is punched in return by the person using it. Thus, the energy created is dissipated and the machine does not move when in use.
In a second embodiment of the invention, shown in FIGS. 6 and 7, the base comprises a foot 56 which is formed from two parallel, spaced apart box beams 58, having one end attached to the center of a shorter box beam 60 to form a T-shaped end. Extending upwardly at approximately a 45° angle from the box beam 60, near the T-end of the foot 56, is a brace 64 which has approximately the same length as the box beams 56 and 58. Thus, the end of the brace lies slightly inwardly from the end of the foot whichis opposite the T-end. A short tie beam 66 extends between the brace and the foot to make the brace more rigid.
Rotatably attached to the upper extremity of the brace 64 is a short floating support 68. The fixed support 12 is connected to the floating support intermediate its ends with the two elements being perpendicular toone another. A pneumatic dampening cylinder 70 extends between the free endof the floating support and an upright post 72, which is attached to the foot 56. Thus the cylinder 70 resists downward movement of the floating support and absorbs a portion of the energy imparted to the machine by a punch. The piston 74 of the cylinder 70 is surrounded by a compression spring 76 which is sized to support the weight of the boxing machine with the floating support being parallel with the foot 56. The spring stores punching energy as it is compressed and directs its force in a direction opposite to that caused by the punches which prevents tipping of the machine. The spring also returns the machine to its normal upright position after it has received a punch.
In use, when the machine is punched or throws a punch the floating support 68 rotates against the piston 70 and spring 76 to absorb most of the force. The remaining force is transmitted through the brace 64 to the foot56 which, due to its length, prevents the machine from tipping over.
A control system 50 initiates operation of the motor 20 to achieve rotationof the shoulder in the proper direction, and thus achieve extension of the associated arm. This can either be accomplished manually, by means such asa joy stick 52, or automatically, by means of a microprocessor 54. In the latter case a commercially available microprocessor can be programmed to throw a series of punches in combination in a predetermined cycle. In either case, the control system can include speed adjustment means for controlling the rotational speed of the motor, and thus the speed of the punches thrown by the machine. Circuitry which will perform the foregoing control function can be devised easily by one skilled in the electronic arts.
In use, once the machine has been started the user can spar with it similarly to sparring with another person by attempting to block the punches being thrown by the machine and by punching the machine back. The ultra high molecular weight polymer used for the arms and ribs is sufficiently strong that it will not break under these circumstances and yet is sufficiently flexible that the punches thrown by the machine will not injure the user. The machine will maintain the user in an aerobic state as long as it is in operation unless the user steps back away from it. This is because merely defending oneself and blocking the punches thrown by the machine requries a high level of output and if one doesn't continue doing so he will be hit by the machine. Throwing punches in return adds to the activity level of the user, and, in addition, will cause development of a wide variety of muscles in the upper body and legs.Unlike most forms of aerobic exercise which can be performed in the home, the boxing machine of the present invention maintains the interest level of the user, and as a result, is not burdensome to use. Thus, the user is more likely to continue the exercise program on a regular basis.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow. | 4y
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This is a division of application Ser. No. 584,564, filed June 6, 1975 now abandoned.
BACKGROUND OF THE INVENTION
Cryogenic powder making is a relatively new mode of providing a powdered raw material which can be put to use in powder metallurgy techniques and other applications. Cryogenic powder holds great promise because it can provide powdered material at a significantly lower cost and it may result in more useable physical properties, if not enhanced physical properties, for a sintered powdered part.
Essentially cryogenic powder making comprises subjecting scrap metal, or other solid starting metal material, to a temperature below the transition temperature of said metal, such as -(30°-40)° F for ferrous based material. The metal becomes so brittle at such depressed temperatures that agitation within a conventional ball mill will reduce the scrap or starting metal material to a powder form over a predetermined period of time and stress from the ball milling elements. At the same time, any oil or other organic materials coating the scrap metal, particularly scrap metal in the form of machine turnings, will also freeze and be removed during the impaction by the ball milling elements; such frozen debris can be screened and separated.
To insure that the scrap metal is in the embrittled condition at the point of impaction, it is necessary to direct a supply of liquid nitrogen against the scrap metal immediately prior to introducing the scrap metal into the mill itself. The comminuted particles resulting from a predetermined amount of ball milling under such embrittled conditions, produces metal particle shapes which are flake-like or irregular, certainly not spherical. The layer-like or flake configuration results from the two facts: (a) the turning was originally ribbon-like, and (b) comminution takes place by fracture.
When such cryogenically produced powder is subjected to conventional powder metallurgy techniques, with a compacted quantity of such powder being heated to a sintering temperature, oxidation of ingredients such as manganese and silicon will typically take place prior to diffusion and completion of the sintering step. Such oxidation results because these elements require more sintering atmosphere control than is normally possible in current, more stringent operations.
SUMMARY OF THE INVENTION
A primary object of this invention is to provide a method of making sintered shapes, which method improves the diffusion kinetics for cryogenically produced powders utilized in such method. Other method objects of this invention comprise (a) a method of making an intermediate powder useful in powder metallurgy techniques, (b) an intermediate powder composition made from scrap machine turnings, and (c) a method of making a cold compacted shape which can be shipped as a commodity useful in subsequent sintering techniques to make a stable permanent metal part.
Another principal object of this invention is to upgrade the physical properties of cryogenic powder and in certain respects to surpass the physical properties of any carbon steel type powder irrespective of whether it is atomized or cryogenically produced.
Yet still another object of this invention is to produce a powder derived from a variety of scrap metal pieces traditionally not useable in scrap melting techniques, the powder so produced being completely substitutable for current commercially made metal powder.
Specific features pursuant to the above objects comprise: (a) continuously impacting the cryogenically produced powder to promote a thin copper shell about substantially each particle of said powder and to provide at least one defect site in each particle of said powder which is in excess of 124 microns, (b) coating and cold working said cryogenically produced powders in a manner to prevent oxidation of alloying ingredients, such as manganese and silicon, (c) imparting strain to a sufficient number of said cryogenically produced powder particles so as to improve atomic diffusion during sintering of said powder, and (d) significantly increasing shrinkage of said sintered powder as a result of improved diffusion kinetics.
SUMMARY OF THE DRAWINGS
FIG. 1 is a schematic flow diagram of the comprehensive method of this invention;
FIG. 2 is a photograph of two sintered shapes, one comprised of cryogenically produced powder and the other comprising conventionally produced atomized ferrous based powder; and
FIG. 3 is a photograph of the fracture surface along one end of each of the specimens illustrated in FIG. 1.
DETAILED DESCRIPTION
A preferred mode for carrying out the method aspects of this invention is depicted in FIG. 1 and is as follows:
(1) Scrap metal and particularly machine turnings 10 are selected as the starting material. "Machine turnings" is defined herein to mean segments of ribbons of low alloy steel. They typically are shavings cut from alloy bar. But machine turnings, preferably ferrous based, include alloying ingredients such as manganese, silicon, chromium, nickel and molybdenum. The turnings should be selected to have a surface-to-volume ratio of at least 60:1, which is characteristic of machine turnings. The scrap pieces will have a size characterized by a width 0.1-1.0inches, thickness of 0.005-0.03inch, and a length of 1-100inches. Machine turnings are usually not suitable for melting in an electric furnace because they prevent efficient melt down due to such surface-to-volume ratio.
This process can be performed with other types or larger pieces of scrap metal, although capital investment costs may increase due to the difficulty of impacting scrap metal sized in particle pieces beyond 0.03inch thick. The scrap pieces should be selected to be generally compatible in chemistry when in the final product; this is achieved optimally when the scrap is selected from a common machining operation where the same metal stock was utilized in forming the turnings.
(2) The selected scrap pieces 10 are then put into a suitable charging passage 11 leading to a ball milling machine 12 or equivalent impacting device. Within the passage, means 13 for freezing such metal pieces is introduced, such as liquid nitrogen; it is sprayed directly onto the metal pieces. Mere contact of the liquid nitrogen with the scrap pieces will freeze them instantly. The application of the liquid nitrogen should be applied uniformly throughout its path to the point of impaction. The ball milling elements 14 are motivated preferably by rotation of the housing 17, to contact and impact the frozen pieces 15 of scrap metal causing them to fracture and be comminuted. Such impaction is carried out to apply sufficient fracturing force (defined to mean less than 1 ft.-lb.) and for sufficient period of time and rate to reduce said scrap pieces to a powder form. The powder 16 will typically have both a coarse and a fine powder proportion. Both proportions will be comprised of particles which are flake or layered in configuration; each particle will be highly irregular in shape and dimension, none being spherical in shape. A typical screen analysis for copper coated powder would be as follows (for a 100 gram sample):
______________________________________ No Milling After 72 Hrs.Mesh (in grams) (in grams)______________________________________60 60.0 31.5100 19.5 11.0140 5.5 7.5200 6.5 18.0325 4.5 22.5+325 4.0 9.5______________________________________
(3) The comminuted cryogenic powder 16 is then subjected to another impacting step, but this time at ambient temperature conditions. The powder is placed preferably in another ball milling machine, the machine having copper laden elements 19 preferably in the form of solid copper balls of about 0.5 inch in diameter. In trials performed herein, the interior chamber was a 3 33 6 inches cylinder, powder charge was 10 in. 3 , and the milling time was about 48 hours. Milling time and rate depend on mill volume, mill diameter size of copper balls, and the speed of rotation. The function of this second impacting step is to transfer, by impact, a portion of the copper ingredient carried by the ball milling elements 19 so as to form a copper shell about substantially each particle of the powder 16. The finer powder will obtain a copper coating by true abrasion or scratching with the surface of the ball milling elements 19. Ball milling elements 19 should have a diameter at least 50 times the largest dimension of any of the particle shapes of the cryogenic powder 16. Secondly, the ball milling operation must generate defect sites in substantially all powder particles above 124 microns; the ball milling operation herein should be carried out so that substantially each coarse particle has at least one defect site therein. This can be accomplished by rotating the housing 20 to impart a predetermined abrading force from the balls 19.
When this step is completed, the particles will be in a condition where they will all substantially have a continuous copper envelope (coating or shell) and be stressed sufficiently so as to have a high degree of cold work. The term "defect site" is defined herein to mean a defect in local atomic arrangement. The term "copper shell" is defined herein to mean a substantially continuous thin envelope intimately formed on the surface of the particle. Although the shell should preferably be an impervious continuous envelope about each particle, it is not critical that it be absolutely impervious. It has been shown, by the test examples performed in connection wih reducing this invention to practice, that cold working of the particles is predominantly influential in increasing diffusion kinetics of this invention, the copper coating or shell operating to predominantly form an anti-oxidation barrier.
(4) A predetermined quantity of powder condition from step (3) is compacted by a conventional press 20 to a predetermined density, preferably about 6.6 g./cc. This is brought about by the application of forces in the range of 30-35 tsi. The presence of the copper envelope about the powder particles improves compressibility. With prior uncoated powders, a density of about 6.4 g./cc. is typically obtained using a compressive force of 85,000 psi; with the powder herein, densities of about 6.6 g./cc. are now obtained at the same force level.
The shape 21 into which such powder is compacted is designed to have an outer configuration larger than that desired for the final part. A significant and highly improved shrinkage takes place as a result of the next step (5); the shrinkage can be a predetermined known factor and allowance can be made in the compacted shape 21 of this step. Shrinkage will be in the controlled limits of 15-15.
(5) The compacted shape 21 is subjected to a sintering treatment within a furnace 22 wherein it is heated to a temperature preferably in the range of 2000°-3100° F, for ferrous based cryogenic powder. The temperature to which the compact is heated should be at least the plastic region for the metal constituting the powder. A controlled or protective atmosphere is maintained in the furnace, preferably consisting of inert or reducing gases.
At the sintering temperatures, atomic diffusion takes place between particles of the powder particularly at solid contact points therebetween; certain atoms of one particle are supplied to fill the defect sites or absence of certain atoms in the crystal structure of the contacting particle, said defect sites being present as a result of cold working in step (3). Diffusion is accelerated to such an extent, that an increase of more than 100 times is obtained. It is theorized that at least 60% of the improvement in physical properties of the resulting sintered shape is due to the controlled cold working of the powder. The increased difffusion is responsible for the increase in shrinkage.
The copper envelope on the particles serves to essentially prevent oxidation of certain elements or ingredients within the powder particles, particularly manganese and silicon. With typical ball milling parameters, (such as physical size of mill speed change and ball size) sufficient to the job, it can be expected that substantially each particle of the cryogenic powder will possess an impervious copper shell. However, a totally impervious shell is not absolutely essential to obtaining an improvement of some of the properties herein.
As a basis for comparison, several as-sintered test samples were prepared. The procedure for preparing the test samples was varied to investigate aspects such as the effect of cold working, the influence of a copper coating without cold working, the manner in which the copper coating is applied, and the influence of particle size. All of the test samples were prepared according to the following fabrication and thermal treatment except as noted. A cryogenically produced powder quantity was admixed with 1% zinc stearate (useful as die wall lubricant) and 0.7-0.8% graphite. The admixture was compacted at a pressure of 25 tons/sq. in. into standard M.P.T.F. transverse rupture strength bars. The bars were preheated at 1450° F. for 20 minutes to burn off the lubricants, the heating was carried out in an endothermic type atmosphere at a 45° F dew point. Sintering was carried out at a higher temperature in the same endothermic atmosphere for an additional 20 minutes.
The first three samples are considered representative of the prior art as a reference base since no separate cold working or copper coating was employed.
______________________________________ Hard-Sample Sintering Transverse Rupture ness As-SinteredNo. Temp. (° F) Strength (psi) (R.sub.B) Density______________________________________1 2050 16,000 62 6.52 2075 20,000 68 6.63 2100 22,000 73 6.6______________________________________
To investigate the effect of cold working, the powder ball milled was in a mill employing steel balls; the ball milling time was varied for each of the three samples in the following sequence: 20 hours, 44 hours and 96 hours.
______________________________________ Hard-Sample Sintering Transverse Rupture ness As-SinteredNo. Temp. (° F) Strength (psi) (R.sub.B) Density______________________________________4 2100 28,000 -- 6.65 2100 46,000 -- 6.66 2100 59,000 -- 6.3______________________________________
To further separate or analyze the effect of fine particle sizes, the starting material was not milled but rather it was screened so as to pass fine particles through a 100 mesh screen. The screened fine particles were then subjected to the treatment outlined above. The results showed:
______________________________________ Hard-Sample Sintering Transverse Rupture ness As-SinteredNo. Temp. (° F) Strength (psi) (R.sub.B) Density______________________________________7 2100 25,000 20-25 5.8______________________________________
An investigation of the influence of copper coating, by itself, without cold working from ball milling elements, was pursued. A copper coating was applied chemically to the particles of the cryogenic powder; for the following first three samples, the coating was applied electrolytically using a copper sulphate (CuSo 4 ) salt in the electroplating bath and the next two samples were prepared utilizing a copper nitrate (CuNo 3 ) salt.
______________________________________ Transverse Hard-Sample Sintering Rupture ness As-SinteredNo. Temp. (° F) Strength (psi) (R.sub.B) Density______________________________________ 8 2100 3,000 -- 5.5 (no special handl- ing) 9 2100 5,000 -- 6.0 (the powder was pre- treated in HCL before plating)10 2100 15,000 -- 6.5 (an alco- hol rinse was applied after plating)11 2100 18,000 -- 6.5 (no special handl- ing)12 2100 12,000 -- 6.4 (an alco- hol rinse was applied after plating)______________________________________
An investigation was made as to whether fine particles, simply copper coated, would provide an improvement. The copper coating was again applied electrolytically utilizing a copper nitrate (CuNo 3 ) salt, the powder particles were restricted to -100 mesh.
______________________________________ Hard-Sample Sintering Transverse Rupture ness As-SinteredNo. Temp. (° F) Strength (psi) (R.sub.B) Density______________________________________13 2100 72,000 -- 6.2______________________________________
Finally, the combined affect of (a) cold working through a ball milling operation and (b) the application of a copper envelope or coating on each of the particles at the same time the ball milling is carried out, was investigated. It is important to point out that the copper coating was applied mechanically by an abrading action between copper balls and the cryogenic powder within the milling machine. Fine particles below 120 mesh probably obtained a copper coating merely by abrading of the soft copper thereonto, while the coarser particle achieved a copper envelope much more by abrading action along with receiving cold work. The bail milling was carried out for a period of 96 hours. The results were as follows:
______________________________________ Hard-Sample Sintering Transverse Rupture ness As-SinteredNo. Temp. (° F) Strength (psi) (R.sub.B) Density______________________________________14 2100 90,000 84 6.7______________________________________
By ball milling for extended periods of time or at an increased stress rate, a transverse rupture strength of at least 95,000 can be obtained. Accordingly, it is concluded that not only is the transverse rupture strength improved by the combination effect herein but such improvement is beyond that obtainable by utilizing conventional atomized powder under the same processing conditions but without cold work or copper coating. Typically, atomized powder will obtain at best a transverse rupture strength of 85,000 psi with a density of around 6.7 g./cc. when processed under the most favorable conditions known to the prior art. Accordingly, with the decrease in cost by use of scrap materials reduced to a powder cryogenically along with the improvement in physical characteristics herein, important advantages have been obtained.
Other conclusions which can be drawn form the above data include: (a) the general effect of cold working by ball milling increases the sinterability of the cryogenically produced powder, (b) decreasing the average particle size of the powder has little effect by itself on the final physical properties, (c) copper coating, by itself, appears only to improve sinterability of fine powders, and (d) the combination of cold working and copper coating by use of copper balls, increases the sintered strength 4-5 fold.
Turning now to FIGS. 2 and 3, there is illustrated comparative examples of an as-sintered shape. The sample in the left hand portion of FIGS. 2 and 3 represents a shape produced in accordance with this invention utilizing cryogenically produced powder and processed with a second ball milling operation where cold working and copper coating is obtained. The sample in the right hand portion in each of the photographs represents an as-sintered shape obtained by conventional powder metallurgy techniques utilizing ordinary atomized iron powder. Such ordinary atomized powder typically consists of primarily 99.1% iron, the remainder may consist of: carbon 0.01-0.045%; silicon 0.005-0.015%; sulphur 0.004-0.016; phosphorous 0.007-0.027; Mn 0.04-0.26%; residual oxides -- weight loss in H 2 is 0.2-0.6%. The atomized powder was merely subjected to a compacting step achieving a green density of about 6.4, and was subjected to heating at a sintering temperature of 2050° F.
In FIG. 2, the right-hand sample of this invention has a particularly evident smooth outer surface as opposed to the relative rough heterogeneously shaded outer surface for the sample on the left. FIG. 3 shows the end face where fracture took place as a result of destructive testing. The sample on the left has a typical fracture, rough and highly porous surface. The sample on the right has a fibrous appearance. The as-sintered shape of this invention is particularly comprised of ferrous particles which are randomly irregular in configuration, none of which are spherical; the particles are bound together by molecular diffusion at contact points therebetween, said shape having no apparent porosity and has a fractured surface as a result of destructive testing which appears as glassy. It is further characterized by a weight to volume ratio of 6.6-6.7, a typical transverse rupture strength of 95,000 psi with the compact at a density of 6.6-6.7 g./cc. (resulting from compression forces of 25-30 tsi). The hardness of such as-sintered shape is at least 84 R B .
A new powder compact has been achieved as a result of practicing a portion of the disclosure herein. Such powder compact uniquely consists essentially of uniformly and homogeneously mixed ferrous based particles having a porportion of fine particles in the size range of -200+325 and a coarse particle proportion in the size range of -60+140, the fine particles being present in the ratio of 1:1 to the coarse particles, the fine and coarse particles each have a copper envelope about substantially each of the coarse particles thereof, and substantially each of the coarse particles have at least one defect site therein, said compact having a density of at least 6.6 g./cc. and a volume shrinkage of about 10% upon being heated to 2050° F. | 4y
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This is a division of application Ser. No. 720,907, filed Sept. 7, 1976, now U.S. Pat. No. 4,089,727.
BACKGROUND OF THE INVENTION
Golf clubs, fishing rods and even utility poles are being made from resinous material incorporating a fiber, or fibrous, reinforcement--more specifically, such goods are being made from liquid, thermosetting resins incorporating roving, fabrics or matted materials and the reinforcement. Goods made from fiber reinforced resin material are, appropriately, designated as FRP members, and one of the principle ways in which FRP members are made is by helically winding a succession of resin impregnated reinforcing strands about a mandrel.
According to prior art techniques, one or more strands, or ribbons, of the reinforcing material is wound onto the mandrel, beginning at a first end thereof, in a helical configuration of one hand, and one or more successive strands, or ribbons, is wound, beginning at the second end thereof, onto the mandrel in a helical configuration of opposite hand. These steps are thereafter repeated with successive strands being wound adjacent the previous winding of like hand until the mandrel is completely covered and the desired thickness is acquired. Thereafter the member is cured.
By employing a successive series of wraps at opposite hand each reinforcing strand after the first lay is crimped as it accommodates to each crossover of previously laid strands. This crimping induces a stress concentration at the crossover when the finished product is stressed and also creates a small interstice where only the resin exists. Overall, this arrangement cannot, therefore, achieve the desideratum in mechanical properties which should be available from the material employed.
In addition, winding of the reinforcing strands has heretofore been accomplished by the use of winding heads that move at a constant rate along the mandrel as the latter rotates at a constant rate. Accordingly, if the mandrel tapers, say from the butt to the tip, the lead angle of the helical wrap will progressively increase from the butt to the tip. As the lead angle increases, the orientation of the reinforcing wrap changes to increase the flexural resistance provided by the reinforcing material. For many applications, such as with fishing poles, it is highly undesirable to increase flexural resistance in the tip portion of the rod.
Moreover, when the lead angle increases the torsional resistance decreases, and for many applications, notably as with golf club shafts, it is highly undesirable to decrease torsional resistance in the tip portion.
It must be appreciated that the FRP members to which the subject invention is directed are those which include reinforcing filaments disposed in an expanded helix and not those in which the filaments are all wound in a tight spiral where each wrap of a reinforcing filament engages the previous wrap of that same filament. Nor is the subject invention directed to FRP members in which the reinforcing filaments are either all longitudinally for a configuration of reinforcing filaments that are disposed in part longitudinally and in part in the aforesaid tight spiral.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the present invention to provide an FRP member in which discrete layers are formed by reinforcing filaments disposed in expanded helices of common hand in order to obviate crimping of the reinforcing strands at crossovers and also to eliminate the resulting interstices.
It is another object of the present invention to provide an FRP member, as above, in which the lead angle of the helically disposed reinforcing strands can be selectively varied along the length of the member in order to provide the desired balance of hoop strength, flexural stiffness and torsional stiffness along the length of the member.
It is a further object of the present invention to provide a method by which to make FRP members, as above.
It is a still further object of the present invention to provide novel apparatus that is relatively inexpensive to build, operate and maintain, and which operates according to the method hereof, in order to produce FRP members embodying the concepts of the present invention.
These and other objects, together with the advantages thereof over existing and prior art forms, which will become apparent from the following specification, are accomplished by means hereinafter described and claimed.
In general, the process of the present invention is directed to the manufacture of FRP members which can be formed by wrapping strands of resin impregnated reinforcing material helically about a mandrel, curing the resin and removing the finished member from the mandrel. The direction and rate of relative movement between the rotating mandrel on which the impregnated reinforcing strands are wrapped and the winding head which feeds the strands onto the mandrel are coordinated to achieve the desired disposition of the helically wrapped reinforcing strands at any given section along the FRP member being made thereby.
The novel apparatus employed to practice the aforesaid method and produce FRP members embodying the concept of the present invention effects relative axial as well as rotational movement between the mandrel and the winding head--the rates of at least one of these relative movements being selectively varied to provide the desired helical lay of the reinforcing filaments from section to section throughout the FRP member.
One preferred, and two alternative, embodiments of apparatus by which articles embodying the concept of the present invention may be made, together with an exemplary form of such an article, are shown by way of example in the accompanying drawings and described in detail, along with the method of the subject invention, without attempting to show all the various forms and modifications in which the invention might be embodied; the invention being measured by the appended claims and not by the details of the specification.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a tapered mandrel which depicts the change in the lead angle of the helically disposed reinforcing filaments when applied according to the prior art apparatus, methods and techniques;
FIG. 2 is an elevation of a portion of a tapered mandrel which depicts the expanded helical lay of reinforcing filaments thereon when wound according to prior art methods, apparatus and techniques--for clarity the mandrel is only partially covered by said reinforcing filaments;
FIG. 3 is a partial cross section taken substantially on line 3--3 of FIG. 2;
FIG. 4 is a view similar to FIG. 1 but depicting, as a selected lay, a constant lead angle for the helically disposed reinforcing filaments when wound onto a tapered mandrel according to the concepts of the present invention;
FIG. 5 is a view generally similar to FIG. 3 but depicting the discrete layers of filaments achieved when wound onto a mandrel according to the present invention;
FIG. 6 is a schematic, frontal perspective of an apparatus embodying the concept of the present invention, and capable of performing the method thereof, which, for clarity, is depicted as winding a portion of the reinforcing filaments onto a tapered mandrel--it being understood that said apparatus is capable of winding an entire discrete layer at one pass;
FIG. 7 is a schematic rear perspective of the apparatus depicted in FIG. 5;
FIG. 8 is an end elevation of the winding head and supporting mechanism by which the reinforcing filaments are directed to the rotating mandrel by the apparatus depicted in FIGS. 4 and 5;
FIG. 9 is an enlarged perspective view of a portion of the filament winding mechanism depicted in FIG. 7 and partially broken away to depict the discrete layers in which the reinforcing filaments of common hand are being wound onto the mandrel and to depict the means by which to anchor the reinforcing strands between relative passes of the mandrel and winding head;
FIG. 10 is a schematic perspective of an alternative embodiment of apparatus according to the concept of the present invention, and capable of performing the method thereof; and,
FIG. 11 is a schematic perspective of another alternative embodiment of apparatus according to the concept of the present invention, and capable of performing the method thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
By way of background, an FRP member may be made according to prior art techniques on a mandrel, even a tapered mandrel as identified generally by the numeral 10 in FIGS. 1 and 2 of the attached drawings. It will be noted that mandrel 10 tapers from the butt 11 to tip 12, and an exemplary reinforcing strand 13 is emphasized in FIG. 1 to depict the helical orientation which results when the strand is wound onto a mandrel that is rotated at a constant rate while the winding head moves along the mandrel at a constant rate. As depicted, the lead angle α in proximity to the butt 11 is lesser than the lead angle β in proximity to the tip 12. This occurs even though the distance along which the winding head moves during one revolution of the mandrel remains constant throughout the length of the mandrel because the diameter of the mandrel gets smaller.
To explain, the distance along which the winding head moves during one revolution of the mandrel can be considered as the side of a right triangle opposite the lead angle; the filament wound onto the mandrel is equivalent to the hypotenuse of that triangle; and, the average circumference of the mandrel along the distance traveled by the winding head during the referenced revolution of the mandrel is equivalent to the side adjacent the lead angle represented in the aforesaid right triangle. Because the circumference of the mandrel is a direct function of its diameter, and because the diameter gets progressively smaller as the winding head moves from the butt toward the tip, the tangent of the lead angle also progressively increases, as does the angle itself.
Test results clearly demonstrate that an increase in the lead angle of the reinforcing filaments in a member effects a corresponding increase in the flexural stiffness of that member. As such, if an FRP member made on a mandrel according to the prior art techniques were to be used as a fishing rod, it would be found that the flexural stiffness of the rod increases toward the tip--the exact opposite of the desired result.
Test results have also revealed that the greatest torsional stiffness is achieved when the lead angle of the reinforcing filaments is approximately 45°. Thus, were the resulting FRP member to be used as a golf club shaft, the torsional stiffness would vary along the length of the shaft as the lead angle varied above or below 45°--also an undesirable result.
Two further, though related, deficiencies inherent to FRP members made according to the prior art concepts of filament winding are depicted in FIGS. 2 and 3. In FIG. 2 six successive wraps, designated as W 1 through W 6 , are depicted. As can best be observed in FIG. 3, each successive wrap is crimped, as at 14, when it crosses over the edge of the previously deposited strand, or strands, leaving an interstice 15 in which only the resin will exist. Even though a plurality of strands may be wound at one time--three are depicted in FIGS. 2 and 3--as each successive wrap is applied it will have crimped over the previously applied wraps until the mandrel is covered. Should the wrapping process continue to apply successive layers, corresponding crimps and interstices will also occur in the successive layers.
The foregoing problems, which are inherent to the prior art techniques, are obviated by the present invention, and as will become apparent from the detailed description of the apparatus hereinafter set forth, an FRP member can be made in which the reinforcing filaments of each hand lie in discrete layers without crimping and without the resulting interstices. FIG. 5, for example, depicts four such discrete layers--L 1 through L 4 --the alternate layers being of opposite hand. The present invention also permits the lead angle to remain constant throughout the length of the member irrespective of whether the mandrel is cylindrical or tapered, as represented by FIG. 4, wherein the mandrel 31 of the apparatus 30 hereinafter described in conjunction with the apparatus depicted in FIGS. 6 through 9 is schematically represented with a single wrap of a reinforcing strand 71 to show the constant lead angle α along the full extent of the mandrel. Alternatively, the lead angle may be altered according to a preselected pattern.
References to FIGS. 6-9 reveals one embodiment of an apparatus indicated generally by the numeral 30 by which to fabricate an improved FRP member according to the concept of the present invention.
As best seen in FIG. 6, a mandrel 31 of tapered section is rotatably mounted between the live spindle 32 and a dead spindle 33. The dead spindle 33 may be adjustably secured along a track 34 to accommodate mandrels of various lengths, and the live spindle 32 is rotated by an operative connection with a motor 35. As shown, a drive belt 36 connects the motor 35 to a gear reducer 38 through variable speed pulleys 39 and 40 which may be manually operated by knob 41, which changes the diameters of pulleys 39 and 40 to control the speed plateau at which the motor pulley 39 drives the input pulley 40 on gear reducer 38. Similarly, the output pulley 43 of the gear reducer 38 may be connected to the driven pulley 44 on the shaft 45 of the live spindle 32.
Wheels 46 presented from the horizontal base plate 48 of a trolley 50 are movable along tracks 51 and 52 formed by angle irons on the frame 53 of apparatus 30. An arm 54 is secured to, and extends downwardly from, the base plate 48 of trolley 50. One link 55 of a chain drive 56 is secured to the trolley 50, as by pin 57, and the chain itself is reeved about registered sprocket wheels 58 and 59. The idler sprocket 58 is mounted at one end of the frame 53 and the drive sprocket 59 is secured to a shaft 60 rotatably mounted at the opposite end of the frame 53 where it is rotated by a second motor 61 connected through gear reducer 62 and chain drive 63 to a second sprocket 64 on shaft 60.
To reciprocate the trolley 50 the sprocket wheels 58 and 59 may be mounted on cantilevered axles, and the pin 57 may be vertically slidable in arm 54 in order to follow the link 55 as it traverses the upper and lower runs 56A and 56B, respectively, of the chain drive 56. Alternatively, a pair of opposed micro switches 65 and 66, as depicted in FIG. 7, may be actuated by trip arms 68 and 69, respectively, carried on the arm 54 to reverse the motor 61 and thereby reciprocate the trolley 50.
The trolley 50 carries an immersion tank 70 within which the reinforcing strands 71 are impregnated with the desired resin 72. The particular type of resin selected will be chosen for its characteristics with respect to the specific service conditions it will need to endure. Among those resins generally suitable for FRP members are the polyesters, the vinylesters and the epoxies. Additional factors which may be considered in selection of the resin are viscosity, gel time, strength, moduli, shrinkage after curing and cost. Ingredients such as pigments, catalysts and fillers are common additives to a resin mixture, and the term resin as used hereinafter is intended to include any mixture of ingredients generally suitable for FRP members. The foregoing resins are generally cured by heat, and the reaction is ordinarily initiated in the range of 250° to 280° F. (121° to 138° C.), but because the reaction is exothermic, the temperature may rise to over 400° F. (204° C.) and it is therefore understood that the temperature ranges will vary with respect to the type of resin selected.
As can be seen by reference to FIGS. 6 and 7, a plurality of continuous strands of fiber reinforcing such as glass, graphite or other filaments, either natural or synthetic, are singularly and/or collectively designated by the numeral 71.
In order to achieve the fullest possible impregnation of the resin into the reinforcing strands 71 the strands are fully immersed within the resin reservoir in the tank 70. The strands 71 pass over a separating and aligning comb 73, beneath an immersion bar 74 within the reservoir of resin 72 in tank 70 and then upwardly out of the tank 70 over a first bar 15, through orifices 76a in bar 76 which control the resin content in the laminate, and over a guide comb 77.
The winding head 80, which directs the reinforcing strands 71 onto the mandrel 31 and which is best seen in FIGS. 8 and 9, is supported on a locator plate 81 which is also carried by trolley 50 and extends outwardly from the tank 70. The winding head 80 fits within a semicircular recess 82A and is secured to the locator plate 81 by nut and bolt combinations 83 and 84 which are connected through arms 85 and 86 extending diametrically outwardly from the mounting plate 88. A second recess 82B may also be provided in the locator plate 81 to permit mounting a second winding head, not shown.
The most uniform results are achieved when the various reinforcing strands 71 are wound onto the mandrel 31 under substantially the same tension, and it has been found that sufficient uniformity results when the strands being fed to various sectors of the winding head 80 are selectively routed across combs which tend to equalize the frictional resistance applied to the individual strands 71.
For example, as the strands 71 which are to feed the three to four o'clock sector of the winding head 80 leave the guide comb 77, they pass across friction combs 90A and 90B at rather obtuse angles before being turned sharply through an acute angle at friction comb 90C into the three to four o'clock sector where they are directed by guide pins 91, 92 and 93 onto the mandrel 31.
Those strands 71 being fed into the five to six o'clock sector of the winding head 80 pass over friction combs 90A, 90B and 90C at oblique angles before being turned through a less severe acute angle by comb 90D before being directed by pins 94 and 95 on the winding head 80 onto the mandrel 31.
Those strands 71 being fed into the eleven to two o'clock sector are turned sharply through a reverse curve by both combs 90E and 90F after leaving the guide comb 77 in order to increase the frictional resistance thereagainst in order to compensate for their closer proximity to the immersion tank 70 before they are directed by guide pins 96 through 100 in the winding head 80 in the eleven to two o'clock sector.
The strands 71 being fed into the nine to ten o'clock sector pass at an obtuse angle across comb 90G and at an acute angle across comb 90H before being directed by pins 101 and 102 in the winding head 80 onto the mandrel 31.
Finally, those strands 71 being fed into the seven to eight o'clock sector pass across both combs 90G and 90H at an obtuse angle before being turned at a moderately acute angle by comb 90J toward pins 103 and 104 in the traverse head 80 onto mandrel 31.
In the embodiment depicted in FIGS. 6-9 the trolley 50 is moved at a constant speed by a motor 61 so that the winding head 80 will move at a correspondingly uniform rate along mandrel 31. However, depending upon the taper, or compound tapers, of mandrel 31 it may be necessary to adjust the rotational speed of the mandrel in order to achieve the desired lead angle for the helical wind of the reinforcing strands 71 thereon. Should it be desired to maintain a constant lead angle, as depicted in FIG. 4, the mandrel 31 will be required to rotate at an increased rate as the diameter of the mandrel decreases.
One manner in which this result is effected is best depicted in FIG. 7. A cam plate 105 is secured to the apparatus 30, and a cam follower 106 rolls along the cam surface 108. The follower 106 may be secured to a rack 109 which rotates a pinion 110 on the control shaft 111 of a linear potentiometer 112 connected in series with the DC motor 35 (FIG. 6) which rotates the mandrel 31. Thus, by coordinating the inclination of the cam surface 108 to the taper, or tapers, of the mandrel 31, the mandrel can be rotated at varying, but controlled, rates to achieve the desired lead angle, or angles, for the reinforcing strands helically wrapped thereon. The base rate, or plateau, at which the mandrel rotates can be selected by virtue of the variable speed pulleys 39 and 40, and the configuration of the cam surface 108 will control the speed with reference to that plateau. Thus, selection of the plateau determines the basic lead angle and the cam surface 108 determines lead angle variations, if any, with respect to the basic lead angle. The lead angle must be at an angle less than 90°--an angle as large as 88° has been successfully applied for the subject apparatus. While most application will require the lead angle of the reinforcing filaments to fall within the range of 88° to approximately 45°, it is expected that some applications will require FRP members in which the lead angle of reinforcing filaments can approach approximately 10°. It should, however, be understood that FRP members to which this invention is directed employ an expanded helix; thus, the lead angle for reinforcing strands in FRP members embodying the concept of the present invention will not approximate 90°.
Referring again to FIG. 6 it will be noted that a first collar 113 is provided on the mandrel 31 in proximity to the butt end 114 thereof and a second collar 115 is provided in proximity to the tip 116 thereof. The space between the collars 113 and 115 delineates the axial extent of the FRP member being made on the mandrel 31, and the space beyond the collars is the waste on which the strands 71 are anchored preparatory to applying a discrete layer of opposite hand.
In order to assure a proper anchoring of the strands exteriorily of the collars 113 and 115 rather sharp depressions 118 and 119 are provided, one at each end of the cam surface 108. The depressions 118 and 119 actuate the potentiometer 112 to effect a sharp increase in the rotational speed of the mandrel 31 and are located such that this increase occurs when the winding head 80 is applying the strands 71 exteriorily of the collars 113 and 115, thus assuring sufficient overlapping of the strands to anchor them preparatory to the application of the successive wrap.
It must be appreciated that a sufficient number of strands are preferably fed into the winding head 80 so that a discrete layer of reinforcing strands will cover the mandrel at one pass. In this way the rotational direction of the mandrel need not be reversed to apply successive discrete layers of opposite hand with each pass of the winding head along the mandrel. In this regard please note the details in the cut-away section of FIG. 9, wherein the discrete layer L 1 is being overlaid with a discrete layer L 2 .
It is, of course, possible to apply a lesser number of strands, but in order for discrete layers to be applied it would then be necessary to reverse the rotational direction of the mandrel with each pass until a discrete layer was formed. This requires extremely exacting coordination between rotation of the mandrel and axial movement of the winding head in order that the successive strands would juxtapose to achieve each discrete layer desired. It will be appreciated that the difficulty of achieving juxtaposition by the successive wraps is further compounded by the necessity of introducing a dwell in the relative axial movement between the mandrel and the winding head as the mandrel continues rotating to anchor the strands before initiating the successive pass. Thus, considerable complications can be avoided simply by applying a discrete layer with each pass, as is readily accomplished with the subject apparatus.
It should also be appreciated that the number of strands required simply to cover the butt portion 114 between the collars 113 and 115 of the mandrel 31 may bunch somewhat when being wound onto the tip 116. This has been found to be perfectly acceptable and in no way denigrates the advantages achieved by the present invention over the prior art.
In the foregoing embodiment the rotational rate of the mandrel was varied in relation to the constant rate at which the winding head axially traversed the mandrel in order to achieve the desired lead angle for the helical lay of the reinforcing filaments. It is also possible to vary the rate at which the winding head traverses the mandrel while rotating the mandrel at a constant rate. One embodiment by which this alternative has been achieved is schematically depicted in FIG. 10.
The alternative apparatus 200 represented in FIG. 10 rotates a mandrel 201 between live and dead spindles 202 and 203, respectively, and the live spindle 202 is rotated at a constant speed by a motor means not shown.
The winding head 204 is presented from a locator plate 205 that is secured to an arm 206 which extends vertically downwardly from one end of the horizontal base plate 208 on trolley 209.
An immersion tank 210 is carried on the base plate 208 of the trolley 209, and the reinforcing strands 211 fed from a creel of spools 212 pass across a separating and aligning comb 213 through the resin bath 214 and out over a bar 215, through orifices 216a in bar 216 for control of the resin content in the laminate, and finally over guide comb 217 to feed the various sectors of the winding head 204, as hereinbefore explained in conjunction with the description of the previously described apparatus 30.
The trolley 209 is movable along, and stabilized by, a trackway 218 comprising a portion of the frame for the apparatus 200. In the embodiment depicted, the trackway has upper and lower rails 219 and 220, respectively, interconnected by vertical tie bars 221. Downwardly directed rollers 222 carried on the base plate 208 engage the upwardly directed surface 223 on rail 219, and upper, lateral, stabilizing rollers 224 and 225 engage the opposite sides 226 and 228 of the upper rail 219. A pair of lower, lateral, stabilizing rollers 229 and 230, which are carried on a horizontal flange 231 extending from the arm 206 beneath the lower rail 220, engage the lateral sides 232 and 233 of the lower rail 220.
That length of a chain 235 which extends between orienting pulleys 236 and 238 is connected to the trolley 209, as at 237, and moves it along the trackway 218. That end of the chain 235 which extends beyond orienting pulley 238 is connected to a counterweight 239, and that end which extends beyond orienting pulley 236 is connected to a timing cam 240.
The cam 240 is driven by a motor 241 connected thereto through a gear reducer 242, and the configuration of the cam 240 is determined so that the throw, or eccentricity, it provides to the chain 235 at every instant during rotation of the cam by motor 241 is coordinated with the location of the winding head 204 along the axial extent of the mandrel 201, thereby controlling the traversing speed of the winding head as it moves axially along the mandrel. The counterweight 239 assures that the trolley 209 will move to the full extent permitted by the cam 240. In this way one can predetermine the lead angle at which the reinforcing strands 211 are wound onto the mandrel 201.
If a discrete layer of reinforcing strands are applied to the mandrel at each pass of the winding head, the mandrel may be rotated at a constant speed in one direction, but the motor 241 which moves the trolley 239 must be reversed at the conclusion of each pass. This can be accomplished by means well known to the art, exemplary of which would be the use of micro switches, not shown, engageable by the trolley as it reaches each end of its desired travel.
Variation of the rate at which the winding head moves with respect to the mandrel, while maintaining the rotational rate of the mandrel constant, can also be achieved by axial movement of the mandrel past a fixedly located winding head. This concept finds particular suitability when the FRP member requires a relatively large number of reinforcing strands, and a schematic representation of such an apparatus is identified generally by the numeral 300 in FIG. 11.
A plurality of winding heads 301 are fixedly supported on a stanchion 302, and each is fed with a plurality of reinforcing strands 303 from banked creels 304, the reinforcing strands passing through banked immersion tanks 305. In order to supply a sufficient number of reinforcing strands it may be necessary to bank the creels and immersion tanks on both sides of the stanchion 302 rather than just on the one side, as depicted in FIG. 11.
A mandrel 306 is rotatably mounted between a live and a dead spindle 309 and 310, respectively, carried on a trolley 311. A motor 312 and gear reducer 313 are also mounted on the trolley and are operatively connected to rotate the mandrel 306 at a preselected constant speed. The trolley 311 itself is movably supported on a plurality of wheels 314 which ride along rails 315 and 316 on each side of a pit 318.
An idler sprocket 319 is rotatably mounted at one end of the pit 318, and a drive sprocket 320 is mounted at the opposite end thereof to be selectively rotated by a DC motor 321.
A continuous, chain drive 322 extends around and between the sprockets 319 and 320, and at least one link 323 thereof is secured, as at 324, to a foot flange 325 presented from the trolley 311. Thus, operation of the DC motor 321 determines both the rate at which, and the extent to which, the trolley 311 moves along the rails 315 and 316, and one manner in which to control the motor 321 is by the regulating cam driven potentiometer 326.
The cam driven potentiometer 326 is provided with a pinion 328 rotated by a rack 329 which in turn carries a cam follower 330 at one end. A second sprocket 331 is provided on the output shaft of the motor 321 and a continuous chain 332 extends around sprocket 331 and a sprocket 333 on the input shaft of a gear reducer 334. A cam 335 is affixed to the output shaft 336 of gear reducer 334 and communicates with cam follower 330. Rotation of the cam 335 is preferably through 270° which causes sufficient movement of the rack 329 and rotation of the pinion 328 for the potentiometer 326 to vary the axial translation of the trolley 311 while the mandrel 306 is rotating so as to achieve the desired lead angle. By changing the cam 335, the desired lead angle may be varied for the continuous helical wrapping of the reinforcing strands upon the mandrel. Of course, the gear reducer 334 enables cams of relatively small diameter, e.g., several inches (cm), to be employed despite axial reciprocation of the trolley 311 over many feet (m).
Thus, the aforedescribed, unique apparatus and method can produce novel FRP members in which the reinforcing strands of common hand are layed in discrete layers and at pre-selected, constant, or varied, lead angles and otherwise accomplish the objects of the invention. As will be apparent to those skilled in the art, combinations of the foregoing embodiments, such as the simultaneous variation of mandrel rotation and relative axial movement between mandrel and winding head, may be employed without departing from the scope of the invention. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 10/043,148; now U.S. Pat. No. 6,716,489, filed on Jan. 14, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a domain wall displacement readout type magneto-optical disc and a manufacturing method thereof and, more in particular, to a method for annealing anneal tracks that exist at both sides of an information recording track.
2. Related Background Art
As a rewritable high density recording system, there is a system available wherein, by using thermal energy of a semiconductor laser, a magnetic domain is written in a magnetic thin film to record information and, by using a magneto-optical effect, this information is read. Further, in recent years, there has been an increasing demand for further increasing the recording density of the magneto-optical disc of this system so as to make it as a large-capacity recording medium. By the way, a line recording density of the magneto-optical disc and the like largely depends on a laser wave length λ of a reproduction optical system and a numerical aperture NA of an objective lens. In other words, when the laser wave length λ of the reproduction optical system and the numerical aperture NA of the objective lens are decided, the diameter of a beam waist is decided and, therefore, a spatial frequency at the time of reproducing a recorded domain has a detectable limit only at about 2 NA/λ.
Accordingly, in order to realize high density by the conventional magneto-optical disc, it is necessary to shorten the laser wave length of the reproduction optical system and enlarge the NA of the objective lens. However, there is a limit to improvement of the laser wave length and the numerical aperture of the objective lens. For this reason, a technology to think out a constitution of the recording medium and a reading method and improve recording density is being developed.
For example, in Japanese Patent Application Laid-Open No. 06-290496, the magneto-optical disc and its manufacturing method are disclosed, the disc using a perpendicular magnetic anisotropy multi-layer film having at least s domain wall displacement layer magnetically linked, a switching layer and a memory layer.
This method uses an ingenious mechanism, wherein, at the time of reproduction, a thermal gradient to be generated by irradiation of an optical beam is used and the domain wall of a recorded mark of the domain wall displacement layer is displaced without changing recorded data in the memory layer, and the domain wall displacement layer is magnetized so that a part of an optical beam spot area is uniformly magnetized and a change of the polarization plane of the reflected light of the optical beam is detected, thereby reproducing a recorded domain of the cycle below a diffraction limit.
By using this reproduction system, a reproduction signal becomes rectangular ( FIG. 11D ), and it is possible to reproduce the recorded mark of the cycle below the diffraction limit of a light without lowering the reproduction signal amplitude by depending on an optical resolving power, and the magneto-optical disc capable of considerably improving the recording density and a transfer velocity becomes possible.
Note that, in this type of magneto-optical disc, in order to utilize the temperature gradient by irradiation of the light beam so as to easily cause the displacement of the domain wall of recorded mark of the domain wall displacement layer, a laser beam of high power is irradiated at the portion of adjacent two pieces of the anneal tracks (guide grooves) which make the information recording track of the magneto-optical disc exist between them, and a magnetic layer of the anneal track (guide groove) is annealed at high temperature and subjected to an annealing process which degenerates a magnetic layer of the portion of the anneal track (guide groove). By this annealing process, a switched connection between the information recording tracks is disconnected and the domain wall is not formed along the side portion of the information domain track of the recorded mark. As a result, the action of a domain wall coercivity is reduced, and more stabilized displacement of the domain wall becomes possible. This annealing process can obtain a good reproduction signal.
The reproducing action of the domain wall replacement type magneto-optical disc will be described by using FIGS. 11A to 11D . Here will be dealt with the constitutions of three layers: a memory layer which governs the storing of the recorded mark; the domain wall displacement layer where the domain wall displaces and directly contributes to the reproduction signal; and a switching layer which switches a link status between the memory layer and the domain wall displacement layer.
FIG. 11A is a typical view which shows a magnetic domain reproducing state. A thick line 111 shows a domain wall of the domain wall displacement layer, and a narrow line 112 shows the domain wall of the memory layer only. FIG. 11B shows a state graph of a recording film, FIG. 11C a temperature state graph of a medium and FIG. 11D the reproduction signal. Note that the two pieces of the anneal tracks (guide grooves) which make the information recording track exist between them, as described above, subjected to the annealing process where a magnetic layer is degenerated by irradiation of high powered laser beam. At the time of reproduction, the anneal track is heated until a Ts temperature condition ( FIG. 11A ) where the domain wall of the domain wall displacement layer of a domain wall displacement medium is displaced by irradiation of a light beam 116 . Here, the Ts is the Curie point of the matter which constitutes the switching layer, and the switching layer 22 ( FIG. 11B ) is in a link state with the memory layer 21 and the domain wall displacement layer 23 by the switched connection in a low temperature area. When the magneto-optical disc displaces in the direction shown by an arrow mark 114 and is heated more than the Ts temperature by irradiation of the light beam, the link between the domain wall displacement layer and the memory layer is put into a disconnected state (inside of a Ts constant temperature line shown by the Ts of FIG. 11A . For this reason, as soon as the domain wall of the recorded mark arrives at this Ts temperature area, an effect of the annealing process (annealing process portion by laser is shown by reference numeral 113 in FIGS. 11A to 11D ) of the two pieces of the anneal tracks (guide grooves) adjacent to the information recording track also takes place, and the domain wall of the domain wall displacement layer instantaneously displaces to the position where the domain wall can stably exist energy-wise in relation to the temperature gradient of the domain wall displacement layer, that is, to the direction of an arrow mark 115 so that the domain wall can cross the information recording track at the highest temperature of the line density direction of the temperature rise by the light beam irradiation. In this way, a large portion of magnetic state of an area S which is covered by the reproduction light beam becomes the same and, therefore, in the usual light beam reproduction principle, even if it is a minute recorded mark which is not possible to reproduce, a reproduction signal nearly in a rectangular shape as shown in the drawing can be obtained.
SUMMARY OF THE INVENTION
The present invention provides a domain wall displacement type magneto-optical disc where an error rate and a jitter of a reproduction signal are improved, and a manufacturing method of the disc.
According to an aspect of the present invention, there is provided a manufacturing method of a domain wall displacement type magneto-optical recording medium comprising the steps of:
depositing a magnetic layer on a substrate to prepare a disc; and
irradiating the magnetic layer with a converged light beam while applying a magnetic field and annealing the magnetic layer a converged light beam between information tracks.
According to another aspect of the present invention, there is provided a domain wall displacement type magneto-optical disc comprising:
a domain wall displacement layer in which a domain wall displaces;
a memory layer that holds a recording magnetic domain according to information;
a switching layer that is provided between the domain wall displacement layer and the memory layer and has a Curie temperature lower than that of those layers; and
a disconnecting area that is provided in the domain wall displacement layer and disconnects a switching connection between information tracks;
wherein the polarity of a residual magnetization at a boundary between the information track and the disconnection area is oriented in a certain direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view to explain a manufacturing method of the present invention;
FIG. 2 shows an annealing device to be used in the manufacturing method of the present invention;
FIGS. 3A , 3 B, 3 C and 3 D show a timing chart to show the action of a first embodiment of the present invention;
FIG. 4 shows an example of an application of an annealing magnetic field;
FIG. 5 shows another example of the application of the annealing magnetic field;
FIG. 6 shows a jitter property graph of the first embodiment of the present invention;
FIG. 7 shows a pulse width fluctuation property graph by a second embodiment of the present invention;
FIG. 8 shows another example of an annealing device to be used in the manufacturing method of the present invention;
FIG. 9 shows a case where an annealing magnetic field parallel to a light beam scanning direction inside the disc surface is applied;
FIG. 10 shows a case where the annealing magnetic field perpendicular to the light beam scanning direction inside the disc surface is applied; and
FIGS. 11A , 11 B, 11 C and 11 D are a view to explain the reproducing method of a domain wall displacement type magneto-optical recording medium.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a schematic diagram to show a property of an annealing method of a magneto-optical disc of the present invention. It shows a sectional view of a magneto-optical disc 3 at the stage where a step of laying on a magneto-optical disc substrate 1 comprising glass or plastic as a material a magnetic layer 2 which includes at least a domain wall displacement layer where the domain wall displaces, a memory layer which holds information as a recording magnetic domain and a switching layer provided between the domain wall displacement layer and the memory layer and having Curie temperature lower than those layers has been completed. While any protective layer is still not formed at the stage of FIG. 1 , it does not matter whether the protective layer exists when annealing the disc. Here, a character d denotes one of the information recording tracks, and the information track is an area which forms a recording magnetic domain to hold the information such as a user data etc. In general, this convex portion provided on the substrate is referred to as a land. Magneto-optical disc of FIG. 1 has a constitution in which the light beam for use of forming an anneal track enters from the back side of the substrate where the magnetic layer 2 is not formed. Characters a and a′ which make an information recording track d exist between them denote anneal tracks, which are formed by a laser annealing with a higher light intensity than that at writing an information on the information recording track d.
In the present drawing, the anneal tracks a and a′ serve also as the guide grooves to control the light beam at the center of the information recording track d in the reproduction step. In general, the concave portion provided on the substrate is referred to as a groove.
In the present embodiment, the lands (convex portions) on the substrate 1 are taken as information recording tracks and the grooves (concave portions) as the anneal tracks, but the constitution of the magneto-optical disc is not limited to this. For example, a constitution wherein the lands (convex portions) are taken as the anneal tracks and the grooves (concaves) are taken as the information recording tracks is also allowable.
The laser spots denoted by characters b and b′ show the converged light beams when annealing anneal tracks a and a′, which enter from the back of the substrate.
In the drawing, the laser spots of b and b′ are illustrated as if the two points were irradiated at the same time. This is to clarify that the directions of annealing magnetic fields applied to the two anneal tracks which are adjacent to the information recording track are different.
Characters c and c′ show the polarities of applied magnetic fields in the case where the anneal tracks a and a′ are annealed. In the present embodiment, the direction of the applied magnetic field is from one side of the substrate on which the magnetic layer 2 is provided to the other side of the substrate (i.e., the back side of the substrate) when anneal track a is annealed, and the direction of the applied magnetic field is from the back side of the substrate to the side on which the magnetic layer 2 is provided when anneal track a′ is annealed. In addition, the annealing magnetic fields at the adjacent anneal tracks with the information recording track d made to exist between them have opposed polarities.
In order to form the anneal tracks by applying thus annealing magnetic fields perpendicular to the substrate surface, a device as shown in FIG. 2 is suitable.
A magneto-optical disc 100 , wherein a magnetic layer 2 is formed on a magneto-optical disc substrate 1 made of glass or plastic and further a protective layer 3 is formed, is held on a spindle motor with a magnetic chucking and the like, and is constituted such that it is rotatable against an axis of rotation.
A laser light for forming the anneal track generated from a semiconductor laser light source 7 is changed to a parallel ray by a collimator lens 8 and passes through a beam splitter 9 and is converged by a condenser lens 6 . Then a predetermined position of the magneto-optical disc 100 is irradiated with the converged laser light as a beam from the back. Note that the condenser lens 6 is driven by a drive actuator 5 .
On this occasion, the condenser lens 6 is constituted such that it is controlled by actuator 5 to move in a focusing direction and a tracking direction so that the laser light successively places a focus on the magnetic layer 2 . The condenser lens 6 also moves along the guide groove engraved on the magneto-optical disc.
On the other hand, the reflected light which reflected from the surface of magneto-optical disc surface passes through a route in reverse to the incident light and arrives at the beam splitter 11 and is reflected at a right angle and passes through a λ/2 plate 10 . This λ/2 plate is a filter to rotate a the reflected light at 90° in the polarizing direction of the incident light.
Further, the reflected light enters the polarized beam splitter 11 and is put into two condenser lenses 12 by the polarity of the magneto-optical disc magnetization of the magneto-optical disc 100 . Two pieces of photo sensors 13 detect the intensities of the incident lights which enter the sensors respectively. The detected resultants are amplified respectively by a differential amplification circuit 14 which differentially amplifies the signal converged and detected respectively according to the polarization direction and by a summing amplification circuit 15 which summing-amplifies the signal converged and detected respectively according to the polarization direction. A light magnetic signal and by a summing signal from the differential amplification circuit 14 and the summing amplification circuit 15 are synthesized and binarized by a digital circuit 200 and outputted to a controller 17 . In addition, the number of rotations of the magneto-optical disc, an annealing radius, an annealing sector information and so forth are inputted to controller 17 , and a signal to control an annealing power is outputted to a LD driver 16 . The LD driver 16 irradiates a laser to a substrate 1 under a predetermined condition according to that signal.
Further, the controller also controls a magnetic head driver 19 at the same time, and outputs a signal which controls the polarity of the annealing magnetization and the like.
Reference numeral 18 denotes a magnetic head to apply a magnetic field to a laser-irradiated portion of magneto-optical disc 1 when forming an anneal track, and sandwiches the magneto-optical disc 100 and is arranged in a manner that opposes to condenser lens 6 . Magnetic head 18 is used to record information and to reproduce it. In the annealing, a semiconductor laser 7 irradiates the LD driver 16 with an anneal laser power and, at the same time, the magnetic head 18 is allowed to generate a perpendicular magnetic field of a polarity corresponding to a polarity signal of a magnetic field applied for annealing an anneal track (hereinafter referred to as “annealing applied magnetic field”) by magnetic head driver 19 . The magnetic head 18 is constituted such that, coupled with an optical head, it moves in the radial direction of the magneto-optical disc 1 and, at the annealing step, applies a magnetic field successively to the laser-irradiated portion of the magneto-optical disc 3 to perform a desired annealing.
However, means which reproduces the information from the reflected light from the magneto-optical disc is not necessarily required. Such a means is utilized as means to detect a pre-format and the like and to reproduce a magneto-optical signal when controlling a timing to switch the polarity of the annealing applied magnetic field by the reflected light from the magneto-optical disc, or when checking whether a desired property develops in the information recording track or not after the annealing of the anneal track. In the case, a construction where a parameter such as a laser power according to the annealing, an applied magnetic field or the like is changed into a value relative to the recording or reproduction by the controller 17 is required.
In the idea of the above described annealing method and the annealing means, the action of annealing the anneal track will be described by using FIGS. 3A to 3D . FIG. 3A shows an annealing power ON/OFF signal which shows the start of the annealing, FIG. 3B shows an applied magnetic field polarity change timing signal which shows a timing to change the polarity of the applied magnetic field, FIG. 3C shows an applied magnetic field polarity control signal which controller 17 outputs to magnetic head driver 19 , and FIG. 3D shows a generated magnetic field of magnetic head 18 . An irradiating power of the laser is set to a desired annealing power by an annealing start command from controller 17 . Although the annealing power is different depending on a property of the magneto-optical disc, but it is typically about two times that of the recording power. At the same time of the irradiation of the laser power, the annealing magnetic field is applied by the magnetic head 18 . On this occasion, the polarity of the applied annealing magnetic field is allowed to generate the magnetic field of the polarity corresponding to a polarity of the applied magnetic field control signal from the controller 17 . As described below, the absolute value of the magnetic field intensity is preferable to be larger than about 50 Oe. In order to execute the property of the present invention, it is necessary to switch the polarity of the applied magnetic field at least more than one time for one cycle, and this switching timing is controlled by an applied magnetic field polarity change timing signal from the controller 17 . The applied magnetic field polarity change timing signal can be formed by counting a clock for rotation control of the spindle and can be also formed by detecting the reflected light such as a phase pit which causes a change of reflectivity embedded in advance in the anneal track of the magneto-optical disc as an applied magnetic field change timing. The later makes it possible to control the magneto-optical disc by higher position accuracy.
Since the switched portion of the polarity of the annealing applied magnetic field is considered to have adverse effect on the information recording track, the area where the polarity of the annealing applied magnetic field is switched is preferably the area where the adjacent information recording track is not an user data area, for example, preferably a header area which shows a sector position information and the like. Further, an applied magnetic field polarity switching area may be specially provided. By these means and processes, it is possible to control the applied magnetic field to a predetermined magnitude and polarity in annealing the anneal tracks adjacent to both sides of the information recording track.
Examples of the applied magnetic field polarity change timing in a case where the magneto-optical disc is annealed by these means are shown in FIGS. 4 and 5 . In FIGS. 4 and 5 , reference numeral 41 denotes the anneal track, and reference numeral 42 denotes the information recording track. Among the anneal tracks, the hatching portion shown by T has the applied magnetic field at the time of annealing in the upward direction to the plane of the drawing, and among the anneal tracks, the hatching portion shown by F has the applied magnetic field at the time of annealing in the downward direction to the plane of the drawing. In FIG. 4 , switching of the polarity of the annealing magnetic field is performed only when the magnetic field-applying means moves to the next anneal track and the switching is one time for one cycle of the anneal track. In contrast to this, in FIG. 5 , since the anneal track of one cycle is divided into four continuous magnetic areas, the switching of the polarity of the applied magnetic field is performed five times. The white portion 42 indicates the information recording track in FIG. 5 . The figure shows that the polarities of the annealing magnetic fields in adjacent portions T and F of the recording tracks are reversed.
The timing of switching the applied magnetic field is not limited to the above. The gist of the switching is adaptable not only to CAV but also to format, of zone CAV, CLV and zone CLV, assuming that the applied magnetic fields at the time of annealing anneal tracks adjacent to both sides of an information track have opposite polarities.
(Embodiment 1)
The present invention was executed by the device described in FIG. 2 . The device of FIG. 2 applies an annealing magnetic field perpendicular to the magneto-optical disc surface.
FIGS. 6 and 7 show properties in embodiments of the present invention and the comparative examples, as explained below.
After completing the formation of the magnetic layer, the annealing of the anneal track was conducted by laser beam under various conditions.
In FIG. 6 , the ordinate shows a jitter property. The jitter property is better as the value of the jitter property is smaller. The abscissas of FIG. 6 shows applying methods of the magnetic field at the time of annealing the anneal track.
Described in order from the left side on the axis of the abscissa are the methods
(1) wherein, as comparative example 1, the applied magnetic fields at both of the anneal tracks adjacent to the information recording track were taken as −300 Oe and were applied to all the anneal tracks the annealing magnetic field of the same polarity at the same magnitude. (2) wherein, as comparative example 2, the applied magnetic fields at both of the anneal tracks adjacent to the information recording track were taken as +300 Oe, which was the same as (1) in annealing magnetic field. (3) wherein, as comparative example 3, the applied magnetic fields at both of the anneal tracks adjacent to the information recording track were taken as 0 Oe, and the annealing magnetic field was not applied at the time of forming the anneal track. (4) wherein, as example 1, the applied magnetic fields at both of the anneal tracks adjacent to the information recording track were inversed in polarity by one cycle interval, and the generated magnetic field was taken as ±300 Oe, which corresponds to FIG. 4 .
FIG. 7 is the same as FIG. 6 in axis of abscissas, and the axis of ordinates shows a aberration amount of the reproduction signal pulse width in relation to the regular pulse width in the reproduction signal. If the pulse width is near to “0”, it shows that it is near to the desired pulse width.
Table 1 shows annealing magnetic field applied conditions and reproduction properties.
TABLE 1
Annealing magnetic field (magnetic field
applied in the direction perpendicular to the disc
surface) and reproduction property.
Comparative
Comparative
Comparative
Example 1
Example 2
Example 3
Example 1
Condition of
Annealing
Magnetization
Applying
Annealing
available
available
not available
available
Magnetization
Applied
Reversal of
not available
not available
not available
available
Polarity
Intensity of
+300
−300
0
±300
Annealing
Magnetization
Length of
one cycle
one cycle
—
one cycle
Continuous
Magnetization
Area
Reproduction
Property
Jitter
good
good
bad
good
Property
Estimation
Pulse Width
bad
Bad
a little
good
Property
bad
Estimation
Overall
bad
bad
bad
very good
Estimation
Regarding jitter property, example 1 shows that a jitter value is low. ( FIG. 6 , Table 1)
The pulse widths regarding the three types of the method for applying the annealing magnetic field were estimated. Comparative examples 1 and 2 have large aberrations in the reproduction signal pulse width ( FIG. 7 , Table 1). Embodiment 1 has the most excellent performance among the four experiments even in pulse width.
From the result of these experiments, it is evident that, in the case where the applied magnetic fields at both of the anneal tracks adjacent to the information recording track are inversed at intervals of every one cycle and the generated magnetic field is taken as ±300 Oe, the jitter property is excellent and the pulse width fluctuation is not generated, and it is the most suitable annealing condition among the above described conditions.
In this way, the remanent magnetization at the boundary between the anneal track, where, though there is a deterioration of the magnetic property due to the laser annealing of the present invention, the magnetic property is not lost completely, and the information recording track is taken as a predetermined polarity by both of the adjacent anneal tracks which make the information recording track exist between them, so that the influence for the magnetic recording track in the information recording track is offset and the influence can be equalized. In this way, it is possible to provide the magneto-optical disc, which can obtain the reproduction signal of high quality, and further improve the recording density.
The remanent magnetization at the time of the above described annealing has been confirmed not to be inversed by a recording power usually used and a recording magnetic field usually used.
(Embodiment 2)
In FIG. 8 is shown a schematic diagram to show a property of the second embodiment of the annealing method of a magneto-optical disc of the present invention. In the drawing, what is different from embodiment 1 is that a ring head is used, where the magnetic disc 18 , which applies the magnetic field at the time of annealing, can apply the annealing magnetic field in the in-plane direction of the face of the disc to a heated area on the recording medium. In this way, the magnetic field which is parallel to the magneto-optical disc surface can be applied to a heated annealing portion. In the case where the magnetic field is applied to the inside of the magneto-optical disc surface, there exist two directions parallel and perpendicular to the scanning direction of the light beam. In FIG. 9 , an example of the annealing applied magnetic field was shown, where the annealing applied magnetic field is in the in-plane direction to the face of the magneto-optical disc and parallel to the light beam scanning direction. In the case where the annealing magnetic field is applied in this direction, it is not necessary to consider the polarity of the magnetic field and it does not matter whether it is the same polarity or different. In FIG. 10 , an example of the annealing applied magnetic field, where the annealing magnetic field is perpendicular in the plane of the face of magneto-optical disc, is shown. In the case of FIG. 10 , when the annealing magnetic field of the reverse polarity is applied, it is necessary to certainly apply the annealing magnetic field of the same polarity since there is a risk of the magnetic field line loop of the remanent magnetization owned by the adjacent anneal tracks being multiplied on the information recording track.
As shown in FIGS. 9 and 10 , in order to change the polarity of the generated magnetic field to the scanning direction of the light beam, the direction of the ring head of FIG. 8 may be changed 90°. As already described as above, in FIG. 10 , although the annealing applied magnetic fields have the same polarity, the polarity of the applied magnetic field does not cause any specific problem in the case where the annealing applied magnetic fields are parallel to the light beam scanning direction. Further, in the present embodiment, though the ring head was used in order to generate the magnetic field parallel to the magneto-optical disc surface, there is no limit to this, but it does not matter specifically whatever shape it has, provided the magnetic field parallel to the magneto-optical disc surface can be applied to the laser irradiated portion at the time of annealing.
In this way, the remanent magnetization at the boundary between the anneal track, where, though there is a deterioration of the magnetic property due to the laser annealing of the present invention, the magnetic property is not lost completely, and the information recording track is directed to the direction of the inside of the magneto-optical disc surface, so that the influence can be reduced for the magnetic area of the perpendicular direction recorded in the information recording track, and it is further possible to equalize the influence.
Note that the remanent magnetization at the time of the above described annealing is confirmed not to be inversed by the usually used recording power and the recording magnetic field.
As described above, the remanent magnetization at the boundary between the anneal track, where, though there is a deterioration of the magnetic property due to the laser annealing of the present invention, the magnetic property is not lost completely, and the information recording track is equalized and the influence of the remanent magnetization is taken as a predetermined polarity by both of the anneal tracks which make the information recording tracks exist between them, so that a bad influence on the information recording track can be offset, and the jitter property and the pulse width fluctuation can be improved. Further, the remanent magnetization at the boundary between the anneal track and the information recording track is directed to the direction of the inside of the magneto-optical disc surface, so that the influence for the magnetic area in the perpendicular direction recorded in the information recording track can be equalized. In this way, the reproduction signal having higher quality than that of the conventional method can be obtained. Furthermore, since the information recording track width can be made narrower than that of the conventional method, it is possible to further improve the recording density of the magneto-optical disc. | 4y
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TECHNICAL FIELD
The present invention relates to methods of and apparatus for handling articles, such as semiconductor devices. The invention relates more particularly to removing such articles, as, for example, semiconductor devices from adhesively coated support diaphragms of temporary mounting frames.
BACKGROUND OF THE INVENTION
Semiconductor devices are typically formed in arrays as a plurality of regions in semiconductor wafers. After a sequence of processing steps which complete the devices as integral parts of the wafers, the wafers are severed to yield a plurality of individual devices. The devices are then typically tested and assembled into protective device housings in subsequent operations such as device mounting, lead bonding and packaging operations.
These latter operations typically are sequential operations in contrast to the wafer processing operations which are generally batch-type operations. Sequential operations tend to be more costly than the batch-type operations. However, some economies are obtained by handling techniques which allow the individual devices to remain in supported arrays until the devices become ultimately mounted in individual device packages. Test data on such arrayed devices, even though obtained by sequential tests on the devices, are recorded as arrayed data to correspond directly to the array positions of the tested devices in the arrays. The arrayed test data are used to direct sorting operations, as, for example, to cause the removal of devices having only certain acceptable parameters and to leave untouched all other devices of the original array.
A technique for preserving the array of devices in a wafer after such wafer is severed into individual devices is to mount the wafer onto an adhesively coated film-type diaphragm which is stretched across an opening of a temporary mounting frame. The wafer is then typically sawed along orthogonal boundary lines between the defined devices. The depth of the saw cut is adjusted to slice through the thickness of the wafer without damaging the underlying film-type material of the diaphragm. The individual devices remain attached to the diaphragm after the sawing operation is completed.
As an example, a particular, temporary mounting frame is made of a flat, rectangular metal sheet having a central, circular opening. The diaphragm is a commercially available adhesively coated polymer film which is stretched across the opening and is adhesively attached to the coplanar metal surface of the frame surrounding the opening. A wafer may then be mounted to the adhesively coated film surface in the opening of the frame.
Individual devices which are supported by such a film-type diaphragm may be removed in a typical sorting operation by commercially available sorting apparatus. In a typical sorting operation, the mounting frame is indexed in the plane of the array of devices to align a device selected for removal with a transfer station.
At the transfer station a pushpin is urged from beneath against the selected device, generating stresses between the adhesive coating on the top surface of the diaphragm and the underside of the device, and urging the device out of adhesive contact with and away from the diaphragm. A vacuum probe which is movably mounted above the array moves from above the selected device into contact with its top surface, generating a vacuum hold on the device and carrying the selected device away from the diaphragm.
According to one technique, the pushpin, which is urged against the underside of the device, is pointed. During its upward movement the pin actually pierces the diaphragm and pushes directly against the underside of the selected device. The resulting motion is a positive pulling motion by the device on the adhesive coating to lift the device off the diaphragm. The diaphragm piercing technique is a frequently used technique which works well with comparatively small devices, such as devices which are in a range of a quarter of a millimeter along each edge.
A problem with using the diaphragm-piercing pushpin is related to a vacuum which typically holds down the diaphragm against the upward directed force initiated by the pin. Piercing the diaphragm with the pin appears to have an unfortunate side effect of extending the vacuum from below the diaphragm to the space between the upper surface of the diaphragm and the base of the device. Such a vacuum tends to slow the separation of the device from the adhesive coating. Also, the piercing pin does not appear to sufficiently flex the diaphragm of larger devices to initiate separation of the selected device from the diaphragm at reasonably desirable speeds. Particularly larger devices appear to resist separation from the diaphragm. A stronger upward push by the pin typically alleviates the problem but tends to raise the force exerted against the devices to an undesirably high value at which some devices become damaged.
Another technique of removing selected devices from the adhesively coated diaphragm involves a pin having a blunt tip, as, for example, a rounded tip. Such a tip does not pierce the diaphragm. Instead it merely pushes against the underside of the diaphragm, thereby flexing the surface of the diaphragm to such an extent with respect to the inflexible adjacent surface of the device that the adhesive coating peels from the underside of the device to release its hold on the device. During the upward movement of the pin during which the peeling takes place, the selected device is raised above the plane of the other devices in the array and moves into contact with the vacuum probe.
A problem with such a non-piercing transfer technique is that at times the adhesive coating tends to peel faster on one side of the device than on the other. As a result, devices tend to tilt and remain at least partially in contact with the diaphragm. The tilted devices cannot be contacted squarely by the vacuum probe and are consequently not removed from the array. The problem of having devices in an array tilt can be alleviated by slowing down the upward movement of the pin. Apparently a slow upward movement of the pin allows more time for the adhesive to peel more uniformly from the selected device. Unfortunately, such slowed down movement of the transfer apparatus also results in a less efficient and hence more costly transfer operation.
SUMMARY OF THE INVENTION
Problems of handling articles, such as semiconductor devices, in effecting the removal of such articles from an adhesively coated diaphragm, or problems relating to undesirably slow separation of the articles from the diaphragm are alleviated by improved apparatus for and methods of handling articles to remove them from such adhesively coated diaphragm. In accordance with the invention, a method of handling articles includes holding an array of the articles on an adhesively coated surface of a flexible diaphragm and selecting an article from such array for removal. The method includes contacting an underside of the diaphragm in the region of a vertical projection of the selected article onto the diaphragm with a plurality of spaced support pins and moving the plurality of support pins in unison upward against the diaphragm to raise the selected article while maintaining the orientation of the selected article.
Apparatus for handling articles in accordance with the invention includes provisions for supporting an array of articles mounted to an adhesive coating of a flexible diaphragm. The apparatus has provisions for raising a selected article from the array while supporting the orientation of the article with respect to the array through spaced support contact elements from beneath the diaphragm. A particular feature of the invention includes a provision for reducing the contact regions between the article and the diaphragm while the article is being raised by such provisions for raising the article.
BRIEF DESCRIPTION OF THE DRAWING
Various other features and advantages of the invention will be best understood when the following detailed description is read in reference to the appended drawing wherein:
FIG. 1 shows a handling apparatus and particularly a compound device lift mechanism as one of the features of the present invention;
FIG. 1a shows a side view of the lift mechanism of FIG. 1;
FIGS. 2 through 7 show schematically a sequence of cooperative actions of the compound device lift mechanism and a transfer probe of the apparatus of FIG. 1 for achieving the removal of a device from a diaphragm of a temporary mounting frame;
FIG. 8 shows in greater detail contact areas between an adhesive coating of such diaphragm and the device to be removed; and
FIG. 9 is a timing diagram illustrating the vertical interrelationship between the device lift mechanism and the transfer probe of the described apparatus.
DETAILED DESCRIPTION
The Apparatus And Its Operation
FIG. 1 shows a device handling apparatus 11 in a cutaway representation which highlights major components and illustrates various features of the present invention. Generally described, the apparatus 11 transfers selected devices 12, such as semiconductor integrated circuit devices, from a first array 14 of such devices located at a pickup station 16 to a receiving station 18. At the receiving station 18 the transferred devices are placed into a sorted, second array 19, as shown in FIG. 1, or, alternatively, they may be mounted directly to circuit substrates or become packaged in other ways not shown.
The first array 14 of the devices 12 is shown as being supported by a planar mounting frame 21. The actual framing member is a rigid metal sheet 22 which has a central opening 23 of substantial size so that the remaining material of the sheet 22 forms a frame about the opening 23. An adhesively coated polymer film 24 is attached through an adhesive coating 26 on one surface thereof to one major surface, namely the underside 27 of the frame 21. Looking downward onto the frame 21, in FIG. 1, only an edge of the underside 27 is showing. A central portion of the film 24 stretches across the entire area of the opening 23 as a tightly stretched, yet flexible diaphragm 29. The upwardly exposed adhesive coating 26 on the diaphragm 29 provides a temporary hold for the devices 12 of the first array 14.
The mounting frame 21 is supported by a first X-Y index table 31 which is controllably movable by predetermined increments in two orthogonal directions indicated by arrows 32 and 33. The directions correspond to rows and columns of the array 14. The movement of the index table is controlled to index the devices 12 in the array in succession into alignment with a pickup axis 34.
The indexing movement of the index table is controlled by a typical apparatus control console 36 which coordinates the functions of the apparatus by applying appropriate control signals in accordance with known practices. Typical commercially available handling apparatus may therefore include electronic microprocessor and memory circuits which are programmable to generate appropriate signal sequences.
At the beginning of an operational cycle of the apparatus 11, the mounting frame is translated by a typically electrically activated movement of the index table 31 to center a selected device 12 on the pickup axis 34. At the pickup axis the selected device 12 is located in vertical alignment with and beneath a first rest position of a first transfer head 38 of a transfer mechanism 39. The transfer mechanism 39 supports the first transfer head 38 and preferably a second transfer head 41 on diametrically opposite ends of a horizontal swing arm 42. The swing arm 42 is centrally supported at an upper end 43 of a vertically oriented transfer actuator shaft 44.
The transfer actuator shaft 44 is movably mounted with respect to a typical fixed support structure 46 to reciprocate vertically in the direction of the arrow 51 and to oscillate through 180° about its vertical axis as indicated by arrow 52. Such compound motion is preferably generated by linear and rotational electromagnetic actuators mounted in the support structure 46. Of course, conventional mechanical drive mechanisms, such as a cam drive for the vertical reciprocation of a linkage actuator or an actuator which moves the swing arm through indexed 180° rotations in the same direction, may be employed to yield equivalent motions.
The rotation and vertical reciprocation of the first and second transfer heads 38 and 41 and a selectively applied vacuum at each of the transfer heads interact to enable the transfer mechanism 39 to pick up selected devices 12 at the pickup station and to deposit them at the receiving station 18. A second X-Y index table 54 at the receiving station 18 translates a device carrier 56 in a predetermined travel pattern to advance consecutive vacant array positions 57 to a second rest position of the transfer heads. As one of the transfer heads places one of the transferred devices into such vacant positions, the other transfer head picks up a subsequent device from the array 14. The pattern of travel of the X-Y index table 54 is, like that of the X-Y index table 31, controlled by electrical signals from the control console 36. Suitable cabling 59 couples the index table 54 like other apparatus components to the control console 36.
The Device Lift Mechanism
Centered on the pickup axis is a device lift mechanism which is designated generally by the numeral 61. A support housing 62 of the mechanism 61 is mounted in the apparatus 11 so that a top surface 63 of the housing 62 lies in the same plane as a top surface 64 of the first index table 31. When the mounting frame 21 is placed on the first index table 31 as shown in FIG. 1, the underside of the diaphragm 29 is supported by the top surface 63 of the housing 62.
A plurality of concentric grooves 66 formed in the top surface 63 are coupled through a typical vacuum tube 67 to a conventional vacuum supply. Such a supply includes typical control valves which respond to electrical input signals. A vacuum suction at the top surface 63 of the housing 62 is therefore capable of being selectively activated or deactivated by, for example, control signals from the control console 36. When the mounting frame 21 is located on the index table 31 and the vacuum at the top surface of the housing 62 is activated, a vacuum pull is exerted on the underside of the diaphragm 29. During such portion of an operational cycle of the apparatus 11 during which the mounting frame 21 is indexed to a new array position, the vacuum coupled to the housing 62 remains deactivated to permit the diaphragm 29 to slide freely with respect to the top surface 63 of the housing 62.
The walls of a central aperture 69 through the housing 62 guide and support a vertical, reciprocating motion of a device lift pedestal 71 of the mechanism 61. Four support pins 72 are mounted to an upper end 73 of the pedestal 71 and are located in symmetry about the pickup axis 34. The horizontal spacing of the pins 72 is chosen in relationship to the size of the devices 12. When the index table 31 has indexed a selected device into alignment with the pickup axis 34, the pins 72 are located within the vertical projection of the selected device 12. Preferably the pins 72 are located adjacent to respective corners of the device 12, but are set inward from adjacent edges 76 of such device by about the width of the pin 72, as shown, for example, in FIG. 1a. Top surfaces 74 of the pins 72 are machined flat in a horizontal support plane. When the pedestal is reciprocated into a lowermost rest position, the top surfaces 74 of the pins 72 are preferred to be positioned no higher than the top surface 63 of the housing 62.
Again in reference to FIGS. 1 and 1a, a fifth pin, namely a pushpin 78, is slidably mounted in the center of the pedestal 71 and is, therefore, located on center with the pickup axis 34. FIG. 1a shows a partially sectioned side view of the device lift mechanism 61 showing particular details which support a reciprocating movement of the pedestal 71 and of the pushpin 78.
A lower end 81 of the pedestal 71 is recessed or cut back along an orthogonal plane through its center coincident with the pickup axis 34. Thus, a guide aperture 82 of circular cross section for the pushpin 78 extends as a semicircular, open channel 83 along a recessed surface 84 of the pedestal 71. A lowermost portion of the lower end 81 of the pedestal is shaped into a scotch yoke-type cam follower 86 supported and driven by a first cam lobe 87 of a camshaft 88. A second cam lobe 89 on the shaft 88 drives a second cam follower 91 which is nested against the recessed surface 84 of the pedestal and which is mounted at its upper end 92 to the pushpin 78. Inasmuch as the pushpin 78 is guidedly held in its guide apertrue 82 in the upper end of the pedestal 71, the pedestal 71 retains the second cam follower 91 against the recessed surface 84.
Referring to FIG. 1, a motor 94, preferably a stepping motor, is electrically coupled to control console 36 by the typical cabling 59. The rotational output of the motor drives the camshaft 88 in a conventional drive connection, such as a flexible shaft, as shown by the symbolic drive coupling 96. During each operational cycle for transferring a selected device 12 from the first array 14 to the sorted array 19, the control console 36 energizes the motor 94 to rotate the camshaft 88 through one complete revolution. Simultaneously with the movement of the camshaft, one of the transfer heads 38 or 41 which is, at that time, located in alignment with the pickup axis 34 approaches the selected device 12 from above to remove such device from the diaphragm 29.
Removing The Device From The Diaphragm
Removing one of the selected devices from the diaphragm 29 has in the past met with problems, particularly when the devices 12 to be handled were relatively large devices, such as, for example, devices of approximately 0.5 cm along each edge. The interaction of the previously described elements of the apparatus 11 in alleviating prior art problems and effecting a fast and efficient removal of the device 12 from the diaphragm 29 is best described in reference to the sequence of FIGS. 2 through 7, the top view of the pedestal 71 in FIG. 8, and the timing diagram of FIG. 9.
FIG. 2 shows an initial significant state of an operational cycle to remove the device 12 from the diaphragm 29. A vacuum force from a vacuum applied to the grooves 66 in the top surface 63 of the housing 62 and to spaces between the support pins 72 of the pedestal 71 has begun to peel the diaphragm 29 from the device 12 in peripheral regions 101 about the pins 72. The support pins 72 have moved slightly upward from a preferred rest position slightly below a base line in the plane of the top surface 63 of the housing 64 and their top surfaces 74 are at this instance in the operational cycle substantially flush with the top surface 63.
The described state is depicted in the diagram of FIG. 9 and is particularly identified at the cyclical status indicator arrow designated "FIG. 2." FIG. 9 identifies the reciprocating motion of the top surfaces 74 of the support pins 72 of the pedestal 71 by the sinusoidal curve 102. At the portrayed cyclical state identified by the indicator FIG. 2, the top surface of the device 12, as identified by the line 103, is still at its rest state one device thickness above the base line identified by numeral 104. A second sinusoidal curve 106 of greater vertical amplitude depicts the reciprocating motion of a rounded top 107 of the pushpin 78. As shown in FIG. 2 and in the diagram of FIG. 9 at the cyclical state described with respect to FIG. 2, the top 107 of the pushpin 78 is still well below the base line 104.
In FIG. 3, the support pins 72 have begun to raise the device 12 above the base line 104, at which the remaining devices 12 are held by the top surface 63 of the support housing 62. It should be noted that the orientation of the selected device 12 parallel to the plane of the array 14 is being maintained by the equal upward motion of the support pins 72 moving in unison.
Maintaining the horizontal orientation of the selected device 12 during the time that it is being lifted from the plane of the array 14 is significant. A typical thickness of a device 12 is, for example, about 530 microns (530×10 -6 meters) while the gap between two adjacent ones of the devices 12 as a result of a typical saw cut amounts only to approximately 50 microns. The drawing, consequently, shows the gaps 109 between adjacent ones of the devices 12 at an exaggerated width to highlight the fact that such adjacent devices 12 in the array are, in fact, separate from each other. In reality, a distance of only 50 microns between two adjacent devices 12 is a narrow gap. It has been found that any tilting of the selected device 12 tends to scrape the edges 76 of adjacent ones of the devices 12 against each other, destroying on occasion one or both of the devices which happened to come into contact with each other during the removal of one of them.
The horizontal support of the selected device 12 during its removal from the array 14 is, consequently, significant. However, it is also significant to urge the selected device 12 from its adhesive hold with the diaphragm. It has been found that the separation of the device 12 from the diaphragm 29 is a dynamic process in that a reactive adhesive force which resists a pulling force is related to the vigor with which the device 12 is removed. An attempt to remove the device 12 more rapidly than at any given rate results in a relatively higher resisting force from the adhesive. The interaction of the vacuum and the lift mechanism 61 optimizes time intervals during which contact regions between the diaphragm 29 and the device 12 become reduced in area before the device 12 is actually lifted from the diaphragm 29. Such reduction tends to effectively diminish the resistive adhesive force exerted by the diaphragm 29 at the time of the removal of the device.
FIG. 2 shows an onset of draping of the diaphragm 29 away from the selected device 12. As the device 12 is lifted by the support pins 72 above the array 14 as shown in FIG. 3, further draping of the diaphragm 29 away from the underside of the device 12 takes place in the peripheral regions 101 about the pins 72. In addition, the adhesive starts to separate from the device 12 toward the center of the device as the diaphragm begins to drape away from the device 12 in regions 111 between adjacent ones of the pins 72. Thus, before the device 12 is transferred, the potential for an excessive adhesive retaining force exerted by the diaphragm 29 on the device 12 is consequently substantially eliminated because of the reduction in contact area between the device 12 and the diaphragm 29.
In a time interval subsequent to the cyclical state described with respect to FIG. 3, the respectively aligned transfer head, for example the first transfer head 38, moves downward, toward the selected device 12 as the device is lifted further by the support pins 72. During this time interval the diaphragm continues to separate from the device 12 as the device 12 is raised above the array 14.
In reference to FIGS. 4 and 9, in FIG. 4 a vacuum probe, shown as a pickup tip 112 of the transfer head 38, contacts the upper surface 103 of the device 12 through a resilient O-ring type seal 113 which is held in a recessed seat 114 at the lower end of the vacuum pickup tip 112. As the seal 113 contacts the upper surface 103 of the device 12, it is not yet compressed and the vacuum in the transfer head 38 is not yet established. At the same time, however, the pushpin 78 moving upward more rapidly than the pedestal 71 reaches and passes the level to which the top surfaces 74 of the support pins 72 have lifted the device 12. As the transfer head 38 reverses its motion and retracts the pickup tip 112 immediately subsequent to the contact position of the tip 112 shown in FIG. 4, the pushpin 78 urges the device 12 into compressive contact with the seal 113 and away from the support of the support pins 72.
FIG. 5 shows in particular the new position of the device 12 wherein the device 12 is peripherally pushed down by a substantially balanced force of the compressed seal 113 and is pushed up in the center of the device 12 by the upward moving pushpin 78 of the lift mechanism 61. Inasmuch as the device 12 remains positively sandwiched at this point between the compressed seal 113 and the pushpin 78, the orientation of the device remains horizontal. It should be noted that at the cyclical state of FIG. 5, the diaphragm 29 has already separated from the device 12 directly above the four contact points of the support pins 72 so that the diaphragm 29 is in contact with the device 12 only at its center coincident with the pickup axis 34. The round tip of the pushpin 78 establishes an outwardly decreasing contact pressure between the device 12 and the adhesive coating on the diaphragm 29 to enhance a final separation of the diaphragm 29 from the outside toward the center of the device 12.
Positions of significant regions of contact between the device 12 and the diaphragm 29 during the described stages of lifting the device are further illustrated in FIG. 8. The four spaced contact areas between the device 12 and the diaphragm 29 are shown as four stippled regions coincident with the support pins 72. The total contact area between the device 12 and the diaphragm 29 has essentially been reduced at the stage of lifting shown in FIG. 4 to such four remaining support areas and a re-established contact area 116 coincident with the contact by the pushpin 78 in the center of the device. When the device 12 is raised from the support pins 72 as described with respect to FIG. 5, only the center contact area 116 remains.
During the time interval from the first contact by the seal 113 with the upper surface of the device and a final upward urging contact against the device by the pushpin 78 as shown in FIG. 6, the vacuum force has been building in the pickup tip of the transfer head 38. Consequently, the final separation of the diaphragm 29 is supported entirely by the vacuum hold exerted by the tip 112 on the device 12. However, at that time of the transfer cycle, the vacuum within the area of the seal 113 is fully established and the remaining contact area 116 by the diaphragm is small in comparison to the area of the device 12, hence the reactive force to pulling the device 12 becomes insignificant to the vacuum force exerted by the tip 112 on the device 12.
FIG. 7 shows the device 12 in a position removed from the diaphragm 29 and the pedestal 71 and the pushpin 78 progressing in their path toward their retracted start positions to ready the lift mechanism for a subsequent cycle. The diagram of FIG. 9 also shows a preferred 30 degree offset in the sinusoidal motion between the first cam lobe and the second cam lobe. Such offset in conjunction with the greater excursion of the motion of the pushpin 78 with respect to that of the pedestal 71 has resulted in consistent removals of the devices 12 from the diaphragm 29.
It should be, of course, understood that various changes and modifications can be made to the described methods of handling the devices 12 in removing them from the diaphragm 29 without departing from the spirit and scope of the described invention. Various possible changes come to mind, such as changing the lead angle of one of the cam lobes with respect to the other, or even totally changing the manner by which the pedestal 71 and the pushpin 78 are raised and lowered. Furthermore, various resilient interactions between the pushpin 78 and the transfer head 38 may be employed or a selectively regulated magnitude of the vacuum may eliminate the need for a resilient interference between the pushpin 78 and the vacuum. Furthermore, the rotational transfer motion of the swing arm 42 may be replaced with other known translational transfer movements of a transfer mechanism. As is apparent from the above, the described apparatus and handling techniques are not at all restricted to semiconductor devices with respect to which the invention has been described. Other, similarly shaped articles may benefit from the described apparatus and techniques. These are only a few examples of various changes and modifications which are possible without departing from the spirit and scope of the present invention. | 4y
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 08/525,495 now U.S. Pat. No. 6,544,626, which was filed on Sep. 5, 1995, and is entitled “Natural Grip.”
FIELD OF THE INVENTION
The present invention relates to gripping and traction surfaces and patterns, particularly for attachment to footwear, handwear, and tools, and more particularly to a footwear sole with an improved pattern having the shape and configuration of the bottom of a human foot, or a palm side of a human hand.
BACKGROUND OF THE INVENTION
It is known in the art to provide a traction or gripping surface made of an elastically deformable and compressible material having a tread pattern of differing shapes and designs to improve the traction of the device to which it is attached, specifically shoe soles, gloves, and mechanical gripping devices. Heretofore, shoe soles have included varying patterns of geometric shapes. During the act of walking or running, the anatomy of the bare human foot, with its numerous curves, contours, and recesses, provides superior traction and gripping ability. Therefore, the need for a sole with an outer surface that very closely approximates the anatomy of a human foot or hand is evident. Previous attempts to provide such a sole have proven inadequate.
DESCRIPTION OF THE PRIOR ART
The applicant is aware of the following patents pertaining to footwear soles:
Patent No.
Issue Date
Inventor
Title
Des. 247,832
May 9, 1978
Glasgow et al.
SHOE BOTTOM
UNIT
Des. 287,903
Jan. 27, 1987
Jones et al.
SHOE SOLE
Des. 295,114
Apr. 12, 1988
Horne
SHOE SOLE
Des. 304,390
Nov. 7, 1989
Nakano
SHOE SOLE
Des. 309,670
Aug. 7, 1990
Mendonca
SHOE SOLE
Des. 319,338
Aug. 27, 1991
Nakano
SHOE SOLE
Des. 337,428
Jul. 20, 1993
Allen, III et al.
SHOE OUTSOLE
U.S. Pat. No.
Sep. 24, 1968
McMorrow
ANIMAL TRACK
3,402,485
FOOTWEAR
SOLES
U.S. Pat. No.
May. 12, 1981
Schmohl
CONTINUOUS
4,266,349
SOLE FOR
SPORTS SHOE
U.S. Pat. No.
Jan. 22, 1985
Lawlor
SHOCK
4,494,321
RESISTANT SHOE
SOLE
U.S. Pat. No.
Oct. 6, 1987
Ganter et al.
BASE FOR AN
4,697,361
ARTICLE OF
FOOTWEAR
U.S. Pat. No.
Nov. 14, 1995
Schumacher et al.
INTEGRAL SOLE
5,465,507
WITH FOOTPRINT
EMBOSSING
Glasgow et al., U.S. Design Pat. 247,832, teaches an ornamental foot-shaped design for a shoe bottom.
Jones et al., U.S. Design Pat. 287,903, teaches an ornamental design for a shoe sole, which looks like an animal paw.
Horne, U.S. Design Pat. 295,114, teaches another ornamental foot-shaped design for a shoe sole.
Mendonca, U.S. Design Pat. 309,670, teaches a further ornamental foot-shaped design of a shoe sole.
McMorrow, U.S. Pat. No. 3,402,485, is directed to footwear that lays simulated animal tracks, which are incorporated into the sole.
Schmohl, U.S. Pat. No. 4,266,349, teaches a continuous sports shoe outsole that includes generally circular pattern elements in the ball and heel areas of the shoe sole to facilitate rotation of the foot. These pattern elements are roughly based on the arrangement of elements of the human foot.
Ganter et al., U.S. Pat. No. 4,697,361, teaches a footwear base made of elastically compressible material which yields in response to the application of stresses by the foot of the wearer of the shoe.
Schumacher et al, U.S. Pat. No. 5,465,507, teaches a footwear having an embossed footprint of a child and a hard rubber perimeter base plate, wherein the base plate provides a stabilizing platform for children learning how to walk.
The remaining patents listed show similar shoe sole designs, and are included for the sake of completeness.
SUMMARY OF THE INVENTION
The present invention embodies the ergonomic design of a gripping and traction surface. The present invention is a device to enhance the gripping or traction of footwear to which it is formed or attached. More particularly, the device is a gripping and traction pattern, formed as an integral part of a shoe sole, that is based on the natural footprint of a human foot. The bottom of the human foot is not a flat surface, but a combination of various anatomical elements of differing size, shape, and contour. The present invention is molded as an integral part of an elastically deformable and compressible outsole, and incorporates the elements and characteristics of the human foot. The sole has multiple projections which stand away from the base of the sole, thereby creating adjacent raised and recessed areas. Projections corresponding to the five toes, and large projections approximating the ball and heel of the foot, are formed in proportion to the actual anatomy of the human foot, thereby creating projections of varying heights. These projections create recessed areas corresponding to the areas between and behind the toes as well as other recessed areas of the human footprint, for instance the arch. These recessed areas allow the ground-engaging projections to adequately deform depending on the force exerted on the sole by the wearer. The outer surface of the outsole is textured with small ridges to mimic the dermal ridges that form the skin pattern of the human foot to further improve traction. The small ridges can generally be classified into five categories, where a category is optimized to either permit angular rotation or to increase traction, and the shape generally has some associated regional specificity. The five categories are lateral traction, backward traction, forward traction, forward pivoting and rearward pivoting. Lateral traction increases resistance to lateral slippage, backward traction increases resistance to forward slippage, forward traction increases resistance to backward slippage, forward pivoting enables angular rotation on the ball of the foot, and rearward pivoting enables angular rotation on the heel of the foot. In general, maximum resistance to slippage is attained when the small ridges are aligned substantially perpendicular to the direction of the force, and minimum resistance to slippage is attained when the dermal ridges are aligned along the direction of the force. Therefore, at or near pivot points, such as the ball of the human foot, the small ridges like dermal ridges are substantially a combination of indefinite loops, whorls and lines, and these naturally occurring patterns are of a human appendage which are non-uniform anatomical features cannot be geometrically characterized. While the footprint of a human foot is easily discernable as belonging to a human, any given footprint has many distinguishing features so that it is very rare for two people to have the same footprint. Accordingly, it is anticipated that there are many variations of the ergonomic design of the gripping and traction surface that fall within the scope of the invention.
Therefore, having neatly classified the texture of small ridges into only five different categories, the reality of the texture of the skin is significantly more complex, and is not easily given to descriptions in terms of simplistic shapes. For instance, closer examination of the dermal ridges in the region of the ball of the foot reveals that only the center most rings are concentric, and the other rings are progressively distorted as the ridges of one shape transform through a continuum to another shape. The continuum reflects an increasing blend of two or more shapes as they evolve to a shape weighted to enhance a performance characteristic, (resistance or slip) that is regionally specific, where the specificity reflects orientation. The small ridges mimic dermal ridges, and are similar in complexity.
The combination of skin texture and projections work in tandem to produce a natural grip which matches the anatomical architecture of the foot. The invention is an outer sole of footwear, wherein the natural grip of the human foot, is reproduced substantially exactly in the external surface of the outer sole.
The outer sole can be a unitary sole wherein the natural grip is a coextensive surface that is integral to the unitary sole. Alternatively, the outer sole can be formed as a laminate, wherein the laminate is comprised of at least two layers, where the surface topography of an outer surface of an outer layer of the laminate is anatomically similar to the sole of a human foot therein providing a natural grip. The laminate has the advantage that composite layers can be formed to impart various levels of flex. For instance a high quality athletic shoe has an outer sole that is a sandwiched laminate of both flexible and stiffer layers, where the flexible layer(s) imparts shock resistance, and the stiffer layer(s) reduces lateral distortion. Outer soles with the natural grip, both laminate and unitary soles, have enhanced gripping capabilities as the human foot is reproduced substantially exactly in the external surface of the outer sole, and the natural grip is imbued with properties which reflect the combination of skin texture and projections. The laminate has the additional advantage that composite layers can be formed such that the stiffer layer has projections which reinforce the outer flexible layer, where the projections correspond to the anatomical regions of the human foot that are reinforced with bone. For instance a toe is a dermal layer stiffened by bone. The counterpart in the invention comprises a laminate sole, wherein a stiffer layer with support projections that is laminated to a flexible layer having an outer surface that is anatomically similar to the outer sole of a human foot, and an inner topography having recesses that receive the support projections of the underlying stiffer layer.
In applications requiring greater tactility, the natural grip is a component of the sole of a bootie, where the bootie fits a foot similar to the way a flexible, stretchable glove fits one's hand. The outer sole of the bootie is comprised of a covering which is a thin, elastically deformable material incorporating the shape, contour, and features of the human footprint. The bootie is especially well suited for activities which currently use specialized slippers, such as ballet slippers, swimming slippers, medical uniform shoe covers, gymnastics shoes and tight rope walking slippers where tactility is of upmost importance, with some measure of protection.
The present invention is envisioned not only to be applicable to shoe soles and booties for wear by humans, but also to the makers and users of movable automated equipment, such as robots, where gripping traction is desired. Additionally, the inventive concept can be expanded to provide devices for superior traction and gripping power for numerous applications, such as gripping tools, prostheses, or any other similar device.
It is further recognized that in certain footwear applications, especially those in which there is a blend of functionality and decoration, such as a sole for a sandal or a flip flop, the full footprint need not be reproduced. The sole can have portions of the human footprint, multiple footprints of varying sizes, footprints with various orientations (for instance backwards) and combinations of the foregoing.
It is also further recognized that a hand print also shares the ergonomic design categories of the gripping and traction surface ascribed to the footprint, and that footwear can have an outer sole with portions of the human hand print, multiple hand prints of varying sizes, hand prints with various orientations (for instance backwards), combinations of the foregoing, and combinations of hand prints and footprints. The anatomical features of both the human hand and the human foot have good traction and gripping properties as well as a distinctively recognizable human appearance.
OBJECTS OF THE INVENTION
The principal object of the invention is to enhance the gripping or traction of articles to which it is formed or attached, namely, footwear and mechanical gripping or traction devices.
A further object of the invention is to provide a gripping and traction pattern for a sole of an article of footwear that approximates the shape and contour of the bottom of a foot, or portions thereof.
A still further object of the invention is to provide a gripping and traction pattern for a shoe sole having tread features that provide superior traction.
A still further object of the invention is to provide a gripping and traction pattern for a shoe sole that gives a more comfortable and natural feel to the wearer.
Another object of the invention is to provide an outer surface for a bootie and similar footwear that has improved tactility approaching the touch and feel that one experiences without a protective covering, yet still provides a measure of protection to the wearer.
A further object of the invention is to provide a gripping and traction pattern for a sole of an article of footwear that approximates the shape and contour of at least one hand print, or portions thereof.
A further object of the invention is to provide a gripping and traction pattern for a sole of an article of footwear that approximates the shape and contour of at least one footprint, or portions thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a sole of a shoe in accordance with the present invention. The right sole is shown.
FIG. 2 is an isometric view of a left shoe of FIG. 1 having a sole embodying the present invention.
FIG. 3 is a side view of the shoe of FIG. 1 having a sole embodying the present invention. The left shoe is shown.
FIG. 4 is an enlarged side view of a portion of the sole of FIG. 3 showing the surface texture of the sole.
FIG. 5 is a cross-sectional view of the sole taken along sectional line 5 — 5 of FIG. 1 . Toes 18 and 20 are obscured by the mid-line portion 37 of the large projection 38 .
FIG. 6 is a side view of a bootie having a unitary sole having a gripping surface pattern embodying the present invention.
FIG. 7 is an enlarged substantially plan view of a portion of the invention shown in FIG. 1 , illustrating the complexity of dermal ridges which make up the surface texture of the skin of a human foot.
FIG. 8 is an isometric view of a mechanical gripping device, where the surface texture is of a human foot (exaggerated).
FIG. 9 is a side view of an athletic shoe having a sole that is a laminate embodying the present invention.
FIG. 10 is a cross-sectional view of the laminate sole taken along sectional line 10 — 10 of FIG. 9 illustrating a stiffer layer with support projections, wherein the stiffer layer is covered with an elastically deformable layer having a natural grip outer surface. Toes 118 and 120 are obscured by the large projection 138 in FIG. 9 .
FIG. 11 is a plan view of a sole of a shoe in accordance with the present invention, wherein the outer sole has a forward hand print and a rearward hand print. The right sole is shown.
FIG. 12 is a plan view of a sole wherein the sole is textured to contain both a foot print and a hand print within the arch.
FIG. 13 is a plan view of a pair of sandals, wherein the soles of the sandals have multiple hand prints.
FIG. 14 is a plan view of a pair of sandals, wherein the soles of the sandals have multiple footprints.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 , 2 , and 3 show a shoe sole 10 constructed from an elastically deformable material. The sole has a base surface 12 that is substantially smooth and flat with a front portion of the base 14 corresponding to the toe area of the sole and a rear portion 16 corresponding to the heel area of the sole. Molded as an integral part of the sole are projections 18 , 20 , 22 , 24 , 26 , 28 , 30 which extend beyond the base surface 12 in varying shapes, contours, and heights.
FIG. 1 shows, at the front portion of the sole 4 , five small projections 18 , 20 , 22 , 24 , and 26 . The size, shape, and location of the projections correspond to the bottom tips of the toes of a human foot. Other large projections 28 , 30 cover a substantial part of the sole 10 , from the heel area to the area of the sole corresponding to the ball of the foot.
The projections are not necessarily uniform in the heights 24 a , 28 a , 37 a and 34 a by which they extend from the base surface 12 , as seen cross-sectionally in FIG. 5 . The height of any projection varies in relation to the variation in the three-dimensional anatomy of the human foot. The variation in projection height can also be based on the respective magnitude of force applied to the respective areas of the sole during walking or athletic activity. For example, the projection height 28 a at the heel is greater than the projection height 34 a at the instep. This variation in projection height, based on the anatomy of the foot, results in some areas on the outer sole where little or no projection occurs, leaving gaps and recesses 32 , 36 as shown in FIG. 1 . These recessed areas 32 , 36 correspond to the areas of a human foot that do not necessarily directly contact the ground when a person is standing, such as the instep, and the areas between and behind the toes. These recessed areas of the human foot are very important to the acts of walking or running, however, because they allow the toes to grip the ground or floor surface when force is applied when walking, thereby creating superior traction. Similarly, the recesses 32 , 36 in the invented sole allow the ground-engaging projections to adequately deform based on the force or stress applied by the wearer of the shoe. This deformation also supplies superior traction and a more natural feel for the wearer of the shoe.
FIG. 4 shows an enlarged view of the outer surface of the projections corresponding to a little toe 18 , and a volar surface of large projection 38 on the base 12 . Integrally formed on all ground-engaging outer surfaces of all projections are a plurality of small ridges 40 that simulate the characteristic footprint of human skin. These small ridges, which are similar to dermal ridges, allow the ground-engaging surfaces of the elastically deformable sole to better grip the walking platform thereby creating superior traction.
The best mode of carrying out the invention is accomplished where the gripping and traction surface is an integral part of the shoe sole 10 , which is constructed of an elastically deformable material that is common to athletic shoes, such as rubber, PVC, polyurethane, or any suitable synthetic elastomeric substance. The shoe sole can be formed as a single layer, where the sole is cast or injection molded directly to the upper part of the shoe to integrally incorporate all of the features of the gripping pattern, including the base, projections, recesses, and ridges. Alternatively, the sole can be formed as a laminate having two or more layers, wherein the outer layer of the sole is cast or injection molded to integrally incorporate all of the features of the gripping pattern, including the base, projections, recesses, and ridges. FIG. 6 is an inner perspective side view of a right bootie 90 having a gripping surface pattern embodying the present invention, wherein the bootie has a unitary outer sole 10 formed by integrally bonding a very flexible rubbery layer imbued with the natural grip to an inner sole (not shown), where the inner sole is a layer of conformable fabric impregnated material. Four of the five small projections 18 , 20 , 24 , and 26 are shown. The middle toe 22 is not visible from this view. The large projections, the heel 28 and the ball 30 and the small projections are on base 12 .
FIG. 7 is an enlarged substantially plan view of a portion of the invention shown in FIG. 1 , illustrating the complexity of small ridges which faithfully reproduces the dermal ridges which make up the surface texture of the skin of a human foot. The area shown in FIG. 7 is the area of the ball 30 of the foot. Note that the small ridges comprising the outer surface of the outer sole mimic the dermal ridges that form the skin pattern of the human foot to further improve traction. The small ridges can generally be categorized into five shapes, where a shape is optimized to either permit angular rotation or to increase traction, and the shape generally has some associated regional specificity. The five categories are lateral traction, backward traction, forward traction, forward pivoting and rearward pivoting. Lateral traction ridges 39 increases resistance to lateral slippage, forward traction ridges 40 increases resistance to backward slippage, backward traction ridges 41 increases resistance to forward slippage, and forward pivoting ridges 31 enables angular rotation on the ball of the foot. The rearward pivoting ridges 45 , as seen in FIG. 1 which enable angular rotation on the heel of the foot, are less specifically defined. In general, maximum resistance to slippage is attained when the small ridges are aligned substantially perpendicular to the direction of the force, and minimum resistance to slippage is attained when the dermal ridges are aligned along the direction of the force. Therefore, at pivot points, such as the ball 30 of the human foot, the small ridges like dermal ridges are substantially concentric rings 31 . From inspection of FIG. 1 , lateral traction is enhanced when the dermal ridges 39 have a slightly angular orientation from the midline. The orientation is a composite to reduce lateral slippage and backward slippage. The dermal ridges on the toes 18 , 20 , 22 , 24 , and 26 are oriented with primarily with traction ridges and some component of lateral ridges. The dermal ridges just in front 40 of the ball 30 are substantially pure forward traction ridges. These ridges 40 undergo elongation minimizing backward slippage.
The dermal ridges to the rear 41 of the ball 30 are substantially pure backward traction ridges. The ridges 41 undergo elongation minimizing forward slippage. The ridges concentrated at the ball of the foot 30 are substantially of the pure forward pivoting type, wherein the ridges are substantially concentric rings that are angularly aligned with the rotation, and are therefore less susceptible to distortion. These naturally occurring patterns are of a human appendage, and as such are non-uniform anatomical features cannot be geometrically characterized. The center of heel 28 is similar to the ball 30 , except that the weight is shifted to the rear, therein enabling rearward pivoting. The rear pivoting ridges are only partially defined for angular rotation.
FIG. 9 is a side view of an athletic shoe having an outer sole that is a laminate embodying the present invention. The outer sole 10 is comprised of an external layer 116 having a base 112 with projections and an underlying support layer 113 a . The support layer 113 a is a relatively stiffer layer with projections that correspond to the supporting bones in a foot, and in a similar fashion, where the bones of toes are covered with a dermal layer, likewise the stiffer layer 113 a is covered with a more pliable layer 112 . The major projections of the laminate outer sole 110 are the heel 128 and the ball and the surrounding area 138 . The minor projections at the front of the outer sole 114 correspond to the toes 118 , 120 , 122 and 124 of a human foot. The big toe is not visible in FIG. 9 . The projections in the stiffer layer and the superimposed projections in the flexible layer form a surface having traction characteristics that are similar to a human foot. The outer sole 10 has the outward appearance of the shoe illustrated in FIG. 2 . The projections originating in the relatively stiffer layer act similar to bones, and enable force to be move directionally precise; that in a sense act somewhat like prosthetic projections of the bones of the foot.
FIG. 10 is a cross-sectional view of the laminate sole taken along sectional line 10 — 10 of FIG. 9 illustrating a stiffer layer 113 a with support projections, wherein the stiffer layer is covered with an elastically deformable layer having a natural grip outer surface. The cross-sectional view illustrates the laminate 10 . As can be seen in FIG. 10 , the relative thickness of the flexible layer 112 is nearly constant at the major projections 137 and 128 , as well as at the minor projections, 124 and 122 , and the recessed areas, 132 and 134 , as indicated by the (respectively double arrows 122 a , 124 a , 128 a , 132 a , 134 a and 137 a ). The stiff layer 113 a above the projections is proportionately thicker so that the total thickness is comparable to those projections shown in FIG. 5 for the unitary sole, and indicated by 22 a , 24 a , 28 a and 37 a.
FIRST ALTERNATIVE EMBODIMENT
The shoe sole 10 illustrated in FIG. 11 depicts an outer sole 4 with a base 12 with at least one hand print 13 . The outer sole 4 has a forward hand print 13 ′ and rearward hand print 13 ″.
The shoe sole 10 shown in FIG. 12 is a composite of projections 26 (big toe), 24 , 22 , 20 and 18 (toes) and large projection 30 . The rear of the base 12 has a portion of a footprint taken from the ball 31 of the foot ( FIG. 7 ). In the area corresponding to the arch, the base 12 of the outer sole 4 has a small representation of a hand print 13 .
Referring to FIG. 13 , which is plan view of a pair of sandals 200 . The outer soles 4 of the sandals have multiple hand prints 13 from the palm side of a human hand, wherein the natural grip of the human hand, is reproduced substantially exactly in the external surface of the outer sole 4 . The outer sole 4 is a unitary sole, wherein the natural grip is a coextensive surface that is integral to the unitary sole 10 .
FIG. 14 is similar to FIG. 13 , albeit the outer soles of the sandals 200 have multiple footprints 11 integral to the outer sole 4 .
SECOND ALTERNATIVE EMBODIMENT
The present invention can be applied not only to footwear to be worn by humans, but also to any application where gripping traction is required, such as on gloves, tools, legs, arm members of automated machinery or robots. The development of technologically advanced machinery capable of carrying out mechanical tasks continues to expand. The invented gripping and traction pattern can be attached to any element of a device or machine in which superior gripping ability or traction is desired. FIG. 8 is an isometric view of a mechanical gripping device 71 , where the surface texture of the rubber fascia plates 72 , have the texture of a human foot. The dermal ridges are selected to prevent slippage, and are incorporated into the facial surface texture of the plate. The specific type of ridges are selected to improve gripping (resistance to slippage) in at least one direction. The mechanical gripping device 71 shown in FIG. 8 has one or more articulating jaws 70 , where a jaw is inner fitted with an elastically deformable and compressible material, such as rubber used in shoe soles.
The gripping and traction pattern can be formed of any material suitable for use on the article to which it is to be attached; for example, the pattern for use on the sole of a shoe can be made of leather.
SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION
From the foregoing, it is readily apparent that I have invented a surface or pattern which enhances the gripping or traction of articles to which it is formed or attached, namely footwear, handwear, and mechanical gripping or traction devices, and which provides a more natural and comfortable feel for the wearer. Similarly, I have invented an improved surface for the gripping or traction portion of a shoe, glove, or mechanical gripping device which provides superior gripping ability and a natural feel.
It is to be understood that the foregoing description and specific embodiments are merely illustrative of the best mode of the invention and the principles thereof, and that various modifications and additions may be made to the apparatus by those skilled in the art, without departing from the spirit and scope of this invention, which is therefore understood to be limited only by the scope of the appended claims. | 4y
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FIELD OF THE INVENTION
[0001] This invention relates to a string of electrically powered ornaments such as a string of lights used for such purposes as decorating Christmas trees and other symbolic things including commercial branding, showroom displays, etc. More particularly, the invention relates to electrically wired ornament strings and provides means to assist in determining which of the various ornaments in a string has failed. In the following description, the invention is described as it applies particularly to a string of Christmas lights, but it is to be understood that this particular application of the invention is only exemplary of its many uses, and the invention is not to be so narrowly construed except as recited in the appended claims.
BACKGROUND OF THE INVENTION
[0002] Light strings frequently are made with fifty or more lights, and when a light fails generally the others remain lit. Occasionally, however, something happens to a bulb that breaks the electrical circuit and all of the lights in the string go out. When that occurs, it is necessary to check each bulb in the string to find the one that failed. When that light is replaced, the entire string will light. Light testers are available to assist in checking all the lights in a string, but it is often difficult to follow the string when it is wound about the branches of a tree and/or used in close proximity with other strings.
[0003] A primary object of the present invention is to provide means to assist a person in tracing a light string so that the bulbs may be tested in order without skipping any of the lights in a string or unknowingly retesting any of them.
[0004] Another object of the present invention is to assist a person using a light tester so that it may be used most efficiently.
SUMMARY OF THE INVENTION
[0005] In accordance with the present invention, the string of ornaments, whether they be lights or other electrically powered elements, are sequentially identified by applying indicia to each ornament in the string such as by numbering or lettering each of the ornaments in sequence. This will enable one to sequentially trace the ornaments in a particular string regardless of how the string is displayed or presented so that each ornament in the string may be tested to identify and replace the failed ornament, to reactivate all of the ornaments in the string.
[0006] These and other objects and features of the invention will be better understood and appreciated from the following detailed description of selected embodiments thereof, presented for purposes of illustration and shown in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a perspective view of a typical Christmas tree illustrating how a number of intertwined or interlaced light strings are typically applied to the tree;
[0008] [0008]FIG. 2 is a diagrammatic view of a string of lights constructed in accordance with the present invention and sequentially numbered to enable the string to be traced even when wound on a tree in the manner generally suggested in FIG. 1 or in any other location;
[0009] [0009]FIG. 3 is an elevation view of a single light including both a socket and lamp carrying indicia, in this case, a letter, so as to enable a series of such lights to be traced to locate a failed bulb so that it may be replaced and thereby render the entire string operative; and
[0010] [0010]FIG. 4 is a fragmentary elevation view of a string of lights with indicia applied to tags attached to the wires connecting them in the string.
DETAILED DESCRIPTION
[0011] In FIG. 1, a Christmas tree 10 is suggested on which are hung a number of string lights 12 , 14 , 16 , . . . , each composed of a substantial number of ornaments 20 . As suggested above, while ordinarily the failure of one bulb will not effect the other lights in a string, occasionally the failure of one will cause the entire string to go dark. The single string, 22 suggested in FIG. 2 includes a plug 21 at one end for connecting the string to a power source. The plug is merely representative of a number of different electrical connectors that may be used. It is not uncommon to have fifty or more lights in a single string, and in large displays a single string may have a very large number, even exceeding 100 or more lights.
[0012] It is not difficult to appreciate that when all the lights in a string go dark, it is a difficult and time consuming task to locate the failed bulb that caused it, and this task is made more difficult because of the need to trace the string and test the bulbs in sequence. While various sophisticated circuits have been developed that will indicate where failure has occurred and so as to avoid the necessity for tracing along an entire string, they are expensive and not fully reliable.
[0013] In accordance with the present invention, sequential indicia is associated with each of the lights in a string. Thus, as FIG. 2 suggests ‘n’ lights in the string, they are consecutively numbered 1-“n”. In accordance with one aspect of the invention, the indicia may be applied to the sockets as suggested in FIGS. 2 and 3, but it should be appreciated that the indicia may alternatively be applied to the wiring adjacent each socket by an inconspicuous tag or label 30 wrapped on the wiring as in FIG. 4, or alternatively the wiring itself between adjacent sockets may be sequentially marked so as to assist a person in tracing the string from one end to the other if necessary to locate the failed bulb or other ornament. While in FIG. 2 the indicia is in the form of consecutive numbers applied to the series of lights in sequence, the numbers may be replaced by sequential letters of the alphabet or any other sequential indicia that a person will readily recognize so as to assist him or her to follow the ornaments in series in the string.
[0014] While in the foregoing description, the invention has been described as applied to a series of Christmas tree lights in a string, the lights may be replaced by any other electrically powered ornament or device.
[0015] While in the foregoing description the lights carry sequential indicia throughout the string, for convenience in manufacturing and to reduce costs, particularly in long strings, an indicia sequence may be repeated. For example in a string of 50 lights, a sequence of 1 through 10 may be repeated five times, or a different sequence may be repeated a sufficient number of times to cover the entire string. In many applications, that arrangement will be adequate to enable a person to trace the string so as to locate the failed light or other ornament.
[0016] Having described this invention in detail, those skilled in the art will appreciate that numerous modifications may be made of this invention without departing from its spirit. Therefore, it is not intended that the breadth of the invention be limited to the specific embodiment illustrated and described. Rather, the breadth of the invention should be determined by the appended claims and their equivalents. | 4y
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FIELD OF THE INVENTION
[0001] The present invention relates to power converters with means, devices and apparatus for adjusting power factor. More specifically, although of course not solely limited thereto, the present invention relates to a single stage power factor corrected power converter (SSPFC).
BACKGROUND OF THE INVENTION
[0002] Power converters, for example, AC/DC converters, are usually equipped with power factor correction means or circuits. An intermediate storage capacitor is typically used to provide the necessary power factor correction or adjustment. However, the intermediate storage capacitor for power factor correction is usually subject to a high voltage stress as the voltage of the intermediate storage capacitor is usually left uncontrolled and can vary widely with respect to the line voltage and the load current. Consequently, the storage capacitor voltage can be substantially higher than the peak line voltage.
[0003] For example, while the ordinary line input voltage ranges from 90 to 265 Vrms, the voltage across the intermediate storage capacitor can vary between 140V to 2500V. If the DC/DC regulator stage operates in the continuous conduction mode (“CCM”) and at a decreasing load, the storage capacitor voltage can go up even higher due to power imbalance between the input and output.
[0004] As a result, a bulkier storage capacitor with a higher voltage rating as well as other high-voltage-rating devices (such as power switches and diodes) which inevitably lead to an increase of the size and the total costs will have to be used.
[0005] Furthermore, as single-stage power-factor-corrected converters (SSPFC) aiming at reducing the cost and simplifying the power stages and control of the converter have been developed by integrating a power factor correction (PFC) circuit with a DC/DC regulator circuit and is becoming more useful, there is therefore an urging need to devise improved power factor corrected power converters so that the demand on the voltage rating of the intermediate storage capacitor can be lessened so that a less bulky storage capacitor with a lower voltage rating can be used.
[0006] In order to alleviate the above problems, various schemes and methodologies such as the use of variable frequency control, bus voltage feedback control and series-charging-parallel-discharging techniques have been reported. In addition, it has been suggested to alleviate the problems by inserting a direct power transfer path to the input stage of a converter to raise conversion efficiency and to lower the voltage stress on the storage capacitor. However, the large storage capacitor voltage swing due to line voltage variation remains a largely unresolved problem. In particular, the voltage across the storage capacitor of the known power-factor-corrected power converters always exceed the peak line input voltage due to the presence of a boost converter in such topologies which inevitably steps up the voltage across the storage capacitor. Garcia et al in “ AC/DC Converters with tight output voltage regulation and with a single control loop,” in IEEE Power Electronics Specialists Conf., 1999, pp. 1098-1104, and Lazaro et al, in “ New family of single - stage PFC converters with series inductance interval,” in IEEE Power Electronics Specialists Conf, 200, pp. 1357-1362 attempted to reduce the storage capacitor voltage below the peak line voltage by using flyback-buckboost and flyback-boost converters respectively. However, such converters require two switches and are less attractive for low-power applications.
OBJECT OF THE INVENTION
[0007] Hence, it is an object of the present invention to provide power-factor-corrected converters with a less stringent demand on the voltage rating of the intermediate storage capacitor so that a less bulky storage capacitor can be utilized for power factor correction. At a minimum, it is an object of the present invention to provide the public with a useful choice of power-factor-corrected converters and circuit topologies and schemes for PFC converters.
SUMMARY OF THE INVENTION
[0008] According to the present invention, there is provided A power converter for operating with an alternate current power source, including a storage capacitive means and a transformer, said storage capacitive means being adapted for power factor correction, said transformer including an input for connecting to an alternating current power source and at least a first output and a second output respectively for connecting to said storage capacitive means and the load, said transformer including input windings, first output windings and second output windings which are respectively connected to said input, said first and second outputs wherein said transformer and said storage capacitive means being adapted that the voltage across said storage capacitive means being related to the voltage of said first output of said transformer.
[0009] According to a second aspect of the present invention, there is provided a single-stage power-factor-corrected power converter including a dual-output flyback transformer, an intermediate storage capacitor, an electronic switching means and an output transformer for coupling power to a load, said intermediate storage capacitor being adapted for power factor correction, said flyback transformer including an input for connecting to an alternate current power source and at least a first output and a second output respectively for connecting to said storage capacitive means and the load, said transformer including input windings, first output windings and second output windings respectively connected to said input and said first and second outputs, said first output windings of said flyback transformer and said intermediate storage capacitor being both connected to said electronic switching means, said second output windings of said flyback transfer being connected to the output of said power connection.
[0010] Preferably, the windings in association with said input and first output terminals of said transformer being adapted that the voltage across said storage capacitive means does not exceed the voltage appearing at said input terminal during normal operation.
[0011] Preferably, said input windings and said first output windings being in series connection with a common switching means, said storage capacitive means be charged and discharged when said switching means being turned on and off.
[0012] Preferably, an electronic switching means being connected simultaneously to first and second circuit loops which respectively contain the input windings of said input terminal and first output windings of said first output terminal of said transformer, wherein, during normal operation when said switching means being in the “on” state, said storage capacitive means being charged up and, when said switching means being in the “off” state, the energy stored in said capacitive storage means being transferred to a load.
[0013] Preferably, during normal operation, the voltage across said storage capacitive means being tied to the output voltage of said second output of said transformer.
[0014] Preferably, the voltage of said storage capacitive means being generally proportional to the output voltage of said second output of said transformer.
[0015] Preferably, the ratio between the voltage across said capacitive means and the output voltage of said second output of said transformer being proportional to the turns ratio between the number of windings.
[0016] Preferably, said transformer being configured as a flyback transformer.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Preferred embodiments of the present invention will be explained in further detail below by way of examples and with reference to the accompanying drawings, in which:
[0018] FIG. 1 shows a schematic circuit diagram of single-switch flyback power-factor-corrected AC/DC power converter (SSPFC) as an example of a preferred embodiment of the present invention,
[0019] FIG. 2 shows an operation and timing diagram of the SSPFC of FIG. 1 in a line cycle,
[0020] FIG. 3 shows the more salient switching waveforms of T 1 primary and secondary currents within a switching period T S at different modes,
[0021] FIGS. 4 a and 4 b respectively show the measured storage capacitor voltage V B (upper), line input voltage (middle) and current (lower) at 90 Vrms and different output power (time base+5 ms/div).
[0022] FIG. 5 is a graph showing the measured storage capacitor voltage V B versus output power at different V in ,
[0023] FIG. 6 is a graph showing the comparison of V B against V in on different converter topologies.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In the description below, a preferred embodiment of a power-factor-corrected power converter will be explained in more detail by reference to the circuitry of a single-stage power-factor-corrected power converter (SSPFC). The power-factor-corrected power converter includes a dual-output transformer, which is configured as a dual-output flyback transformer T 1 , a storage capacitive means which is an intermediate storage capacitor C B in the present example, an electronic switching means S 1 which is a MOSFET switch in the present example and an isolating output transformer T 2 . The dual-output flyback transformer T 1 includes an input, a first output and a second output which are respectively connected to input windings, first output windings and second output windings respectively with the respective winding ratios 1:n1:n3.
[0025] The transformer T 1 is configured in a flyback topology so that the transformer can simultaneously serve as a filter, a power transferring transformer and a storage element which at the same time provides circuit isolation between the input and the output. This flyback topology is in contrast to the forward topology in which the transformer only serves to transfer power and to provide isolation between the input and the outputs. In the forward transformer configuration, an additional inductor is required to implement the filter and storage functions. Furthermore, the flyback transformer topology has the further benefit of accepting a wider range of input voltage because it can either step up or step down the input voltage while the forward transformer topology is generally for stepping down input voltage. In this example, flyback transformer is used as a preferred example.
[0026] The intermediate storage capacitor C B is used primarily for buffering the power imbalance between the alternating current (AC) input power and the output power. That is, when the AC input power is less than the output power, the storage capacitor means, namely, the intermediate storage capacitor C B in the present example, will deliver the extra energy required to maintain a substantially constant output power. On the other hand, the intermediate storage capacitor C B will store excess energy when the input power exceeds the output power. In addition, the intermediate storage capacitor C B is also adapted to provide a sufficient hold-up time for the power supply to maintain a short period of power output when the input is cut off momentarily.
[0027] Hence, the transformer and the intermediate storage capacitor co-operate as the primary components to achieve power factor correction as well as controlled output voltage regulation as to be described below.
[0028] An electronically controllable switching device, such as, for example, a MOSFET, an IGBT or other appropriate switching devices is included to enable the alternative power charging on the intermediate storage capacitor and power output to the load. In this specific configuration, the two switching terminals of the switching device S 1 are connected in series to the input winding and the first output of the dual-output flyback transformer. As can be seen from the schematic circuit diagram of FIG. 1 , the switching means S 1 is included in a loop containing the first output winding of the dual-output transformer, a diode D 2 , windings L P2 of the output transformer and another diode D 1 . In addition, it also forms part of the loop containing the intermediate storage capacitor C B , the diode D 2 and the winding L P2 . Furthermore, the switching device also forms part of the loop containing the input windings of the flyback transformer T 1 and the power source.
[0029] As can be noted from the circuit diagram, the input of the input windings of the flyback transformer T 1 is for connection to an alternating power source and the output of the input windings L P1 is connected to a node intermediate between the windings L P2 of the output transformer and the switching means S 1 . Hence, it would be appreciated from the circuit diagram and the description above that a single or common switching device is simultaneously connected in series with the input windings and the first output windings of the flyback transformer, thereby alleviating the need of two separate switches as is required by the known flyback-buckboost or flyback-boost converters.
[0030] The dual-output flyback transformer T 1 includes a second output which is connected with the second output windings. This second output windings are connected to the output or a load via a diode D 3 . The connection between the second output winding of the flyback transformer and the output provides a feedback path so that the output voltage V 0 is fed back to the first output windings by the ratio N3/N1 in a perfectly coupled transformer, although a more detailed analysis of the coupling will be described below. By this feedback arrangement via the second output windings of the flyback transformer, the voltage across the intermediate storage capacitive means or the intermediate storage capacitor C B will be controlled with reference to the magnitude of the output voltage, V 0 and the turns ratio N3/N1.
[0031] The output transformer T 2 is provided for coupling power from the primary circuit (including the flyback transformer and the intermediate power capacitor) to the load. Of course, the output voltage V 0 can be adjusted by varying the turns ratio N2 in the output transformer without loss of generality.
[0032] Furthermore, the output transformer T 2 also provides the necessary isolation to enable paths that can be selectively isolated by means of electronic switching for power transfer to the load and, alternatively, for power storage.
[0033] Detailed operation of the present preferred embodiment of a SSPFC will be explained below.
[0000] Operation
[0034] Referring to the schematic circuit diagram of FIG. 1 , the dual-output flyback transformer T 1 is connected to the line to shape the input current (it works in the Discontinuous Conduction Mode DCM for PFC function), to deliver energy to the intermediate storage capacitor C B , to provide a direct power transfer path to output for the converter and, more importantly, to control the voltage of C B . C B delivers power through the flyback transformer T 2 , which operates in either DCM or CCM.
[0035] The operation of the flyback SSPFC is described generally below. When the power switch S 1 is turned on, L p1 and L p2 are charged up linearly by the rectified input voltage V in and the voltage across the storage capacitor V B respectively. Diodes D 1 , D 3 and D 4 are reverse biased at this instant and are therefore not conducting. The output capacitor C o sustains the output voltage V o . After the period d 1 T s has lapsed, the switch S 1 is turned off as shown in FIG. 3 , the diode D 4 is forward biased and the energy stored in T 2 will be coupled to the load. Meanwhile, the energy stored in T 1 is transferred to C B and R o through D 1 and D 3 respectively. Before S 1 is turned on again to begin the next switching cycle, all the energy stored in T 1 would have normally been completely transferred to the load and C B (thus, i D1 and i D3 will fall to zero). If T 2 runs in CCM, V o is maintained by the energy delivered from T 2 through D 4 . On the other hand, if T 2 operates in DCM, no current will flow in T 2 before S 1 is turned on. V o is then sustained by C o . To repeat the operation cycle, S 1 is switched on again.
[0036] When IV in l sis going through a half line cycle, the transformer T 2 enters into different conduction modes, as shown in FIG. 2 . Although transformer T 1 works in DCM, the inevitable leakage inductance in T 1 will alter the downslopes and shapes of the secondary currents. Typically, there are three modes of operation and they are described below with reference to FIG. 2 .
[0037] Mode 1 : during this mode, T 2 runs in CCM. As the input power is lower than the output power, T 2 handles most of the output power. The major portion of stored energy in T 1 will be coupled to C B through D 1 . i D1 has a generally trapezoidal waveform while i D3 has a generally triangular waveform, as shown in FIG. 3 ( a ). In addition, because the duty ratio of S 1 is substantially constant within this interval, more input power as well as more output power will be handled by T 1 as input voltage increases. On one hand, this pushes T 2 towards DCM as T 1 provides more output current. On the other hand, the current in D 1 becomes smaller.
[0038] Mode 2 : In this mode, T 2 runs in DCM and T 1 handles most of the output power. i D3 now has a trapezoidal shape and i D1 has a triangular shape, as shown in FIG. 3 ( b ). When T 2 runs in CCM, it automatically corrects the current difference in D 3 and D 4 by shifting the level of CCM. But when both transformers T 1 and T 2 work in DCM, the duty ratio has to be decreased to maintain a constant output power, as the line voltage increases.
[0039] Mode 3 : As input voltage reduces, T 2 again handles the major part of the output power as the input power becomes smaller. The duty ratio remains constant as in Mode 1 . The only difference is that the distribution of the secondary currents of T 1 are maintained substantially the same as that in Mode 2 .
[0040] It should be noted that V o is substantially free from low frequency components of the line voltage at both operation modes (DCM and CCM) of T 2 . When T 2 runs in CCM, the duty ratio of S 1 is constant due to fast self-adjustment of the transformer current. When T 2 runs in DCM (Mode 2 in FIG. 2 ), the transformer current adjustment disappears but the fast feedback loop of V o gives a valley-shape duty ratio of S 1 which maintains the output constant.
[0000] Analysis of Storage Capacitor Voltage
[0041] For ideal coupling transformer (i.e. in the absence of leakage inductance), the storage capacitor voltage V B will be merely controlled by the turns ratio of transformer T 1 as the output voltage V o is tightly regulated and it is given by equation (1) below:
V B = n 1 n 3 V o ( 1 )
[0042] However, in practice, the wiring inductance and the leakage inductance of transformer degrade the cross regulation of the converter. Equation (1) is no longer valid. By inspecting the current waveforms in Mode 1 and using input-output power balance between T 1 , T 2 and V o , the steady state expression of the storage capacitor voltage during this mode can be found.
V B = n 1 n 3 K 2 + K 2 2 - 4 K 1 K 3 2 K 1 V o where ( 2 ) K 1 = 1 16 [ 16 π n 3 M 1 2 k c ( 2 - k ) 2 / d 1 2 - 8 n 1 M 1 ( 2 - k ) ( 3 - 2 k ) + π n 3 ( 1 - k ) ( 2 - k ) ( 3 - k ) ] ( 3 ) K 2 = 1 16 [ 16 π n 3 M 1 2 k c ( 2 - k ) / d 1 2 - 8 M 1 ( 3 - k ) 2 + π n 3 ( 1 - k ) ( 3 - k ) ] ( 4 ) K 3 = 1 2 [ 2 π n 3 M 1 2 k c / d 1 2 - M 1 k ] ( 5 )
[0043] In the above equations, M 1 is the ratio of output voltage to peak input voltage, k is the coupling coefficient of T 1 and k c =Lp1/(R o T s ). Equation (2) holds provided that T 2 operates in CCM throughout the entire line cycle. Otherwise, the equation of steady state V B over a half line cycle will involve different modes of operation and complex calculation. However, from equation (2) it is enough for one to predict that V B will be controlled not only by the turns ratio and V O1 by the peak input voltage. When the peak input voltage increases, V B will also increase.
[0000] Analysis of Input Current
[0044] The average input current <i in > of the proposed converter within one switching period equals the average primary current of T 1 <i in >L p1 and is given by
〈 i in 〉 = d 1 2 Ts 2 L p1 V in ( t ) ( 6 )
[0045] This resembles the input current of a normal flyback converter serving as a power factor correction circuit. Hence, the proposed flyback SSPFC inherits unity factor property provided that T 2 is working in CCM throughout the line cycle so that the duty ratio d 1 can be kept constant. It is observed from FIG. 2 that T 2 may enter DCM in Mode 2 , resulting in distorted input current as the third current harmonic component increases (and higher odd harmonics but of smaller quantity). The longer the duration of Mode 2 , the poorer the power factor will be. In fact when the output power becomes light, T 2 has larger tendency to enter DCM.
[0000] Experimental Results
[0046] In order to verify the operation of the proposed SSPFC shown in FIG. 1 , a 28 Vdc-70 W hardware prototype with input voltage range 90-240 Vrms and 100 kHz switching frequency has been implemented and tested. The circuit parameters used for the experiment are L p 1=70 μH, n 1 =0.31, n 3 =1.54; L p2 =900 μH, n 2 =3.3; C B =200 μF; C o =1000 μF; S 1 : MTW14N50E, D 1 : MUR4100E, D 2 : MUR460, D 3 and D 4 :MUR860. FIG. 4 shows the waveforms of the storage capacitor voltage, the input line voltage and the line current at 90 Vrms for a light load (30 W) and at full load (70 W). The measured power factor is 0.946 at 30 W and 0.997 at 70 W. The storage capacitor voltage V B throughout the load range at different line voltages is recorded in FIG. 5 . In theory, V B equals (1.54/0.31)*28=139V according to equation (1). In practice, due to inevitable wiring and leakage inductances, V B increases as input voltage increases, as have been predicted in (2). However, the increment of V B of the proposed single-switch SSPFC (around 50-75V for 90-240 Vrms input) is much smaller than that of the existing single-stage topologies (at least 200V difference). It can also be seen that the variation of V B is small even for large changes of output power (or load current). Furthermore, it is shown that V B can be loosely regulated at a voltage lower than the peak input voltage at high line (240 Vrms in this case), so that a smaller voltage-rating capacitor can be used (e.g. 250V). When comparing with existing converter topologies, FIG. 6 shows that the proposed SSPFC has the lowest V H at high line voltage. FIG. 7 shows that the measured efficiency of the SSPFC at different input voltages is around 80% at output power above 20 W.
[0047] While the present invention has been explained by reference to the preferred embodiments described above, it will be appreciated that the embodiments are illustrated as examples to assist understanding of the present invention and are not meant to be restrictive on the scope and spirit of the present invention. The scope of this invention should be determined from the general principles and spirit of the invention as described above. In particular, variations or modifications which are obvious or trivial to persons skilled in the art, as well as improvements made on the basis of the present invention, should be considered as falling within the scope and boundary of the present invention.
[0048] Furthermore, while the present invention has been explained by reference to a single stage power factor correction power converter, it should be appreciated that the invention can apply, whether with or without modification, to other multiple stage power converters without loss of generality. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/139,081 filed on Aug. 24, 1998, which in turn is a continuation-in-part of U.S. patent application Ser. No. 08/715,724, filed Sep. 19, 1996, the entire content of each prior application being incorporated expressly hereinto by reference.
FIELD OF THE INVENTION
[0002] This invention relates to stain-resistant, dyeable sheath/core filaments and methods. More particularly, this invention relates to sheath/core filaments wherein the core component is susceptible to dyeing by dye chemicals in a dye bath, while the sheath component is resistant to dyeing by such dye chemicals in the dye bath.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] As used herein, “dyed” refers to the results of an intentional coloration process performed by exhaust or continuous dyeing methods that are known in the art after the material (i.e., fiber) is extruded by incorporating one or more colored chemical compositions into the material at elevated temperature. In contrast, the term “stained” means the discoloration of fibers caused by the binding of a colored material either ionically, covalently, or through chemical partitioning to the fiber. The term “stain resistant” and “stain resistance” as used herein with respect to polyamide fibers or carpets refers to the ability of the fiber or carpet to resist red drink and/or coffee stains. “Inherently chemically compatible” means that the materials referred to are miscible.
[0004] Polyamide fibers are relatively inexpensive and offer a combination of desirable qualities such as comfort, warmth and ease of manufacture into a broad range of colors, patterns and textures. As a result, polyamide fibers are widely used in a variety of household and commercial articles, including, e.g., carpets, drapery material, upholstery and clothing. Carpets made from polyamide fibers are a popular floor covering for both residential and commercial applications.
[0005] Polyamide fibers tend to be easily permanently stained by certain natural and artificial colorants such as those found in such common household beverages as coffee, wine and soft drinks. Such household beverages may contain a variety of colored anionic compounds including acid dyes, such as the red dyes used in children's drinks. The stains resulting from such compounds cannot easily be removed under ordinary cleaning conditions.
[0006] The ability of a staining material like an acid dye to bind to a fiber is a function of the type of active functional groups on the fiber and of the staining material. For example, polyamides usually have terminal (often protonated) amine groups which bond with negatively charged active groups on an acid dye (or staining agent).
[0007] A commonly used acid dye colorant and one which severely stains nylon at room temperature is Color Index (“C.I.”) Food Red 17, also known as FD&C Red Dye 40. Acid dyes such as C.I. Food Red 17 often form strong ionic bonds with the protonated terminal amine groups in the polyamide polymers, thereby dyeing, i.e., staining, the fiber. Thus, in contrast to soils which are capable of being physically removed from the polyamide carpet by typical cleaning procedures, acid dye colorants such as C.I. Food Red 17 penetrate and chemically react with the polyamide to form bonds therewith which make complete removal of such colorants from the polyamide fibers impractical or impossible.
[0008] The exact mechanism of coffee as a staining agent is not well understood. However, as with acid dye stains, coffee stains are notoriously difficult to remove from polyamide carpet by conventional cleaning procedures.
[0009] This severe staining of carpeting is a major problem for consumers. In fact, surveys show that more carpets are replaced due to staining than due to wear. Accordingly, it is desirable to provide polyamide fibers which resist common household stains like red drink and coffee stains, thereby increasing the life of the carpet.
[0010] Methods to decrease the acid dye affinity of nylons by reducing the number of dye sites are known. For example, U.S. Pat. No. 3,328,341 to Corbin, et al. describes decreasing nylon dyeability with butrylactone. U.S. Pat. No. 3,846,507 to Thomm et al. describes reducing acid dye affinity of polyamide by blending a polyamide with a polymer having benzene sulfonate functionality. U.S. Pat. No. 5,108,684 to Anton et al. describes fibers made from polyamide copolymers containing 0.25 to 4.0 percent by weight of an aromatic sulfonate, which are stain-resistant to acid dyes. U.S. Pat. No. 5,340,886, Hoyt et al. describes acid dye resistant polyamide fibers made by incorporating within the polymer sufficient SO 3 H groups or salts thereof to give the polymer a sulfur content of between about 1 and about 160 equivalents per 10 6 grams polymer and, chemically blocking with a chemical blocking agent a portion of amine end groups present in the sulfonated polymer. Modified polymers such as described in these patents are generally expensive to make.
[0011] In addition to polymer modifications, topical treatments for carpets have been proposed as a cost effective means to impart acid dye resistance to polyamide carpet fibers. These topical treatments may be sulfonated materials that act as “colorless dyes” and bind the amine dye sites on the polyamide polymer. Sulfonated products for topical application to polyamide substrates are described in, for example, U.S. Pat. No. 4,963,409 to Liss et al.; U.S. Pat. No. 5,223,340 to Moss, III, et al.; U.S. Pat. No. 5,316,850 to Sargent et al.; and U.S. Pat. No. 5,436,049 to Hu. (Hu describes also a polyamide substrate that is made by melt mixing a polyamide with an amine end group reducing compound prior to fiber formation.) Topical treatments tend to be non-permanent and to wash away with one or more shampooings of the carpet.
[0012] Fibers may be formed in a variety of shapes and from a variety of materials. For example, some fibers have more than one type of polymer in distinct longitudinally co-extensive portions of the transverse cross-section and extending along the length of the fiber. Fibers that have two such portions are known as “bicomponent fibers”. Bicomponent fibers having one of the portions surrounding or substantially surrounding the other are referred to as having a sheath/core configuration.
[0013] Sheath/core bicomponent polyamide fibers are known. U.S. Pat. No. 5,445,884 to Hoyt and Wilson discloses a filament with reduced stainability having a polyamide core and a sheath of a hydrophobic polymer. The weight ratio between the core and sheath is from about 2:1 to about 10:1. If the sheath is very thin, a compatibilizer must be used. Compatibilizers are generally expensive. The compatibilizer can, in some cases, be eliminated by making the sheath relatively thick, i.e., more than 15 wt % of the cross-section. However, if the sheath material is expensive, this also can add significantly to the cost of the fibers.
[0014] U.S. Pat. No. 4,075,378 to Anton discloses sheath/core bicomponent polyamide fibers containing a polyamide core and a polyamide sheath. The core polyamide is acid-dyeable while the sheath polyamide is basic-dyeable due to sulfonation.
[0015] U.S. Pat. No. 3,679,541 to Davis et al. describes a sheath/core bicomponent filament having soil-release, anti-soil redeposition and antistatic properties through use of a copolyester or copolyamide sheath around a polyamide core.
[0016] U.S. Pat. No. 3,645,819 to Fujii et al. discloses polyamide bicomponent fibers for use in tire cords, bowstrings, fishing nets and racket guts.
[0017] U.S. Pat. No. 3,616,183 to Brayford discloses polyester sheath/core bicomponent fibers having antistatic and soil-release characteristics.
[0018] U.S. Pat. No. 2,989,798 to Bannerman describes sheath/core bicomponent which is said to have improved dyeability by modifying the amine end group level of the sheath relative to the core. The sheath has less amine end groups than the core.
[0019] Fibers that are non-round in transverse cross-section are known. For example, U.S. Pat. Nos. 2,939,202 and 2,939,201, both to Holland, describe fibers having a trilobal cross-section.
[0020] Polyamide fibers may be dyed to popular colors, usually after being tufted or woven into carpet face fiber. The dyestuffs used to dye the fibers are subject to fading. One mode of fading of dyed yarns is via ozone. This is a particular problem in areas that are near coastlines (i.e., hot and humid) or in homes that have electrostatic dust precipitators. Carpets installed in automobiles are also subject to heat and humidity. Ozone reacts with dyestuffs, especially disperse and cationic dyestuffs, and renders them colorless or off-shade. Acid dyestuffs are also susceptible to ozone fading. Fading is a significant barrier to the sales of uncolored nylon 6 yarn (which is intended to be dyed) into the commercial carpet (contrasted to the residential) market. To achieve acceptable ozone fading resistance in commercial applications, the yarn often must be pigmented during spinning rather than using the more flexible (with respect to color and style) dyeing processes that are performed at the carpet mill rather than upstream at the fiber producer.
[0021] Broadly, the present invention relates to dyeable filaments and methods. More specifically, the present invention relates to bath-dyed or dyeable filaments and methods for sheath/core filaments having a core and a sheath which surrounds entirely the core. The core is formed of a core polymer which is susceptible to dyeing by a bath dye chemical, while the sheath is formed of a sheath polymer which is resistant to dyeing by the bath dye chemical. When the filament is brought into contact with a dye bath containing the dye chemical, the dye chemical in the dye bath will be physically transported (that is, will diffuse, migrate or penetrate) through said sheath polymer to cause the core polymer to be dyed a color of the dye chemical, while the sheath polymer is substantially undyed thereby.
[0022] These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0023] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0024] Reference will hereinafter be made to the accompanying drawings, wherein like reference numerals throughout the various FIGURES denote like structural elements, and wherein;
[0025] [0025]FIG. 1 is a bar chart showing ozone fastness in terms of ΔE* values of carpet fibers dyed beige with acid dyes in a laboratory simulated continuous dyeing process, including dyed fibers used in the invention;
[0026] [0026]FIG. 2 is a bar chart showing ozone fastness in terms of ΔE* values of carpet fibers dyed gray with acid dyes in a laboratory simulated continuous dyeing process, including dyed fibers used in the invention;
[0027] [0027]FIG. 3 is a bar chart showing ozone fastness in terms of ΔE* values of carpet fibers dyed blue-gray with acid dyes in a laboratory simulated continuous dyeing process, including dyed fibers used in the invention;
[0028] [0028]FIG. 4 is a bar chart showing ozone fastness in terms of ΔE* values of carpet fibers dyed green with acid dyes in a laboratory simulated continuous dyeing process, including dyed fibers used in the invention;
[0029] [0029]FIG. 5 is a bar chart showing ozone fastness in terms of ΔE* values of carpet fibers dyed blue with disperse dyes in a laboratory simulated continuous dyeing process; and
[0030] [0030]FIG. 6 is a color photomicrograph of a dyed sheath/core trilobal fiber cross-section in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] To promote an understanding of the principles of the present invention, descriptions of specific embodiments of the invention follow and specific language is used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is intended by the use of specific language. Alterations, further modifications and such further applications of the principles of the invention discussed are contemplated as would normally occur to one ordinarily skilled in the art to which the invention pertains.
[0032] Dyed carpets made according to the present invention resist ozone fading. They also resist staining caused by both acid dyes and coffee and yet are dyeable with conventional polyamide dyeing methods. They exhibit lightfastness performance comparable to conventional dyed nylon 6 carpets so that this trait is not sacrificed (and might be improved).
[0033] These carpets are made from bicomponent face fibers composed of a polyamide core portion substantially or completely surrounded by a polymer that resists dye migration. The fibers are dyed with acid dyes, disperse dyes, or other dyes that are known to be susceptible to ozone fading or shade changes.
[0034] The fiber of this invention preferably contains from about 97% by weight to about 70% by weight of the core portion and from about 3% by weight to about 30% by weight of the sheath portion. More preferably, the fiber used in the carpet of this invention contains from about 97% by weight to about 85% by weight of the core portion and from about 3% by weight to about 15% by weight of the sheath portion. Most preferably, the fiber contains from about 97% by weight to 90% by weight of the core portion and about 3% by weight to less than 10% by weight of the sheath portion. In fact, it is surprising that sheath proportions less than 10 weight % show superior performance over sheath proportions around 10%, especially in ozone fastness.
[0035] The core may be formed from any fiber-forming polyamide or copolyamide. Fiber-forming polyamides suitable for the core include polymers having, as an integral part of the polymer backbone chain, recurring amide groups (—CO—NR—) where R is an alkyl, aryl, alkenyl, or alkynyl substituent. Non-limiting examples of such polyamides include homopolyamides and copolyamides which are obtained by the polymerization of lactam or aminocaproic acid or a copolymerization product from any of the possible permutative mixtures of diamines, dicarboxylic acids or lactams. The core may be an acid-dyeable polyamide such as a polyamide having amine end groups available as dye sites. Possibly, the core may be a basic-dyeable polyamide, such as made when polyamide forming monomers are polymerized in the presence of anionic groups such as sulfonated monomers. Such polyamides and methods of forming them are well known to those ordinarily skilled in the art and are generally among the class of polyamides having 15 or less carbon atoms in a repeating unit (or monomer in the case of mixed monomer starting materials). More preferably, the polyamide will have less than seven carbon atoms in the repeating unit such as in nylon 6. Other polyamides such as nylon 6/6, nylon 12, nylon 11, nylon 6/12, nylon 6/10, etc., that for some reason have been modified so that they have become stainable with acid dyes or coffee, may be used. Most preferably, the core polyamide is nylon 6 or nylon 6/6. Possibly, the core polyamide may have an amine end-group content of from greater than about 5 milliequivalents per kilogram (meq/kg) to less than about 100 milliequivalents per kilogram, more preferably from about 20 to about 50 milliequivalents per kilogram.
[0036] The sheath portion of the fiber is composed of a fiber forming polymer that resists dye migration (at room temperature, relative to nylon 6). Suitable polymers include polyolefins (e.g., polypropylene, polybutylene, etc.), fiber-forming polystyrene, fiber-forming polyurethane, and certain polyamides. Preferably, the sheath is composed of a polymer that is inherently chemically compatible with the core polymer. Preferably, the sheath is a polyamide polymer that is acid dye and coffee stain resistant, such that when the face fiber is exposed to C.I. Food Red No. 17, the red drink staining depth of the face fiber is about 15 or less CIEL*a*b* ΔE units under the Daylight 6500 Standard Illuminant; and such that when the face fiber is exposed to coffee, the coffee staining depth under Daylight 6500 Standard Illuminant is about 10 or less CIEL*a*b* ΔE* units. More preferably, the red drink staining depth is about 10 or less ΔE*units.
[0037] Preferably, the sheath polymer is a polyamide selected from the group consisting of polyamides having the structure:
[0038] (a) [NH—(CH 2 ) x —NH—CO—(CH 2 ) y —CO] n
[0039] where x and y may be the same or different integers, preferably from about 4 to about 30 and the sum of x and y is greater than 13, more preferably from about 9 to about 20, and most preferably from about 9 to about 15 and n is greater than about 40; and
[0040] where z is an integer preferably from about 9 to about 30, more preferably from about 9 to about 20, and most preferably from about 9 to about 15 and m is greater than about 40;
[0041] (c) derivatives of (a) or (b) including polymers substituted with one or more sulfonate, halogenate, aliphatic or aromatic functionality; and
[0042] (d) copolymers and blends of (a), (b) and (c).
[0043] The preferable sheath polymers have greater than 80% of the non-carbonyl backbone or substituent carbons as alkyl, alkenyl, alkynyl, aryl, fluoroalkyl, fluoroalkenyl, fluoroalkynyl, fluoroaryl, chloroalkyl, chloroalkenyl, chloroalkynyl, chloroaryl, and the like, and do not have polar substituents such as hydroxy, amino, sulfoxyl, carboxyl, nitroxyl, or other such functionalities capable of hydrogen-bonding. Non-limiting examples of suitable fiber-forming polyamides which can be used as the sheath polyamide include nylon 6/10, nylon 6/12, nylon 10, nylon 11 and nylon 12. The fiber-forming sheath polyamide may be sulfonated but is preferably substantially sulfonate-free. Optionally, the sheath polyamide component may have a titratable amine-end-group concentration of less than about 30 meq/kg, and preferably less than about 15 meq/kg, and desirably less than about 10 meq/kg. If the polymers are amine end group blocked, useful amine-end-group-blocking agents include lactones, such as caprolactones and butyrolactones. Most preferably, the sheath polymer is nylon-6/12 having an AEG content of less than about 5.0 meq/kg. In preferred embodiments, the nylon-6/12 sheath polymer is a homopolymer.
[0044] As mentioned previously, the sheath of the fiber will preferably substantially or completely cover the core of the fiber. Methods for forming sheath/core fibers are known to those of ordinary skill in the art. One preferred method of forming sheath/core fibers is described in U.S. Pat. No. 5,162,074 to Hills, which is hereby incorporated by reference for the bicomponent spinning techniques taught therein. The sheath/core arrangement may be eccentric or concentric.
[0045] The fibers used as face fiber in the carpet of this invention are preferably multilobal. Trilobal cross-sections are currently preferred. Additionally, the fibers might contain one or more internal void spaces, for example, a central axial void.
[0046] The fibers used in this invention may be continuous fibers or staple fibers, either alone or in admixture with other fibers. The fibers are particularly useful as bulked continuous filament yarns.
[0047] Common melt-spinning and after processing techniques may be employed to make the fibers. The fibers may be textured to produce bulked yarns by known methods including stuffer-box crimping, gear-crimping, edge-crimping, false-twist texturing and hot-fluid jet bulking. Several ends may be combined in a variety of manners and twist levels according to conventional techniques, for example, groups of the fibers may be plied into yarn. The yarn may be cabled (i.e., plied and twisted). Preferably, the yarn is heatset.
[0048] It is especially preferred and especially beneficial if the fibers used in the present invention are cabled and heatset. As those of ordinary skill in the art will recognize, “cabled” refers to yarn that is plied and twisted. Cabling and heatsetting can be accomplished according to any method conventionally used in the art. It is not believed that the method of cabling or heatsetting is essential to the benefit of the invention. Typically, conventional dyed and heatset yarn has worse ozone fading performance (i.e., more fading upon ozone exposure) than dyed yarn that has not been heatset. However, it was surprisingly discovered that the carpets of the present invention have little degradation of ozone fading resistance from heatsetting. That is, the heatset face yarn on the carpet of the present invention performs at least as well as, and in some cases better than, non-heatset yarn.
[0049] Also, polyamide yarns will often shrink during heatsetting. Preferably, the fiber used in this invention has a steam heatsetting shrinkage value of about 70% or less relative to the steam heatsetting shrinkage value of fiber which is manufactured in the identical manner but which consists only of the core polyamide component.
[0050] Carpet may be made from the yarn by conventional carpet making techniques like weaving or tufting the face fibers into a backing material and binding the face fiber to the backing with latex or other adhesives. The carpet may be cut-pile, berber, multilevel loop, level loop, cut-pile/loop combination or any other style according to the popular fashion. If it is desired, the carpet of the present invention may be in the form of carpet tiles or mats. As an example, in the case of cut-pile carpeting, the yarn is tufted into a primary backing and the loops are cut to form cut-pile carpeting. The primary backing may be woven or non-woven and comprised of nylon, polyester, polypropylene, etc. The cut-pile carpeting is dyed to the desired shade. A secondary backing, if required, is adhered to the non-pile side, typically using a latex-based adhesive. The secondary backing may be jute, polypropylene, nylon, polyester, etc. The carpet of the present invention may be foam backed or not. The carpet of the present invention can be a variety of pile weights, pile heights and styles. There is not currently believed to be any limitation on the carpet style.
[0051] As noted, the fibers used in the carpets of the present invention are dyed with dyes, and exhibit surprising resistance to color fading under exposure to ozone. The fibers may be dyed before the carpet is made, such as with skein dyeing, or the fibers may be dyed when already present in the backing. That is, the constructed carpet may be dyed. Although a variety of dyes are envisioned for use in the present invention, the presently preferred dyes are: C.I. Acid Yellow 246, C.I. Acid Red 361, C.I. Acid Blue 277 and combinations of these with each other or other dyes. Dyes of similar chemical structures are also contemplated as useful to achieve the beneficial results of the present invention. Disperse dyes, which are notoriously unstable to ozone exposure are remarkably benefited by the present invention.
[0052] The invention will now be described by referring to the following detailed examples. These examples are set forth by way of illustration and are not intended to be limiting in scope. Knit fabrics are used in some of the following examples to demonstrate the stain resisting nature of fibers useful to make carpets of the present invention. This is merely for illustration and it is believed that the fibers would exhibit substantially identical attributes as face fiber in carpet.
[0053] The following test methods and procedures are used in the Examples:
[0054] Linear Density, Tenacity, Elongation, and Work to Break
[0055] The linear density, tenacity, elongation, and work to break are measured using test method ASTM D2256-97. The gauge length used is 10 inches (0.254 meters) and a cross head speed of 10 inches/min (0.0042 meters/second) is used.
[0056] Boiling Water Shrinkage
[0057] Boiling water shrinkage is determined using ASTM D2259-71.
[0058] Modification Ratio
[0059] For non-round cross-sections (e.g., trilobal), modification ratio is the ratio of the smallest possible circumscribed circle to the largest possible inscribed circle for a cross section of a filament from the yarn. The number reported is the average for 10 filaments.
[0060] Heatsetting
[0061] The yarn to be heatset is wound into skeins and is heatset in a standard autoclave used in the carpet industry. The first step of the heatsetting process in the autoclave involves raising the temperature to 110° C. for 3 minutes at a pressure of 6 psig (41 kPa). The pressure is then released and then the first step is repeated. The second step of the heatsetting process in the autoclave involves raising the temperature to 132° C. at pressure of 28 psig (193 kPa) for 3 minutes. The pressure is then broken and this step is repeated two more times.
[0062] Ozone Exposure Procedure
[0063] Using AATCC method 129-1996 (similar to ISO 105-G03) all dyed samples are subjected to 1, 2, 3, 4, 5 and 6 cycles of ozone fading. In this method (and other methods herein referencing the color or color change), the total color differences between exposed and corresponding unexposed samples are calculated using the CIEL*a*b* system as described by the Commission Internationale de l'Eclairage in CIE Publication No. 15 (E-1.3.1) for a Daylight 6500 standard illuminant.
[0064] A spectrophotometric measurement of the exposed and unexposed materials is made and the CIEL*a*b* total color difference (CIEL*a*b* ΔE* (as used in this application: “ΔE*” or “Delta E*”)) between the exposed and unexposed materials is calculated under the CIEL*a*b* system. For details of these calculations see, for example, Billmeyer, Jr., Fred W. and Saltzman, Max, Principles of Color Technology, John Wiley & Sons, New York (1966). The lower the ΔE* value (i.e., the total color change from the unexposed control) the less the color of the material has changed.
[0065] The AATCC Color Change Gray Scale is a scale for visually rating the color change of a specimen relative to the differences shown by the scale. A 5 rating represents no color change. A 1 rating represents severe color change. A 3 rating represents noticeable , but in most cases, acceptable color change. For the purposes of this application, a delta E* value of 3.4 or less is equivalent to a 3 rating or better on the AATCC scale. In general, commercially acceptable ozone resistance performance is a ΔE* rating of 3.2 or less.
[0066] As shown in the following examples, the present invention fades (as measured by ΔE*) after exposure to three cycles of ozone only one-half or less than a carpet having fiber composed substantially completely of the core polyamide (i.e., without the sheath) that is dyed with the same dyes. It should be noted that in making this comparison, the fibers and yarns used in the invention and the fibers and yarns made only of the core material must be of similar denier, cross-sectional shape and texturing. This is because any one of these factors can affect the apparent dye shade depth (as measured by the CIEL*a*b* system) of the unexposed sample used as the control for measuring ozone fade. For example, as a general rule, lower denier (per filament) yarn appears to dye less deeply than higher total denier (per filament yarn). Textured yarn dyes more deeply than untextured yarn, and so forth. This principle will be understood by those who are of at least ordinary skill in this art.
DYEING PROCEDURES
[0067] Laboratory Simulated Continuous Dyeing Procedure
[0068] A two yard (1.8 meter) sample of knitted tube is used. The volume of dye formulation is determined by the weight of the fabric to be dyed. In the examples, a 2.5:1 ratio of ml/g (bath volume to fabric weight) is used. The knitted tube is dipped into a beaker containing one of the dye formulations described below. In the process, the dye saturated fabric is squeezed and released several times distributing the dye bath uniformly throughout the knitted tube. The knitted tube is then exposed to 99° C. steam for 4 minutes. The knitted tubes are then rinsed in cold water and the excess water and dye bath is removed by extraction in a centrifugal extractor for 30 seconds.
[0069] The dye formulations are made according to the following recipe:
[0070] 0.25 g/L ethylenediaminetetraacetate (Versene® from Dow Chemical Company, Midland, Mich.)
[0071] 0.5 g/L dioctyl sulfosuccinate surfactant (Amwet DOSS from American Emulsion Co., Dalton, Ga.)
[0072] 1.0 g/L anionic dye leveling agent (Amlev DFX, American Emulsion Co., Dalton, Ga.)
[0073] 0.5 g/L trisodium phosphate
[0074] acetic acid to adjust pH to 6.5
[0075] Dyestuffs According to the Following
[0076] Acid Beige Dye
[0077] 0.132 g/L C.I. Acid Yellow 246 (Tectilon® Yellow 3R 200%)
[0078] 0.088 g/L C.I. Acid Red 361 (Tectilon® Red 2B 200%)
[0079] 0.088 g/L C.I Acid Blue 277 (Tectilon® Blue 4R)
[0080] Acid Gray Dye
[0081] 0.108 g/L C.I. Acid Yellow 246
[0082] 0.116 g/L C.I. Acid Red 361
[0083] 0.240 g/L C.I. Acid Blue 277
[0084] Acid Blue-Gray Dye
[0085] 0.068 g/L C.I. Acid Yellow 246
[0086] 0.136 g/L C.1. Acid Red 361
[0087] 0.424 g/L C.I. Acid Blue 277
[0088] Acid Green Dye
[0089] 0.980 g/L C.I. Acid Yellow 246
[0090] 0.104 g/L C.I. Acid Red 361
[0091] 0.532 g/L C.I. Acid Blue 277
[0092] 4.976 g/L of Acid Blue dye with a green cast (Tectilon® Blue 5G)
[0093] Disperse Blue Dye
[0094] 0.132 g/L C.I. Disperse Blue 3 (Akasperse® Blue BN available from Akash Chemicals & Dye-stuffs Inc. of Glendale Heights, Ill.
[0095] (Tectilon dyes are available from Ciba Specialty Chemicals, Greensboro, N.C.)
[0096] Exhaust Dyeing Procedure
[0097] A 30 g sample of knitted tube is placed in a closed container with one of the dye formulations below. The dye formulation was added at a 20:1 ratio (dyebath volume in mL to fabric weight in grams). The tube in the container is heated to 95° C. over 30 minutes and then held at 95° C. for an additional 30 minutes. The dyebath is then cooled and the knit tube is rinsed.
[0098] The dye formulations are made according to the following:
[0099] 0.25 g/L ethylenediaminetetraacetate
[0100] 0.5 g/L anionic dye leveling agent (Supralev® AC, available from Rhone-Poulenc, Inc., Lawrence, Ga.)
[0101] 0.5 g/L trisodium phosphate
[0102] acetic acid to adjust pH to 6.5
[0103] Dyestuffs According to the Following Recipes: (“owf” means “on weight of fiber)
[0104] Acid Beige Dye
[0105] 0.033% owf C.I. Acid Yellow 246
[0106] 0.022% owf C.I. Acid Red 361
[0107] 0.022% owf C.I. Acid Blue 277
[0108] Acid Gray Dye
[0109] 0.027% owf C.I. Acid Yellow 246
[0110] 0.029% owf C.I. Acid Red 361
[0111] 0.060% owf C.I. Acid Blue 277
[0112] Acid Blue-Gray Dye
[0113] 0.017% owf C.I. Acid Yellow 246
[0114] 0.034% owf C.I. Acid Red 361
[0115] 0.106% owf C.I. Acid Blue 277
[0116] Acid Green Dye
[0117] 0.245% owf C.I. Acid Yellow 246
[0118] 0.026% owf C.I. Acid Red 361
[0119] 0.133% owf C.I. Acid Blue 277
[0120] 1.244% owf Tectilon Blue 5G
[0121] Disperse Blue Dye
[0122] 0.3% owf C.I. Disperse Blue 3
STAIN TESTING PROCEDURES
[0123] Acid dye and coffee stain resistance of the various fabric samples is determined according the following procedures. Generally, a ΔE* value of less than 5 is considered essentially unstained; a ΔE* value of 5 to 10 indicates very light staining; and a ΔE* value of greater than 10 is considered significantly stained.
[0124] Stain Resistance to C.I. Food Red 17
[0125] “Red drink staining depth” refers to the “ΔE*” (total color difference) between stained and unstained samples as quantified using a spectrophotometer when samples are stained with C.I. Food Red 17 as follows. A solution of 100 mg C.I. Food Red 17 per liter of deionized water is prepared and adjusted to pH 2.8 with citric acid. Each sample to be tested is placed individually in a beaker in a 10:1 bath ratio of the red dye solution for five minutes at room temperature. After five minutes, the samples are removed, squeezed slightly by hand to remove excess liquid and placed on a screen to dry for 16 hours at room temperature. After 16 hours, the samples are rinsed in cold water until no more color is removed, centrifugally extracted and tumble dried. The color (stain) of the stain tested samples is measured on the spectrophotometer and ΔE* is calculated relative to an unstained control.
[0126] Coffee Stain Resistance
[0127] “Coffee staining depth” refers to the ΔE* value between stained and unstained samples as measured using a spectrophotometer when the stained samples are stained according to the following procedure. Coffee staining is measured by a spectrophotometer on knitted fabric samples stained as follows: A solution of 5.6 g Folger's® Instant Coffee per liter of deionized water is prepared and heated to 66° C. Each sample to be tested is spread out in the bottom of individual beakers and 2.5:1 bath ratio of the heated coffee solution is pipetted onto the sample in a manner as to distribute the coffee solution over the entire sample. The samples are allowed to remain in the beakers for 20 minutes and are then removed and placed on a screen to dry for 24 hours at room temperature. After 24 hours, the samples are rinsed in cold water until no more color is removed, then centrifugally extracted and tumble dried. The color (stain) of the samples is measured on a spectrophotometer and CIEL*a*b* Delta E* is calculated relative to an unstained control.
COLOR MEASUREMENT GENERALLY
[0128] In understanding the significance of the following examples, it is useful to understand the following principles of the CIEL*a*b* system.
[0129] The system assigns color coordinates along three axes in three dimensional color space. The three axes are named L*, a* and b*. The L* value is a measurement of the depth of shade (lightness-darkness). An L* value of 100 is pure white and 0 is pure black. Therefore, the lower the L* value the darker the shade. A ΔL* value of 1 is visible to the naked eye viewing the samples side-by-side. A ΔL* value of 4-5 is significantly different.
[0130] The a* axis represents red and green. Negative a* values are green and positive values are red. The absolute value of the a* value rarely exceeds 20.
[0131] The b* axis represents yellow and blue. Negative b* values are blue and positive values are yellow. The absolute value of the b* value rarely exceeds 20.
EXAMPLE 1 (COMPARATIVE)—100% NYLON 6
Simulated Continuous Dyeing—Acid Beige Dye
[0132] A 100% nylon 6 (“N6”) (from BS-700F chip available from BASF Corporation, Mt. Olive, N.J.) yarn is spun in a one-step spin-draw-texture (“SDT”) process. The polymer temperature is 267° C. Two extruders are used. One extruder supplies the nylon 6 polymer as a core component to a bicomponent spin pack. The second extruder supplies the nylon 6 as a sheath. The sheath polymer is metered at 10% by weight of the nylon fed to the spin pack. A spin pack using the principles described in U.S. Pat. No. 5,344,297 to Hills is used to produce a sheath-core trilobal fiber. The draw ratio is about 3. The filaments are combined into a 58 filament yarn having the yarn properties summarized in Table 1.
[0133] The yarn is knitted on a circular weft knitting machine to make a knit tube. This tube is dyed using the simulated continuous dye procedure and the beige shade. The color change after ozone exposure is given in Table 2 and FIG. 1
EXAMPLE 2 (INVENTION)—10% NYLON 6, 12 SHEATH
Simulated Continuous Dyeing—Acid Beige Dye
[0134] Using the equipment and settings of Example 1 the nylon 6 in the second extruder is replaced with nylon 6, 12 (“N6, 12”) (poly(hexamethylene dodecanediamide)) (Vestamid® D16 available from Creanova, Somerset, N.J.). A 58 filament yarn is produced and has the properties summarized in Table 1.
[0135] The yarn is knitted on a circular weft knitting machine. The knit tube is dyed using the simulated continuous dye procedure using the beige shade formulation. In a first attempt to dye this yarn using the same formulation as used in Example 1 (comparative) the color is noticeably lighter than that achieved in Example 1. Accordingly, the dyeing procedure is modified by doubling the concentration of dyes (not auxiliaries) and lowering the pH to 6.0 with acetic acid. The time of steaming is doubled to 8 minutes. The resulting knitted tube has a similar depth of color to that achieved in Example 1. This tube (not the first attempt) is exposed to ozone and the color change after ozone exposure is given in Table 2 and FIG. 1.
EXAMPLE 3 (INVENTION) 5% NYLON 6, 12 SHEATH
Simulated Continuous Dyeing—Acid Beige Dye
[0136] Using the equipment and settings of Example 1 the nylon 6 in the second extruder is replaced with nylon 6, 12. The metering pumps supplying the spin pack are adjusted to provide 5% by weight of the nylon 6, 12 from the second extruder. A 58 filament yarn is produced and has the properties summarized in Table 1.
[0137] The yarn is knitted into a tube on a circular weft knitting machine. This tube is dyed using the simulated continuous dye procedure given above using the beige shade formulation. Because the first attempt to dye this yarn using the same formulation as used in Example 1 (comparative) results in a noticeably lighter color than that achieved in Example 1, the modified dyeing procedure of Example 2 is followed. The resulting knitted tube has a similar depth of color to that achieved in Example 1. This tube (not the first attempt) is exposed to ozone and the color change after ozone exposure is given in Table 2 and FIG. 1.
TABLE 1 Properties of Yarns from Examples 1-3 Total Boiling Filament Linear Elonga- Work to Water Modifi- Exam- Density Tenacity tion Break Shrinkage cation ple (denier) (g/den) (%) (g/cm) (%) Ratio 1 1260 2.82 36.1 4452 9.1 2.52 2 1282 2.88 37.4 4726 7.3 2.70 3 1257 2.83 36.9 4197 6.3 2.62
[0138] [0138] TABLE 2 Acid Beige Dye (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 1 100% N6 2.2 2.8 3.9 5.2 5.9 6.7 Ex 2 10% N6, 12 Sheath 0.5 0.8 0.6 0.8 1.2 0.9 Ex 3 5% N6, 12 Sheath 0.6 0.6 0.7 1.1 1.6 1.8
EXAMPLE 4 (COMPARATIVE) 100% N6
Simulated Continuous Dyeing—Acid Gray Dye
[0139] A knit tube of yarn from Example 1 is dyed using the simulated continuous dye procedure given above using the gray shade formulation. The color change after ozone exposure is given in Table 3 and FIG. 2.
EXAMPLE 5 (INVENTION) 10% N6, 12 SHEATH
Simulated Continuous Dyeing—Acid Gray Dye
[0140] A knit tube of yarn from Example 2 is dyed using the simulated continuous dye procedure given above using the gray shade formulation. The color change after ozone exposure is given in Table 3 and FIG. 2.
EXAMPLE 6 (INVENTION) 5% N6, 12
Simulated Continuous Dyeing—Acid Gray Dye
[0141] A knit tube of yarn from Example 3 is dyed using the simulated continuous dye procedure given above using the gray shade formulation. The color change after ozone exposure is given in Table 3 and FIG. 5.
TABLE 3 Acid Gray Dye (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 4 100% N6 1.2 1.7 2.9 4.0 4.2 5.7 Ex 5 10% N6, 12 Sheath 0.8 0.9 1.0 1.0 1.5 1.2 Ex 6 5% N6, 12 Sheath 1.2 1.4 2.2 1.9 1.6 2.2
EXAMPLE 7 (COMPARATIVE) 100% N6
Simulated Continuous Dyeing—Acid Blue-Gray Dye
[0142] A knit tube of yarn from Example 1 is dyed using the simulated continuous dye procedure given above using the blue-gray shade formulation. The color change after ozone exposure is given in Table 4 and FIG. 3.
EXAMPLE 8 (INVENTION) 10% N6, 12 SHEATH
Simulated Continuous Dyeing—Acid Blue-Gray Dye
[0143] A knit tube of yarn from Example 2 is dyed using the simulated continuous dye procedure given above using the blue-gray shade formulation. The color change after ozone exposure is given in Table 4 and FIG. 3.
EXAMPLE 9 (INVENTION) 5% N6, 12 SHEATH
Simulated Continuous Dyeing—Acid Blue-Gray Dye
[0144] A knit tube of yarn from Example 3 is dyed using the simulated continuous dye procedure given above using the blue gray shade formulation. The color change after ozone exposure is given in Table 4 and FIG. 3.
TABLE 4 Acid Blue-Gray Dye (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 7 100% N6 1.6 2.7 4.6 5.7 6.1 7.6 Ex 8 10% N6, 12 Sheath 0.5 1.7 0.6 1.8 1.3 2.7 Ex 9 5% N6, 12 Sheath 0.8 0.9 1.0 1.0 1.5 1.2
EXAMPLE 10 (COMPARATIVE) 100% N6
Simulated Continuous Dyeing—Acid Green Dye
[0145] A knit tube of yarn from Example 1 is dyed using the simulated continuous dye procedure given above using the green shade formulation. The color change after ozone exposure is given in Table 5 and FIG. 4.
EXAMPLE 11 (INVENTION) 10% N6, 12 SHEATH
Simulated Continuous Dyeing—Acid Green Dye
[0146] A knit tube of yarn from Example 2 is dyed using the simulated continuous dye procedure given above using the green shade formulation. Because the first attempt at dyeing results in a shade that is noticeably lighter than that of Example 10. The dyeing procedure is modified as described in Example 2 and the resulting dyed knitted tube has a very similar color to that of Example 10. The color change after ozone exposure is given in Table 5 and FIG. 4.
EXAMPLE 12 (INVENTION) 5% N6, 12 SHEATH
Simulated Continuous Dyeing—Acid Green Dye
[0147] A knit tube of yarn from Example 3 is dyed using the simulated continuous dye procedure given above using the green shade formulation. Because the first attempt at dyeing results in a shade that is noticeably lighter than that of Example 10, the dyeing procedure is modified as described in Example 2 and the resulting dyed knitted tube has a very similar color to that of Example 10. The color change after ozone exposure is given in Table 5 and FIG. 4.
TABLE 5 Acid Green Dye (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 10 100% N6 1.7 2.9 3.6 4.8 5.6 6.7 Ex 11 10% N6, 12 Sheath 0.7 1.1 0.8 1.1 1.0 1.4 Ex 12 5% N6, 12 Sheath 1.0 0.8 1.5 1.7 2.0 1.6
EXAMPLE 13 (COMPARATIVE) 100% N6
Simulated Continuous Dyeing—Disperse Blue Dye
[0148] A knit tube of yarn from Example 1 is dyed using the simulated continuous dye procedure given above using the disperse blue formulation. The color change after ozone exposure is given in Table 6 and FIG. 5.
EXAMPLE 14 (COMPARATIVE) 10% N6, 12 SHEATH
Simulated Continuous Dyeing—Disperse Blue Dye
[0149] A knit tube of yarn from Example 2 is dyed using the simulated continuous dye procedure given above using the disperse blue formulation. The color change after ozone exposure is given in Table 6 and FIG. 5.
EXAMPLE 15 (COMPARATIVE) 5% N6, 12 SHEATH
Simulated Continuous Dyeing—Disperse Blue Dye
[0150] A knit tube of yarn from Example 3 is dyed using the simulated continuous dye procedure given above using the disperse blue formulation. The color change after ozone exposure is given in Table 6 and FIG. 5.
TABLE 6 Blue Disperse Dye (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 13 100% N6 11.0 14.4 20.7 22.1 23.1 28.3 Ex 14 10% N6, 12 Sheath 2.9 4.3 6.1 7.0 7.1 9.1 Ex 15 5% N6, 12 Sheath 3.8 5.8 8.6 10.1 11.8 15.0
EXAMPLE 16 (COMPARATIVE) 100% N6
Heatset and Exhaust Dyed with Acid Beige Dye
[0151] Yarn prepared as in Example 1 (except that it is not first knitted into a tube) is cabled to a twist level of 5 twists per inch (197 twists/meter) on a Volkmann cable twister and heatset. The yarn is then knitted on a circular weft knitting machine and dyed using the exhaust dye procedure given above using the beige acid dyes formulation. The color change after ozone exposure is given in Table 7 and FIG. 6.
EXAMPLE 17 (INVENTION) 10% N6, 12 SHEATH
Heatset and Exhaust Dyed with Acid Beige Dye
[0152] The yarn from Example 2 is cabled, heatset, knit into a tube and exhaust dyed to a beige shade as described in Example 16. The color change after ozone exposure is given in Table 7 and FIG. 6.
EXAMPLE 18 (INVENTION) 5% N6, 12 SHEATH
Heatset and Exhaust Dyed with Acid Beige Dye
[0153] The yarn from Example 3 is cabled, heatset, knit into a tube and exhaust dyed to a beige shade as described in Example 16. The color change after ozone exposure is given in Table 7 and FIG. 6.
TABLE 7 Heatset-Exhaust Dyed Beige (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 16 100% N6 1.5 2.8 4.1 5.6 5.4 8.1 Ex 17 10% N6, 12 Sheath 0.5 0.4 0.8 0.6 0.9 1.0 Ex 18 5% N6, 12 Sheath 1.1 0.8 1.2 1.0 1.0 1.0
EXAMPLE 19 (COMPARATIVE) 100% N6
Heatset and Exhaust Dyed with Acid Gray Dye
[0154] The yarn from Example 1 is cabled, heatset, knit into a tube as described in Example 16 and exhaust dyed to a gray shade. The color change after ozone exposure is given in Table 8 and FIG. 7.
EXAMPLE 20 (INVENTION) 10% N6, 12 SHEATH
Heatset and Exhaust Dyed with Acid Gray Dye
[0155] The yarn from Example 2 is cabled, heatset, knit into a tube as described in Example 16 and exhaust dyed to a gray shade. The color change after ozone exposure is given in Table 8 and FIG. 7.
EXAMPLE 21 (INVENTION) 5% N6
Heatset and Exhaust Dyed with Acid Gray Dye
[0156] The yarn from Example 3 is cabled, heatset, knit into a tube as described in Example 16 and exhaust dyed to a gray shade. The color change after ozone exposure is given in Table 8 and FIG. 7.
TABLE 8 Heatset-Exhaust Dyed Gray (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 19 100% N6 1.7 3.6 6.1 7.1 8.3 10.7 Ex 20 10% N6, 12 Sheath 0.6 0.4 1.1 0.9 1.1 1.4 Ex 21 5% N6, 12 Sheath 0.6 0.3 1.0 0.8 0.9 1.3
EXAMPLE 22 (COMPARATIVE) 100% N6
Heatset and Exhaust Dyed with Acid Blue-Gray Dye
[0157] The yarn from Example 1 is cabled, heatset, knit into a tube as described in Example 16 and exhaust dyed to a blue-gray shade. The color change after ozone exposure is given in Table 9 and FIG. 8.
EXAMPLE 23 (INVENTION) 10% N6, 12 SHEATH
Heatset and Exhaust Dyed with Acid Blue-Gray Dye
[0158] The yarn from Example 2 is cabled, heatset, knit into a tube as described in Example 16 and exhaust dyed to a blue-gray shade. The color change after ozone exposure is given in Table 9 and FIG. 8.
EXAMPLE 24 (INVENTION) 5% N6, 12 SHEATH
Heatset and Exhaust Dyed with Acid Blue-Gray
[0159] The yarn from Example 3 is cabled, heatset, knit into a tube as described in Example 16 and exhaust dyed to a gray shade. The color change after ozone exposure is given in Table 9 and FIG. 8.
TABLE 9 Heatset-Exhaust Dyed Blue-Gray (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 22 100% N6 2.0 4.3 5.6 7.6 8.7 10.7 Ex 23 10% N6, 12 Sheath 0.3 0.4 1.1 1.1 1.4 1.2 Ex 24 5% N6, 12 Sheath 0.4 0.5 0.9 0.8 0.9 0.7
EXAMPLE 25 (COMPARATIVE) 100% N6
Heatset and Exhaust Dyed with Acid Green Dye
[0160] The yarn from Example 1 is cabled, heatset, knit into a tube as described in Example 16 and exhaust dyed to a green shade. The color change after ozone exposure is given in Table 10 and FIG. 9.
EXAMPLE 26 (INVENTION) 10% N6, 12 SHEATH
Heatset and Exhaust Dyed with Acid Green Dye
[0161] Yarn from Example 2 is cabled, heatset, knitted into a tube as described in Example 16. The knit tube is exhaust dyed to a green shade using the exhaust dye procedure except that, because in a first attempt to dye this yarn using the same formulation as used in Example 25 the color is noticeably lighter than that achieved in Example 25, the dyeing procedure is modified by increasing the length of the dyeing procedure from 30 minutes (1800 seconds) at 95° C. to 60 minutes (3600 seconds) at 95° C. A slight color difference from that of Example 25 is still noted. The color change after ozone exposure is given in Table 10 and FIG. 9.
EXAMPLE 27 (INVENTION) 5% N6, 12 SHEATH
Heatset and Exhaust Dyed with Acid Green Dye
[0162] Yarn from Example 3 is cabled, heatset, knitted into a tube as described in Example 16. The knit tube is exhaust dyed to a green shade using the exhaust dye procedure except that, because in a first attempt to dye this yarn using the same formulation as used in Example 25 the color is noticeably lighter than that achieved in Example 25, the dyeing procedure is modified as described in Example 26. A slight color difference from that of Example 25 is still noted. The color change after ozone exposure is given in Table 10 and FIG. 9.
TABLE 10 Heatset-Exhaust Dyed Green (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 25 100% N6 1.1 2.4 3.4 4.2 4.8 5.8 Ex 26 10% N6, 12 Sheath 0.2 0.5 1.0 1.1 1.2 1.1 Ex 27 5% N6, 12 Sheath 0.8 1.0 1.6 0.7 0.9 1.1
EXAMPLE 28 (COMPARATIVE) 100% N6
Heatset and Exhaust Dyed with Disperse Blue Dye
[0163] The yarn from Example 1 is cabled, heatset, knit into a tube as described in Example 16. The tube is exhaust dyed with the disperse blue dye formulation. The color change after ozone exposure is given in Table 11 and FIG. 10.
EXAMPLE 29 (COMPARATIVE) 10% N6, 12 SHEATH
Heatset and Exhaust Dyed with Disperse Blue Dye
[0164] The yarn from Example 2 is cabled, heatset, knit into a tube as described in Example 16. The tube is exhaust dyed with the disperse blue dye formulation. The color change after ozone exposure is given in Table 11 and FIG. 10.
EXAMPLE 30(COMPARATIVE) 5% N6, 12 SHEATH
Heatset and Exhaust Dyed with Disperse Blue Dye
[0165] The yarn from Example 3 is cabled, heatset, knit into a tube as described in Example 16. The tube is exhaust dyed with the disperse blue dye formulation. The color change after ozone exposure is given in Table 11 and FIG. 10.
TABLE 11 Heatset-Exhaust Dyed-Disperse Blue Dye (ΔE*) Ozone Cycles 1 2 3 4 5 6 Ex 28 100% N6 20.2 32.8 41.4 42.0 44.7 46.6 Ex 29 10% N6 Sheath 3.3 6.3 10.4 10.9 13.7 14.1 Ex 30 5% N6 Sheath 2.3 4.3 5.4 6.8 7.9 8.5
EXAMPLE 31: STAIN TESTING—UNDYED SAMPLES AND DYED SAMPLES
[0166] Knit tubes made as described in Examples 1-3 before dyeing, are subjected to the red drink stain test and the coffee stain test. Similarly, knit tubes dyed blue-gray as described in Examples 7-9 are subjected to red drink and coffee stain testing. The results are presented in Table 12.
TABLE 12 Stain Testing (ΔE*) Undyed Dyed Undyed Dyed Red Drink Red Drink Coffee Coffee 100% N6 60.1 20.0 28.7 1.2 10% N6, 12 Sheath 10.9 0.9 16.8 0.2 5% N6, 12 Sheath 13.2 0.8 19.9 0.2
EXAMPLE 32: COMPARATIVE DYEING TRIALS—N6 YARN VERSUS N6, 12 YARN
EXAMPLE 32 A: N6
[0167] On a pilot scale spinning machine, a 100% N6 yarn is extruded from a single screw extruder at a melt temperature of 265° C. into a spinneret to produce 14 round filaments. The yarn is accumulated on a winder at approximately 400 meters/minute with the godets operated with a very small (less than 10 m/min) speed differential, such that the yarn is undrawn.
[0168] In a separate step this yarn is heated and drawn 3.1 times its original length on a drawknitting machine. The final linear density is approximately 252 denier. Knit tubes are formed from the yarn and these are dyed to beige, gray, blue-gray and green using the Exhaust Dye Procedure.
[0169] The color of the original tubes are measured according to the CIEL*a*b* system and the tubes are exposed to 1, 2, 3, 4, 5 and 6 cycles of ozone. The results are presented in Table 13.
EXAMPLE 32B - N6, 12
[0170] N6, 12 is extruded and formed into yarn as in Example 32A except that the first godet is slowed such that a draw ratio of 2:1 is induced in the yarn. The first godet runs at 200 m/min and the second at 400 m/min. This drawing step is required because the undrawn yarn does not form a stable package. The yarn relaxes on the package and cannot be processed.
[0171] In a separate step this yarn is knitted (bypassing the heating and drawing steps) on the same drawknitter as in Example 32A but without further drawing. Thus, the final linear density is approximately 391. Knit tubes are formed from the yarn and these are dyed to beige, gray, blue-gray and green using the Exhaust Dye Procedure.
[0172] The color of the original tubes are measured according to the CIEL*a*b* system and the tubes are exposed to ozone. The results are presented in Table 13.
TABLE 13 Relative to Nylon Ozone Fastness (ΔE* after 6 Sample respective number As Dyed Material Delta Delta of cycles of exposure) L* a* B* E* L* 1 2 3 4 5 6 Ex- 57.8 3.8 15.4 1.0 1.6 2.4 2.9 4.3 5.0 ample 32A - Beige Ex- 65.7 0.9 9.1 10.4 7.8 0.8 1.1 1.4 1.5 1.3 1.3 ample 32B - Beige Ex- 49.2 −2.2 3.1 0.9 1.8 2.4 3.5 4.7 5.7 ample 32A - Gray Ex- 59.8 −3.4 4.3 12.1 10.6 0.8 1.1 1.3 1.6 1.7 1.6 ample 32B - Gray Ex- 44.4 −3.0 −11.1 1.0 2.0 2.4 3.2 4.5 5.2 ample 32A - Blue - Gray Ex- 56.7 −3.3 −14.8 12.8 12.3 0.6 0.8 1.2 1.6 1.6 1.8 ample 32B - Blue - Gray Ex- 30.9 −20.0 11.0 0.6 0.8 1.0 1.0 2.0 2.5 ample 32A - Green Ex- 55.0 −16.5 10.9 24.3 −24.0 0.8 1.0 1.2 1.3 1.5 1.5 ample 32B - Green
[0173] The Delta E* and Delta L* values compare the two similarly dyed knitted fabrics. The greater the Delta E* value the greater the difference in the appearance of the two shades. The Delta L* value is of particular interest here because this is a measure of the change in lightness/darkness of the two shades. Delta L* is calculated as follows: L* sample −L* standard =Delta L*. For the values in the above table, a positive value for each of the Example 32B samples indicates the color is lighter, hence has dyed less. For all of the acid dyes examined, the fabrics made from nylon 6, 12 did dye, but to a much smaller amount than those from Example A. Such a drastic reduction in color yield would be unacceptable under current carpet industry expectations for yarn dyeability.
EXAMPLE 33: SHEATH POLYMER STAIN SCREENING
[0174] Polymer was charged into an extruder and extruded into mono-component trilobal filaments at about 270° C. The extruded filaments were cooled in air and lubricated with spin finish. Yarns comprised of the filaments were taken up on a winder at speed of about 900 m/min. The yarns were drawn prior to winding and the draw ratio was around 3. The final denier of the yarns with trilobal cross-section is 826 denier/64 filaments. The amino end group (AEG) content and stain test results are summarized in Table 14 below.
TABLE 14 Food Red-17 Coffee Stain AEG Stain Test Test (meq/kg) (Delta E) (Delta E) Nylon-6 45.3 50.81 14.74 Nylon-6, 12 Homopolymer 3.4 3.69 3.44 Nylon-6, 12 Copolymer 48.0 57.17 18.78 Nylon-6, 12 Copolymer 12.8 49.01 18.59 w/reduced AEG
[0175] As can be seen from the data above, the nylon-6, 12 homopolymer with low AEG content is an exemplary polymer suitable for the sheath component in sheath/core filaments due to its minimal staining with Food Red 17 and coffee.
EXAMPLE 34: DYED SHEATH CORE FILAMENT
[0176] Yarn formed of individual trilobal sheath/core filaments was spun with a bicomponent melt-spinning apparatus that keeps the molten sheath polymer stream separate from the core polymer stream until just before entering the spinneret hole capillary. The core polymer of the trilobal filaments was cationic dyeable nylon 6 polymer, BS 600C (BASF Corporation), and the sheath polymer was VESTAMID® D16 nylon 6/12 commercially obtained from Creanova. The core polymer contained 0.3% TiO 2 while the sheath contained no additives. The yarn is spun at 275° C. through a symmetrical trilobal capillary shape and cooled by a stream of cool quench air blowing across the filaments. The yarn sample was taken from within the cooling cabinet before the yarn was drawn or textured. The polymer pumps were set to deliver the sheath polymer at 15% (by weight) and the core polymer at 85% by weight.
[0177] The yarn was dyed along with production hoselegs with a laboratory dye procedure, as follows:
[0178] Dyeing Apparatus=Hunter Dye Beck
[0179] Dyestuff=Sevron Red YCN (0.4% owf)
[0180] Dyebath Auxiliaries=Luratex (1.0% owf) Intralan Salt HA (0.15% owf)
[0181] Liquor Ratio=40 to 1
[0182] pH=6.0 to 6.2 (Adjust with trisodium phosphate (TSP) or citric acid)
[0183] Dyeing=at boil for 30 minutes
[0184] A photomicrograph of a cross-section of an exemplary dyed sheath/core filament is shown in accompanying FIG. 6. As can be seen, the dye in the dye bath physically penetrated the sheath so as to impart a dyed color to the core, while leaving the sheath substantially undyed. The color of the dyed core polymer was thus visibly perceptible through the substantially undyed sheath polymer providing a color dyed appearance to the yarn overall while retaining the stain resistance attributable to the sheath polymer.
[0185] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
This Application is a U.S. National Phase of the International Application No. PCT/CN05/000630 filed May 8, 2005 designating the U.S. and published on Nov. 17, 2005 as WO 05/108288, which claims priority to Chinese Patent Application No. 200410023180.1, filed May 11, 2004 and Chinese Patent Application No. 200410063033.7, filed Jul. 6, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to a method for the preparation of self-assembled silicon nanotubes (SiNTs), in particular, to a method for the synthesis of self-assembled SiNTs from inorganic solution (hydrothermal solution).
2. Description of the Related Art
Although the difficulty in the synthesis of SiNTs is widely attributed to the sp 3 hybridization in silicon, the possibility of the existence of SiNTs has been suggested theoretically. The preparation of SiNTs, especially self-assembled SiNTs is still very challenging at present. Great interest has focused on carbon nanotubes (CNTs) owing to their excellent properties, and many researchers in the world are attempting to prepare self-assembled SiNTs. Recently SiNTs were prepared using a template method respectively by Jeong and his coworkers in Sungkyunkwan University, and Sha and his coworkers in Zhejiang University. The corresponding research results were published in Advanced Materials (Adv Mater), which is a famous international journal in the field of materials.
SiNTs with an outer diameter of less than 100 nm were synthesized by Jeong and his coworkers using alumina templates. The templates were brought into a molecular beam epitaxy (MBE) chamber where the chamber was evacuated to a pressure of 5×10 −10 Torr. The Si atoms/clusters were sputtered for 10 min by an electron-beam evaporator. The temperature of alumina templates was maintained at 400° C. After the deposition, the sample was further heat treated at 600° C. or 750° C. under ambient conditions for oxidation.
SiNTs with an outer diameter of less than 100 nm were also fabricated by Sha and his coworkers using a nanochannel Al 2 O 3 (NCA), silane as the silicon source and gold as the catalyst at 620° C. and 1450 Pa by a chemical vapor deposition (CVD) process.
Although SiNTs have been prepared by the alumina template and NCA, the SiNTs were formed in the inner wall of templates by aggregation and not by self-assembled growth of the elemental Si. Therefore SiNTs obtained by the templates are not really self-assembled SiNTs.
SUMMARY OF THE INVENTION
One objective of the invention is to prepare self-assembled SiNTs from silicon source materials without metallic catalysts and templates. This method has many advantages including simple process, easy to operate and control the equipment, low cost and no pollution. In addition, a hydrothermal method may be used to prepare self-assembled SiNTs with small diameter and uniform diameter distribution.
One embodiment provides a method for preparing self-assembled SiNTs comprising forming a mixture of silicon oxide and water, wherein the mixture has a silicon oxide to water ratio of 0.01% to 10% by weight. The mixture is maintained at a temperature of about 200° C. to about 500° C. and a pressure of about 3 MPa to about 40 MPa for 1 to 5 hours while stirring.
Another embodiment provides a self-assembled silicon nanotube comprising a tubular body having a crystalline silicon wall layer having a thickness of about 5 nm or less and defining an inner pore diameter of about 5 nm or less. The tubular body has an outer amorphous silica layer having a thickness of less than 2 nm. The tubular body has closed ends and an outer diameter in the range of about 8 to 20 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a self-assembled growth schematic of the self-assembled SiNTs.
FIG. 2 is a transmission electron microscopy (TEM) image of the self-assembled SiNTs prepared in accordance with one embodiment of the invention.
FIG. 3 is a selected area electron diffraction (SAED) image of the self-assembled SiNTs prepared in accordance with one embodiment of the invention.
FIG. 4 is the energy dispersive X-ray spectroscopy (EDS) of the self-assembled SiNTs prepared in accordance with one embodiment of the invention.
FIG. 5 is a high-resolution transmission electron microscopy (HRTEM) image of a tubular body of the self-assembled SiNTs prepared in accordance with one embodiment of the invention.
FIG. 6 is a HRTEM image of a tubular growth tip of the self-assembled SiNTs prepared in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preparation of self-assembled SiNTs can be performed by the following process. Silicon oxide is mixed with water (e.g., a solvent) to form a mixture with a silicon oxide to water ratio of 0.01% to 10% by weight. Once the silicon oxide and water are mixed, the mixture is put into a sealed reaction kettle or container. The reaction container is maintained under the condition of about 200-500° C. and about 3-40 MPa of pressure for 1-5 hours with substantially uniform stirring. The mixture may be stirred using a magnetic stirrer. In one embodiment, the ratio of silicon oxide to water is preferably 0.05% to 8% by weight, and more preferably 0.1% to 6% by weight.
In another embodiment, the self-assembled SiNTs can be prepared under conditions with a temperature of 250° C. to 500° C. and a pressure of 8 MPa to 35 MPa for 1-4 hours with substantially uniform stirring. In a more preferred embodiment, the self-assembled SiNTs can be prepared under conditions with a temperature of 300° C. to 450° C. and a pressure of 10 MPa to 30 MPa for 1-3 hours with substantially uniform stirring. In another more preferred embodiment, the self-assembled SiNTs can be prepared under conditions with a temperature of 300° C. to 400° C. and a pressure of 6 MPa to 10 MPa for 3-4 hours with substantially uniform stirring.
No metallic catalysts and templates are used in the preparation of SiNTs using the hydrothermal method disclosed in the present invention. The SiNTs prepared by the hydrothermal method of the present invention are identified as a kind of self-assembled SiNTs according to the results of characterization. The common problems of nanoscale materials, including the ease of congregation and the difficulty of dispersion, are solved because the self-assembled SiNTs are obtained from water where no congregation occurs. At the same time, the self-assembled SiNTs makes it possible to increase the strength and toughness of composites due to the ability of forming SiNTs with larger length to diameter ratios. Many researchers have shown that silicon nanowires (SiNWs) have great potential for practical applications due to the typical quantum confinement effect and excellent physical properties. Theoretical studies have shown that SiNTs can take advantage of the quantum confinement effect more easily and can be more stable than SiNWs. Therefore, SiNTs are predicted to be a promising nanoscale material for potential applications in the nanotechnology field, which provides a new approach for making nanodevices that are highly integrated and miniaturized.
The method of the present invention operates simply and easily. Since simple equipment is used, the low cost can provide the opportunity for practical applications of the self-assembled SiNTs. The starting materials and the process do not pollute the environment, and therefore large quantities of self-assembled SiNTs can be prepared industrially in accordance with the development trend of modern industry for environmental protection.
The growth mechanism of the self-assembled SiNTs prepared by the method of present invention is proposed based on the “lip-lip” interaction growth model by Charlier et al. During the growth phase of the nanotubes, chemical bonding at the end of nanotubes (NTs) is in a metastable energy minimum, which prevents the closure of the growth end of NTs. The atoms connect with each other continuously resulting in the sustained growth of NTs. With the change of conditions, such as the decrease of temperature, the chemical bonding of the growing NTs approaches a more stable state. Since the closed structure is more stable than the open state, it results in the closure of the growth end of NTs.
FIG. 1 is a schematic of the growth process of self-assembled SiNTs. Chemical bonding between atoms are all in a metastable state and abundant H + , Si atoms and O 2− atoms are formed due to the high temperature and high pressure of the hydrothermal condition and the reactive nature of the Si and silicon oxide in gaseous form. Nucleation starts relatively uniformly from the vapor substances in the reaction kettle because of the stirring. Then the temperature rises rapidly in the kettle due to the exothermic process, which suggests that the growth process of the SiNTs has taken place. There is a temperature gradient inside the reaction container, i.e. the temperature goes from high in the center of the reaction kettle to low at the edge of the reaction kettle. The tubular structures are initially formed in the low temperature area where the Si and Si connect during the growth of SiNTs ( FIG. 1( a )). The Si—Si bonding at the growth edge of the tubular structures in a metastable energy minimum prevents the closure of the growth edge of SiNTs. At the same time, the possibility of collision with different atoms increases because SiNTs move continually between low temperature areas and high temperature areas with stirring. Thus abundant Si atoms in high temperature areas enter into the tubular walls of SiNTs and are combined with Si in the tubular wall resulting in the one-dimensional growth of SiNTs along the temperature gradient.
A stable SiO 2 layer is formed when the Si atoms at the interface of the tube wall and the atomic O 2 — in the environment react with each other, therefore preventing the growth of SiNTs in non-one-dimensional direction ( FIG. 1( b )). Abundant H + in the hydrothermal condition may cause one of four Si atoms in the crystalline Si to be substituted by H + and possibly cause a part of Si in the tubular wall of SiNTs to become amorphous Si. The possible result is the formation of a tubular wall that is similar to a graphite layer structure.
Once the heating of the reaction kettle has been stopped, Si—Si bonding at the growth end of SiNTs is changed gradually from the metastable state to a more stable state due to the falling of temperature and pressure. At the same time, the temperature gradient in the kettle also slowly disappears, resulting in the closure of the growth end and the growth of SiNTs stops ( FIGS. 1( c ), ( d )).
The TEM image of the self-assembled SiNTs in FIG. 2 shows that an abundance of nanotubes were formed using the hydrothermal method. Most nanotubes are straight in shape and the surfaces of self-assembled SiNTs are smooth. The outer diameter is usually less than 5 nm, the distribution range is about 8-20 nm, and the lengths of SiNTs are several hundreds of nanometers to microns. The diameter of the inner pore (e.g., inner diameter) is smaller than 5 nm in general with a small diameter distribution range. The growth tips of the self-assembled SiNTs are in closed semicircular form showing that no catalyst particles exist in the SiNTs and no growth tips with open end structure are observed.
The self-assembled SiNTs are mostly poly-crystalline structures according to the SAED pattern ( FIG. 3 ). The SAED patterns; of the first, second, and third order diffraction rings, from the inside to the outside of a nanotube, match well with the (1 1 1), (2 2 0) and (3 1 1) diffraction crystal planes, respectively.
The EDS analysis in FIG. 4 shows that the chemical composition of the products consists of Si and O. The equal peak height of Si and O suggests that the atomic ratio of Si and O is 1:1, which is consistent with that of silicon monoxide.
The interplanar spacing, outer and inner diameters, the thicknesses of amorphous outer layer and Si wall layer of SiNTs were measured HRTEM and calculated using a software by Digital Micrograph applied in the HRTEM. The hollow inner pore, crystalline silicon wall layer and amorphous silica outer layer can be clearly observed in the HRTEM images. The crystalline layer grows along the axial direction of SiNTs. The interplanar spacing of crystalline in the SiNTs is around 0.31 nm according to the measurement and the calculation, which agrees with the {111} plane of silicon. The outer diameter of the tubular body in FIG. 5 is about 14 nm, the diameter of inner pore is about 5 nm and the thicknesses of crystalline Si and amorphous outer layer are about 5 nm and less than 2 nm, respectively. The outer diameter of the tubular growth tip in FIG. 6 is about 18 nm and the diameter of inner pore is about 3 nm. The inner diameter of the growth tip is larger than that of the tubular body. The corresponding Si wall thickness is 5 nm and the amorphous outer layer thickness less than 2 nm.
The amorphous silicon oxide outer layer at the growth tip of the self-assembled SiNTs does not distribute evenly and some defects exist The environment in the reaction kettle is an oxidation environment, and there are two elements Si and O in the products (e.g., SiNTs). Since silicon oxide is the most stable compound of silica, the outer layers of the SiNTs can be identified as amorphous silica. The appearance of the same number of lattice fringes and amorphous silica outer layers on both sides of a self-assembled SiNTs shows that it has a seamless tubular structure. Therefore, the structures of SiNTs are composed of three parts: hollow inner pore with a diameter of several nanometers in the middle, crystalline silicon wall layers with a thickness of less than 5 nm and amorphous silica outer layers with less than 2 nm thickness.
EXAMPLE 1
Silicon oxide and water were mixed together to form a mixture of 0.01% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 200° C. under 3 MPa pressure for 1 hour with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed.
EXAMPLE 2
Silicon oxide and water were mixed together to form a mixture of 0.1% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 380° C. under 8 MPa pressure for 1 hour with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed.
EXAMPLE 3
Silicon oxide and water were mixed together to form a mixture of 0.5% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 500° C. under 8 MPa pressure for 1 hour with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 mm were formed.
EXAMPLE 4
Silicon oxide and water were mixed together to form a mixture of 1% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 300° C. under 10 MPa pressure for 3 hours with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed.
EXAMPLE 5
Silicon oxide and water were mixed together to form a mixture of 4% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 380° C. under 15 MPa pressure for 1 hour with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed.
EXAMPLE 6
Silicon oxide and water were mixed together to form a mixture of 6% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 500° C. under 20 MPa pressure for 1 hour with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed.
EXAMPLE 7
Silicon oxide and water were mixed together to form a mixture of 6% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 380° C. under 8 MPa pressure for 3 hours with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed.
EXAMPLE 8
Silicon oxide and water were mixed together to form a mixture of 8% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 500° C. under 30 MPa pressure for 2 hours with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed.
EXAMPLE 9
Silicon oxide and water were mixed together to form a mixture of 10% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 500° C. under 30 MPa pressure for 4 hours with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed.
EXAMPLE 10
Silicon oxide and water were mixed together to form a mixture of 8% by weight, and the mixture was place in a sealed reaction kettle. The mixture was maintained at 450° C. under 30 MPa pressure for 3 hours with substantially uniform stirring using a magnetic stirrer. Self-assembled SiNTs with an average inner diameter of less than 5 nm and an average outer diameter of around 15 nm were formed. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/805,127 filed Jun. 19, 2006, which is hereby incorporated by reference herein for all purposes.
TECHNICAL FIELD
[0002] The invention generally related to a restraint system using electronic locks. In particular, the invention relates to handcuffs or shackles that incorporate a combination of mechanical locks and electronic locks for use with an electronic key.
BACKGROUND
[0003] Since the invention of handcuffs in the early twentieth century, defeating its locking mechanism has posed a threat to law enforcement and the public more generally. Escaped prisoners are typically desperate to avoid recapture and may resort to violence in the process of fleeing authority. Cases in which prisoners have freed themselves from standard cuffs are all too common.
[0004] The design of the common cuff lock has changed little in seventy-five years and is well understood by those who seek to defeat it. In addition, the standard cuff key possesses a generic design and can be used to open most any set of handcuffs or leg restraints. Compounding the problem is the ready availability of the handcuff keys. Handcuff keys can be easily and inexpensively purchased at any American gun show, sporting goods store, or through the Internet.
[0005] Criminals have also learned to breach or bypass standard cuff locks even when in prison or jail. Cuff keys may be smuggled into the prison or a facsimile of a key hand crafted using a wide variety of materials on hand including scrap metal, paper clips, hairpins, toothbrushes, wood, and bone, for example.
[0006] There is therefore a need for a restraint system that employs a lock mechanism that is tamper-proof and a key that is both unique and difficult to improvise.
SUMMARY
[0007] The invention features a combination mechanical and electronic lock system for use in cuffs and various other lock applications. In the preferred embodiment, the cuff is configured to receive a matching cuff key that transmits a code that disengages the electronic lock from the mechanical lock so that the mechanical lock can be manually opened by the user. The cuff, for example, comprises a mechanical lock including a single lock mechanism and a double lock mechanism; and at least one electronic lock configured to selectively unlock at least a portion of the mechanical lock upon receipt of the proper passcode from the cuff key. The power needed to operate the electronic lock, preferably a solenoid or other actuator, is received directly or indirectly from the cuff key so that the cuff need not possess a battery.
[0008] The cuff may include a solid state memory device, for example, to store at least one passcode for comparison with the received passcode from the cuff key. Additional passcodes may be uploaded to the cuff to permit different keys access to the cuff or different levels of access to the cuff. The cuff may also be configured to receive and retain a serial number identifying the key used to open or unlock the cuff. Similarly, the cuff may be uploaded with a black list passcode specifying a passcode that is not authorized to unlock the electronic lock. The passcode is preferably a digital code which can be processed with a digital micro-processor.
[0009] In another embodiment of the invention, the lock includes a cuff housing; a ratchet pivotably coupled to the housing; a lock mechanism configured to restrict rotation of the ratchet about the cuff housing; an electronic lock configured to restrict or otherwise prevent the lock mechanism from being unlocked without the appropriate electronic key; and a processor configured to: store at least one passcode; receive a passcode from a key; and unlock at least one of the one or more electronic locks if the received passcode matches the stored passcode. The lock mechanism may include what are referred to as a single lock mechanism and a double lock mechanism. The electronic lock may include a first electronic lock and a second electronic lock. The first electronic lock generally restricts movement of the single lock mechanism, and the second electronic lock restricts the movement of at least the double lock mechanism.
[0010] The single lock mechanism generally includes a pawl that is biased onto the ratchet. The teeth of the pawl and ratchet are engaged in such a manner that the ratchet cannot be opened or otherwise removed from a prisoner's wrist without the appropriate electronic key. The pawl can only be pulled away from the ratchet with a lifter arm when acted on by a key. The first electronic lock includes an actuator that prevents the lifter arm from disengaging the pawl from the ratchet when locked, and permits the lifter arm to disengage the pawl from the ratchet when unlocked. The double lock mechanism includes a bolt configured to prevent the pawl from disengaging the ratchet when locked, and permit the pawl to disengage the ratchet when unlocked. The second electronic lock includes an actuator configured to prevent the bolt from disengaging the pawl when the second electronic lock is locked, and permit the bolt to disengage the pawl when unlocked. As discussed above, the power required to drive the one or more actuators is derived from the key since the lock has no internal power source.
[0011] In another embodiment, the invention features an electronic lock having at least one actuator coupled to a mechanical lock; memory configured to store at least one passcode; and a processor configured to: receive a passcode from a key; compare the received passcode to the stored passcode; and activate the at least one actuator to unlock the mechanical lock, if the received passcode matches the stored passcode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, and in which:
[0013] FIG. 1 is a pair of electronic shackles;
[0014] FIG. 2 is an exemplary electronic cuff, in accordance with one embodiment of the present invention;
[0015] FIG. 3 is an exemplary electronic cuff key, in accordance with one embodiment of the present invention;
[0016] FIG. 4 is a partial cross section of an electronic cuff in a single lock configuration, in accordance with one embodiment of the present invention;
[0017] FIG. 5 is a partial cross section of an electronic cuff as the single lock is disengaged, in accordance with one embodiment of the present invention; and
[0018] FIG. 6 is a partial cross section of an electronic cuff in a double lock configuration, in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The preferred embodiment of the present invention is an electronic restraint system including an electronic shackle or cuff and corresponding electronic key. Illustrated in FIG. 1 is an electronic shackle 100 for enhancing the restraint of an individual and the safety of law enforcement personnel. The shackle 100 includes a pair of metal cuffs 102 or manacles adapted to encircle and confine the wrist or ankle of a person in the custody of law enforcement, this person being referred to herein as a prisoner. Each cuff 102 includes a cheek plate 104 , ratchet 106 pivotably attached to the cheek plate by means of hinge 109 , and a primary keyway 120 configured to receive a cuff key. The cheek plate 104 conceals a pawl with teeth 130 that engage the teeth 108 of the ratchet 106 . The cuffs 102 are flexibly coupled together with a chain 110 or bolt and swivel eyes 112 to bind the prisoner's wrists or ankles together.
[0020] Referring to FIG. 2 , each cuff 102 comprises a cheek plate 104 of hardened-steel for housing one or more mechanical and electronic locks, a ratchet 106 rotatably attached to the cuff housing by means of a pivot point 109 , a primary keyway 120 sized to receive a cuff key to disengage a single lock mechanism and double lock mechanism, and a secondary keyway 220 sized to receive the pin of a cuff key to engage the double lock mechanism. In accordance with some embodiments, the cuff further incorporates one or more electronic locks including a first electronic lock 260 and a second electronic lock 270 , each of which is electrically coupled to a passcode processor 250 protectively concealed within the cuff.
[0021] Illustrated in FIG. 3 is an exemplary cuff key 300 , which functions at both a mechanical level and an electrical level to open the electronic restraint system. In the preferred embodiment, the lower portion 310 of the cuff key comprises a form of barrel key with a hollow, cylindrical shaft 312 and a rectangular tooth or bit 316 . The barrel 310 is sized to fit within the primary keyway 120 and over a protrusion 122 that juts into the primary keyway from the inside of the cuff. The rectangular tooth or bit 316 is configured to turn within the cuff housing and unlock the single lock and double lock mechanisms. In addition, the upper portion of the cuff key includes an eye hole 322 and a pin 320 adapted to engage the double lock mechanism and the second electronic lock when inserted into the second keyway 220 . The central portion of the cuff key includes a passcode generator 350 for communicating an internal passcode to the cuff as well as a battery 360 configured to provide operational power to the passcode generator 350 , the passcode processor 250 , the first electronic lock 260 , and the second electronic lock 270 .
[0022] Illustrated in FIG. 4 is a partial cross section of a cuff with the single lock mechanism engaged (i.e., locked) and the double lock mechanism disengaged (i.e., unlocked). The cuff includes a housing defined by wall 402 , a ratchet 106 , a pawl 410 with spring 412 , a lifter arm 420 , and a bolt 430 . Consistent with a conventional cuff with the single lock engaged, the spring 412 continually biases the pawl 410 downward toward the ratchet 106 . The pawl 410 , however, may be raised upward when the ratchet 106 is closed if and when the slopped faces of the ratchet's teeth 108 are forced from right to left. As such, the single lock mechanism of the present embodiment allows the ratchet 106 to freely rotate in a closing direction (counter-clockwise about hinge 109 ) toward the housing to enable law enforcement personnel to quickly immobilize a prisoner's wrist or ankle, for example. Due to the asymmetric shape of the teeth on the ratchet and pawl, however, the single lock mechanism generally prevents the ratchet 106 from rotating in an opening direction (clockwise) unless the single lock mechanism is first disengaged with the cuff key 300 .
[0023] Illustrated in FIG. 5 is a partial cross section of a cuff 102 as the single lock is disengaged. To mechanically disengage the single lock, the cuff key is inserted into the first keyway 120 and the key turned clockwise to engage a flange 423 on the lifter arm 420 . When turned beyond about 135 degrees, the key's bit 316 pulls the lifter arm 420 away from the ratchet 106 in a generally upward direction. When a torque sufficient to compress the spring 412 is applied, the lifter arm 420 pivots counter-clockwise about its axis 422 , which causes the distal end at the right to push the pawl 410 upward away from the ratchet.
[0024] The preferred embodiment of the cuff further includes a double lock mechanism for added security. Illustrated in FIG. 6 is a partial cross section of a cuff with both the single lock mechanism and double lock mechanism engaged. The double lock is engaged by inserting the cuff key's pin 320 into the secondary keyway 220 to push the bolt 430 to the right into a position directly between the pawl 410 and housing wall 402 , thereby preventing the pawl from being lifted away from the ratchet 106 . As such, the pawl 410 is held in place to prevent the ratchet 106 from either opening (loosened) or closing (tightened) until the double lock is subsequently disengaged. To disengage the double lock, the same cuff key used for the single lock is inserted into the primary keyway 120 and turned counter clockwise (opposite direction needed to unlock the single lock mechanism), which pushes the bolt 430 back to the left when the key's bit 316 engages a flange 630 on the bolt 430 . When pushed back to its initial station, the bolt 430 is once again clear of the pawl 410 to permit the pawl to retract from the ratchet 106 .
[0025] The cuff 102 of the preferred embodiment further includes a first electronic lock 260 and a second electronic lock 270 . The first and second electronic locks are configured to cooperate with and reinforce the single and double lock mechanisms, respectively. Both electronic locks are connected to the passcode processor 250 configured to compare the passcode received from a key to a stored passcode before disengaging the electronic locks. The passcode is communicated to the processor 250 by means of one or more electrical contacts 314 in the cuff key's bit 316 and corresponding electrical contacts in one or more of the keyway 120 , 220 . When the first electronic lock 260 is engaged, for example, the single lock mechanism can only be opened when the processor 250 receives the proper security code from a cuff key inserted into the primary keyway 120 . The electronic cuff cannot, therefore, be opened by a standard cuff key even though it possesses the same physical shape and dimensions as the electronic cuff key 300 depicted in FIG. 3 .
[0026] The first electronic lock 260 is automatically engaged when the single lock mechanism is engaged (i.e., when the ratchet engages the pawl), and automatically disengaged when the proper key is inserted and/or turned clockwise in the primary keyway 120 . Similarly, the second electronic lock 270 is automatically engaged when the double lock mechanism is engaged via the second keyway 220 (i.e., when the bolt is slid behind the pawl), and automatically disengaged when the proper key is inserted and/or turned counter-clockwise in the first keyway 120 .
[0027] Referring to FIG. 4 again, the first electronic lock 260 includes a first actuator while the second electronic lock 270 includes a second actuator, both of which are connected to the passcode processor 250 . In the preferred embodiment, the actuators are electromagnetic solenoids although various other types of linear and rotary actuators known to those skilled in the art may be employed. The first actuator includes a coil 450 and a retractable projection 452 . When engaged, the projection 452 extends into the path of the lifter arm 420 , thereby preventing the lifter arm from pulling the pawl 410 away from the ratchet 106 .
[0028] Referring to FIG. 5 again, if and when the first electronic lock is disengaged, the processor 250 applies a power signal to the first solenoid 260 , which causes the projection 452 to be temporarily retracted. When retracted, the lifter arm 420 may be turned counter-clockwise and the pawl 410 lifted. Without the proper key, the projection 452 remains extended to prevent a key from turning the lifter arm 420 to open the ratchet.
[0029] Referring to FIG. 6 again, the second solenoid 270 also includes an electromagnetic coil 460 and a projection 462 adapted to physically obstruct the bolt 430 from sliding in an unlocking direction without the proper cuff key. If and when the second electronic lock is disengaged, the processor 250 applies a power signal to the second solenoid 270 , which causes the projection 462 to be retracted from a recess in the bolt. With the projection 462 clear of the bolt 430 , the bolt may be manually slid to the left and clear of the pawl 410 . Without the proper key, the projection 462 secures the bolt 410 to prevent a key from disengaging the second lock mechanism.
[0030] In accordance with some embodiments, the power to actuate the first and second solenoids is provided by the cuff key 300 , which includes a portable energy source including one or more batteries 360 . The power signal may be transmitted serially after the passcode is transmitted to the cuff 102 , transmitted in parallel via a second channel operably coupling the key and passcode processor, or communicated to the cuff via a capacitive or inductive link. The cuff 102 in the preferred embodiment, however, does not include any internal energy source.
[0031] The passcode processor 250 in the preferred embodiment is a solid state micro-processor such as a Programmed Integrated Circuits (PIC), for example. The processor authenticates the passcode by comparing the passcode received from the key to one or more approved passcodes retained in on-board memory in the cuff's passcode processor 250 , for example. A passcode is preferably a 256 or 512 bit digital code or combination representing an alphanumeric string of characters. The passcode may be stored to on-board memory when the cuff is manufactured; programmably written to memory using an erasable programmable read-only-memory (EPROM), for example; or a combination thereof.
[0032] The set of passcodes with which the cuff 102 can be opened may consist of a single passcode associated with one or more keys, or comprise multiple passcodes associated with different geographic areas or the different levels of a law enforcement organization. For example, there may be a first passcode associated with the key of an officer; a second passcode associated with a local law enforcement department, a third passcode associated with a county law enforcement department; a fourth passcode associated with a state law enforcement department; or any combination of the above. This avoids the problems associated with the universal key in traditional cuffs. The preferred embodiment also isolates problems due to lost keys, for example, since the loss of a key used in one police department does not affect another department using a different passcode.
[0033] In some embodiments, the cuff 102 is further adapted to retain a black list including passcodes that are barred from unlocking the cuff, thereby providing a mechanism for neutralizing the passcodes associated with keys that are lost or stolen, for example. The authorized passcodes and black list codes may be periodically uploaded to the cuff using a docking station, such as a cradle maintained by the law enforcement office or manufacturer.
[0034] The electronic cuff key 300 in the preferred embodiment comprises a traditional skeleton key or barrel key with one or more bits 316 having one or more electrical contacts 314 ; a memory for retaining one or more passcodes; a processor 350 or circuit board for generating the passcode; one or more batteries 360 or other power source; and a cylinder 370 to house the batteries. The key 300 should be sufficiently large to prevent a stolen key from being easily concealed by a prisoner during a pat-down search, for example. This may be effectively achieved using a key with two or more AA or AAA batteries, for example. The key may have assigned to it a unique serial number that is also communicated to the cuff each time the cuff is unlocked.
[0035] In some embodiments, the cuff key 300 includes a miniature recharging apparatus in the key, the recharging apparatus being consistent with the recharger used in hands-free headsets for cellular phones. A light emitting diode may be used as a low battery charge level indicator, and/or an audible alert used to notify the user of a low battery charge level or malfunction. When low, the batteries can then be recharged with a AC to DC converter, which could save the law enforcement departments the expense of replacing batteries.
[0036] In some embodiments, the key and/or cuff includes a light emitting diode (LED) whose light level can be used to indicate to law enforcement personnel whether the first or second locking mechanism has been properly engaged and/or disengaged. Similarly, the cuff key 300 and/or cuff 102 may include an audible alarm for generating a beep to indicate when the electronic cuff is locked and/or unlocked.
[0037] In some additional embodiments, the cuff 102 is adapted to measure, record, and upload information about the cuff and key usage. Information indicating the degree to which the cuff is locked may also be recorded to enable law enforcement to reconstruct the conditions under which cuff was applied to a prisoner. That is, the cuff 102 is adapted to indicate the position of the ratchet relative to the housing, thus indicating how much or how little pressure was used to constrain the prisoner's wrist within the cuff. The position of the ratchet may be measured and recorded in terms of the number and position of the ratchet teeth 108 that engage the pawl 410 when the cuff is secured in the single or double locked position. The information may further include a timestamp and the information periodically uploaded to a cradle or docking station, for example.
[0038] The information recorded by the cuff for subsequent download may further include the serial number of the previous one or more keys used to unlock the cuff. This information may then be stored in the cuff and retrieved if necessary to identify which key was used to unlock the cuff, determine the identity of the person to whom the key was assigned, and whether the individual with the key was authorized to unlock the cuff.
[0039] The preferred embodiment of the invention herein is intended for use in a cuff or other restraint system. One skilled in the art, however, will appreciate that the invention is also applicable to numerous other locking applications including automobiles, homes, gates, filing cabinets, lock boxes, safes, chests, briefcases, padlocks, and trigger locks, for example.
[0040] Although the description above contains many specifications, 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.
[0041] Therefore, the invention has been disclosed by way of example and not limitation, and reference should be made to the following claims to determine the scope of the present invention. | 4y
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FIELD
This invention relates to selecting applications in a mobile device, more particularly, to methods, systems and apparatus for user selectable programmable housing skin sensors on the mobile device for user mode optimization and control.
DESCRIPTION OF THE RELATED ART
Presently, mobile communication devices and hand held portable devices such as mobile phones, pagers, portable games, remote controls, and the like, provide communication and other functionality for users on the go. For example, a user with a mobile phone can place a call while engaging in another activity, such as walking.
Each user may hold a mobile phone slightly different from the next user. This can adversely affect microphone and speaker performance, which results in poor detection of the user's voice and non-optimal volume output from the speaker, respectively. Furthermore, the user may hold the phone with the antenna at a varying distance from the user's head. This can adversely affect antenna and transmission performance because of sub-optimal tuning of antenna matching circuitry.
In addition, as the user is engaged in another activity, it can be difficult for the user to select the proper mode of operation of the hand held portable device. One example can be switching from a call mode to an image capture mode on the device while driving. Safety concerns demand that full attention to be paid to the driving activity. Moreover, as part of switching operating modes of a handheld portable device, conventional devices often require the user to navigate through numerous menus to select a mode or function (e.g., text messaging, camera, game, etc.).
Accordingly, there is a need in the art to be able to personalize the functions of a mobile telephone to the use habits of the user to optimize performance of the mobile telephone. Moreover, there is a need for the mobile telephone to find a mechanism to switch modes in a more efficient manner.
SUMMARY
An embodiment relates generally to a method of operating a device. The method includes providing for a plurality of sensors, where each sensor is configured to sense and transmit data values associated with an interaction with the device by a user. A subset of the sensors of the plurality of sensors is associated with a respective facing on a housing of the device. The method also includes operating the plurality of sensors to detect the interaction with the device by the user and receiving sensor data associated with the interaction from the plurality of sensors. The method further includes determining a user mode of the device based on the sensor data associated with the interaction and/or handling of the device.
Another embodiment pertains generally to an apparatus for customizing a user experience. The apparatus includes a controller and a housing configured to enclose the controller. The apparatus also includes a plurality of sensors, where each sensor is configured to sense and transmit data values to the controller in response to an interaction with the apparatus by a user and where at least one sensor of the plurality of sensors is associated with a side of a housing. The apparatus further includes a user personalization module coupled with the controller and configured to personalize the device by storing a plurality of user modes. The controller is configured to receive sensor data associated with the interaction from the plurality of sensors and to determine a selected user mode from the plurality of user modes based on the received sensor data associated with the interaction from the plurality of sensors.
Yet another embodiment relates generally to a method of personalizing a mobile telephone. The method includes providing for a plurality of sensors, where each sensor is configured to sense and transmit data values associated with an interaction with the mobile telephone by a user and a subset of the sensors of the plurality of sensors is associated with a respective facing on a housing of the mobile telephone. The method also includes storing a plurality of user modes for the mobile telephone, where each user mode is associated with a set of sensor values from the plurality of sensors. The method further includes operating the plurality of sensors to detect a current interaction with the mobile telephone by the user and selecting a user mode of the mobile telephone based on the sensor data from the plurality of sensors associated with the current interaction.
Accordingly, a user can personalize a mobile telephone with the respective use habits of the user. As a result, a user can use the mobile telephone more efficiently and in a safer manner while engaged in other activities.
BRIEF DESCRIPTION OF THE DRAWINGS
Various features of the embodiments can be more fully appreciated, as the same become better understood with reference to the following detailed description of the embodiments when considered in connection with the accompanying figures, in which:
FIGS. 1A-D , collectively, depict distribution of skin sensors on the housing of a mobile telephone in accordance with an embodiment;
FIGS. 2A-D , collectively, illustrate exemplary sensors in accordance with various embodiments;
FIG. 3 illustrates a block diagram of a mobile telephone in accordance with yet another embodiment;
FIG. 4 depicts a block diagram of a controller and the sensor network in accordance with yet another embodiment;
FIG. 5 illustrates an exemplary flow diagram executed by the controller in accordance with yet another embodiment;
FIG. 6 shows another exemplary flow diagram in accordance with yet another embodiment; and
FIG. 7 depicts yet another exemplary flow diagram in accordance with yet another embodiment.
DETAILED DESCRIPTION OF EMBODIMENTS
For simplicity and illustrative purposes, the principles of the present invention are described by referring mainly to exemplary embodiments thereof. However, one of ordinary skill in the art would readily recognize that the same principles are equally applicable to, and can be implemented in, all types of mobile communication devices, and that any such variations do not depart from the true spirit and scope of the present invention. Moreover, in the following detailed description, references are made to the accompanying figures, which illustrate specific embodiments. Electrical, mechanical, logical and structural changes may be made to the embodiments 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 by the appended claims and their equivalents.
Embodiments pertain generally to methods and apparatus for personalizing a mobile telephone. More particularly, a controller can be configured to couple with a network of sensors. The sensors can be distributed over the housing of the mobile telephone. Each sensor can be assigned to an area of the housing and can be implemented as a capacitive, pressure, conductive, or other touch sensitive sensor.
The controller can execute a personalization module that can be configured to personalize or program the mobile telephone to the user. More specifically, the personalization module can generate an image of a mode, e.g., talking, of the mobile telephone for the user to emulate in a calibration (or configuration, program, etc.) mode. As the user emulates the displayed image, the personalization module can then be configured to collect the data from the network of sensors through the controller to obtain a set of data for a predetermined amount of time as a sensor profile. The received sensor profile is associated with the mode and stored. Subsequently, as the user manipulates the mobile telephone, the mobile telephone can determine a use mode by comparing the stored sensor profiles with the current sensor profile.
The personalization module can also be configured to update the configuration data associated with a (use) mode. More particularly, a user may eventually drift from the initial position captured by the data collection during the programming mode, i.e., tactile interaction. Accordingly, the personalization module can periodically collect data from the network of sensors during a selected mode as a current sensor profile and compare the use data with the associated configuration data, i.e., stored sensor profiles. If the variance between the current sensor profile and the stored sensor profiles exceeds a predetermined threshold, the personalization module can be configured to initiate the programming mode for the selected mode. Alternatively, the personalization module can update the stored sensor profile with the current sensor profile.
FIGS. 1A-C collectively illustrate an exemplary distribution of sensors over a housing of a mobile telephone. For the shown embodiments, it should be readily apparent to those of ordinary skill in the art that the number of sensors and the placements of the sensors can be varied without departing from the scope and breadth of the claimed invention. Moreover, FIGS. 1A-C share some common features. Accordingly, the description of the common features in the latter figures are being omitted and that the description of these feature with respect to the first figure are being relied upon to provide adequate description of the common features.
FIG. 1A shows a front view of a mobile telephone 100 and FIG. 1B depicts a back view of the mobile telephone 100 . The mobile telephone 100 includes an exterior display 105 and a housing 110 . The housing 110 can be a “clamshell” configuration. Other embodiments of the housing 110 can be a “candy-bar”, a slider configuration, or other mobile telephone housings. The housing 110 can be partitioned into sensor areas 115 . Each sensor area 115 can be serviced by a single sensor or multiple sensors (e.g., tactile, distance, gyroscope, accelerometer, etc.).
FIG. 1C illustrates a side view of the mobile telephone 100 with side sensor areas 120 . In some embodiments, the side sensor areas 120 can be part of respective sensor area 115 from the top and bottom of the housing 110 .
FIG. 1D shows a view of the mobile telephone 100 in an open configuration. As shown 9 in FIG. 1D , the interior sensor areas 125 can be placed surrounding the speaker 130 , an interior display 135 , a keypad 140 , and a microphone 145 . While the sensors associated with a particular surface are illustrated as being fairly uniform in size and shape, one skilled in the art will readily recognize that the size, shape and concentration of discrete sensors can vary relative to different areas of a particular housing surface of the handheld device without departing from the teachings of the present invention. For example, there may be an increase in the density of discrete sensors and a corresponding increase in the number of sensors proximate an area where a user is more likely to interact with the housing.
The sensor(s) (not shown in FIGS. 1A-D ) servicing each sensor area 115 , 120 , and 125 can be implemented as sensor deposits. The sensor can be deposited as carbon paint during the housing manufacturing phase, which is then painted over (in the event of outside skin deposits) to internal sensing deposits placed on the inside of the housing material. The sensor deposits can be prepared from materials such as copper, carbon, or other materials with some level of conductivity.
Other methods for applying conductive material on exterior surfaces can include a flex circuit, a conductive paint, a conductive label, plating, vacuum metallization, plasma coating, in mold decoration (conductive ink), film insert molding (conductive ink), metal insert (e.g., glob label or decorative metal bezel), conductive plastic molding, etc.
The sensor deposits can be designed to make contact with a hardware contact of the sensor network that connects the sensors with the controller. The controller can be configured with numerous integrated electrical switches, which then drives the sensing hardware. The switches can be controlled by the processor of the mobile telephone and can be re-programmed as needed. Examples of the electrical interface between the sensor deposits and the sensor network are shown in FIGS. 2A-D .
FIG. 2A shows a capacitive interconnect 200 A between an exterior conductive material 205 A and an interior conductive material 210 A. The exterior conductive material 205 A can be deposited over the interior conductive material 210 A, which is then coupled to an external sensor plate (not shown).
FIG. 2B depicts an insert molded contact configuration 200 B in accordance with another embodiment. As shown in FIG. 2B , the configuration 200 B has a metal clip 205 B that can be insert molded into a plastic 210 B. The plastic 210 B can be flush with an exterior surface of the housing 110 . An in mold/film decoration 215 B can be used as a conductive surface with a decorative/protective overcoat 220 B. In other embodiments, the mold/film decoration 215 can be painted with a conductive paint.
FIG. 2C illustrates a spring contact configuration 200 C in accordance with yet another embodiment. As shown in FIG. 2C , the configuration 200 C can comprise a protective surface 205 C deposited over a cosmetic layer 210 C and underneath the housing of the mobile telephone. The cosmetic layer 210 C can be adjacent to a conductive sensor material 215 C, which abuts a wall 220 C of the housing 110 . The wall 220 C can then be positioned next to the interior of the mobile telephone.
The cosmetic layer 210 can have a voided area that exposes the conductive sensor material 215 C. A spring clip can then be used to connect the exterior contact zone to the interior part of the phone. The configuration 200 C can require an opening in the housing 110 .
FIG. 2D shows a flex/conductive label contact configuration 200 D in accordance with yet another embodiment. As shown in FIG. 2D , configuration 200 D can comprise a cosmetic overlay layer 205 D deposited over a flex circuit 210 D embedded within housing wall 215 D. In this embodiment, a tail portion of the flex circuit 210 D can be coupled through a housing opening for contact to the interior electronics. A pressure contact 220 D can be coupled to a capacitive touch sensor circuit 225 D. As a user presses or holds the exterior of the housing wall, the housing wall can make contact with flex circuit 210 D and complete the circuit of the flex circuit 210 D, the pressure contact 220 D and the capacitive touch sensor circuit 225 D.
FIG. 3 illustrates a block diagram 300 of the mobile telephone 100 in accordance with yet another embodiment. It should be readily apparent to those of ordinary skill in the art that the block diagram depicted in FIG. 3 represents a generalized schematic illustration and that other components may be added or existing components may be removed, combined or modified.
As shown in FIG. 3 , the mobile telephone 100 can include a controller 310 , input/output (I/O) circuitry 320 , transmitter circuitry 330 , receiver circuitry 340 , and a bus 350 . In operation, the bus 350 allows the various circuitry and components of the mobile telephone 100 to communicate with each other. The I/O circuitry 320 provides an interface for the I/O devices such as the exterior display 105 , the speaker 130 , the display 135 , the keypad 140 , and the microphone 145 . The transmitter circuitry 330 provides for the transmission of communication signals to other mobile communication devices, base stations, or the like. The receiver circuitry 340 provides for the reception of communication signals from other mobile telephones, base stations, or the like. The controller 310 controls the operation of the mobile telephone 100 .
In some embodiments, the controller 310 can be interfaced with a sensor network as shown in FIG. 4 . As shown in FIG. 4 , the controller 310 can be coupled to a sensor network 405 through a switch 410 . The sensor network 405 can be implemented with skin sensors as previously described. One or more skin sensors can be implemented in a sensor area (see FIGS. 1A-D , areas 110 , 115 , 120 , and 125 ) on the housing 110 of the mobile telephone 100 . The switch 410 can be configured to direct data from the sensor network 405 to the controller 310 for processing.
The controller 310 can be configured to include a personalization module as shown in FIG. 5 , which depicts an exemplary block diagram of the personalization module 500 in accordance with yet another embodiment. It should be readily apparent to those of ordinary skill in the art that the block diagram 500 depicted in FIG. 5 represents a generalized schematic illustration and that other components may be added or existing components may be removed or modified.
As shown in FIG. 5 the personalization module 500 can comprise a manager module 505 , a sensor module 510 , a mode library module 515 and a sensor profile module 520 . The manager module 505 can be configured to provide the functionality of the personalization module 500 as described previously and in greater detail below. The manager module 505 can be coupled to the sensor module 510 . The sensor module 510 can be configured to interface with the sensor network 405 through the switch 410 . The sensor module 510 can then provide an interface for the manager module 505 to collect data from the respective sensors 415 of the sensor network 405 .
The manager module 505 can also be coupled with the mode library module 515 . The mode library module 515 can be configured to store images or icons associated with respective modes of the mobile telephone. For example, image 525 A can be an image of a user holding a telephone to represent or image 525 B can be an image of a user using the telephone in a speakerphone mode. Accordingly, when the manager module 505 is placed in a calibration (or personalization, program, etc.) mode, the manager module 505 can display a selected image of a user mode for a user to emulate. As the user is emulating the displayed image, the manager module 505 can then collect a set of configuration/calibration data, i.e., a sensor profile, from the sensors 415 of the sensor network 405 through the sensor module 510 . Subsequently, the manager module 505 can store and associate the received sensor profile with the selected mode in the sensor profile module 520 . As a result of storing sensor profiles for each mode of operation of the mobile telephone, a user can operate a mobile telephone in different modes by merely changing how the user holds the mobile telephone.
The sensor profile module 520 can store use modes such as anticipation modes. One example of an anticipation mode can be a mobile telephone can initiate full power on, the display being turned on, etc. in response to detecting that it is being picked up by the user. Another example of an anticipation mode can be the mobile telephone changing ring tone, increasing the volume, turning off the display, etc., in response to detecting that it is being put on a table. Yet another example of an anticipation mode can be the mobile telephone enabling an idle mode in response to detecting that it is plugged to a charger.
FIG. 6 shows a flow diagram 600 executed by the manager module 505 in accordance with yet another embodiment. It should be readily apparent to those of ordinary skill in the art that the flow diagram 600 depicted in FIG. 6 represents a generalized schematic illustration and that other steps may be added or existing steps may be removed or modified.
As shown in FIG. 6 , the manager module 505 can be configured to be in a calibration mode, in step 600 . More particularly, a user may have manipulated the keypad 140 of the mobile telephone 100 to enter a configuration/calibration mode. The manager module 505 can be configured to display a predetermined number of images that represent each mode of the mobile telephone. A user could scroll through the images by operating appropriate buttons of the keypad 140 . The manager module 505 can then enter a wait state until a user selects a mode to calibrate or program.
In step 610 , the manager module 505 can receive the selection of the mode to program. Accordingly, the manager module 505 can display the selected image on the LCD 140 .
In step 615 , the manager module 505 can be configured to collect data from the sensors 415 of the sensor network 405 for a predetermined amount of time. The manger module 505 can buffer the incoming data from sensor network.
In step 620 , the manager module 505 can be configured to store the collected data as a set of configuration data, i.e., a sensor profile, for the selected mode. The manager module 505 can then store the sensor profile linked with the selected mode in the sensor profile module 520 . Subsequently, the manager module 505 can then exit the calibration/programming mode.
FIG. 7 shows a flow diagram 700 executed by the manager module 505 in accordance with yet another embodiment. It should be readily apparent to those of ordinary skill in the art that the flow diagram 700 depicted in FIG. 7 represents a generalized schematic illustration and that other steps may be added or existing steps may be removed or modified.
As shown in FIG. 7 , the manager module 505 of the personalization module 500 can be configured to detect a tactile interaction by the user, in step 705 . More particularly, the sensor module 510 can receive a set of operating data as a current sensor profile from the active sensors 415 of the sensor 405 .
In step 710 , the manager module 505 can be configured to initially buffer the current sensor profile from the sensor module 510 . In step 715 , the manager module 505 can be configured to determine a mode based on the collected sensor profiles stored in the sensor profile module 520 . More particularly, the manager module 505 can compare the current sensor profile with the stored sensor profiles.
If there is a match between the current sensor profile and a stored sensor profile, in step 720 , the manager module 505 can notify the controller 310 to operate the mobile telephone in the matching mode, in step 725 . Subsequently, the manager module 505 can enter a monitoring state, in step 730 .
Otherwise, if there is not a match, in step 720 , the manager module 505 can be configured to determine whether the current sensor profile is within a predetermined threshold of any of the stored sensor profiles, in step 735 .
If one of the stored sensor profiles is within the predetermined threshold, the manager module 505 can be configured to update the matching sensor profile with the current sensor profile, in step 750 , thereby allowing the previously stored interaction associated with a particular mode to migrate and/or change over time without necessarily requiring a new interaction to be associated with an existing mode to be expressly detected and stored to accommodate an aggregate of multiple subtle migratory changes in user interaction over time, which might no longer match the originally stored interaction. Subsequently, the manager module 505 can then enter the monitoring state, in step 755 .
If none of the stored sensor profiles are within the predetermined threshold, in step 735 , the manager module 505 can be configured to collect the operating parameters of the mobile telephone 100 , in step 740 . The manager module 505 can then be configured to associate the current sensor profile with the current operating parameters of the mobile telephone 100 as a new mode. The manager module 505 can then store the sensor profile in the sensor profile module 520 . Subsequently, the manager module 505 can enter a monitoring state of step 730 .
Certain embodiments may be performed as a computer program. The computer program may exist in a variety of forms both active and inactive. For example, the computer program can exist as software program(s) comprised of program instructions in source code, object code, executable code or other formats; firmware program(s); or hardware description language (HDL) files. Any of the above can be embodied on a computer readable medium, which include storage devices and signals, in compressed or uncompressed form. Exemplary computer readable storage devices include conventional computer system RAM (random access memory), ROM (read-only memory), EPROM (erasable, programmable ROM), EEPROM (electrically erasable, programmable ROM), and magnetic or optical disks or tapes. Exemplary computer readable signals, whether modulated using a carrier or not, are signals that a computer system hosting or running the present invention can be configured to access, including signals downloaded through the Internet or other networks. Concrete examples of the foregoing include distribution of executable software program(s) of the computer program on a CD-ROM or via Internet download. In a sense, the Internet itself, as an abstract entity, is a computer readable medium. The same is true of computer networks in general.
While the invention has been described with reference to the exemplary embodiments thereof, those skilled in the art will be able to make various modifications to the described embodiments without departing from the true spirit and scope. The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. In particular, although the method has been described by examples, the steps of the method may be performed in a different order than illustrated or simultaneously. Those skilled in the art will recognize that these and other variations are possible within the spirit and scope as defined in the following claims and their equivalents. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2002-59429, filed on Mar. 5. 2002, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a resist pattern-improving material and a method for preparing a pattern by using the same. The present invention, in particular, relates to an improvement for forming a coating layer on the surface of the resist pattern by photo irradiation, and intermixing the coating layer with the surface of the resist pattern, and thereby reducing an edge roughness of the pattern. Such a pattern is used in semiconductor devices, magnetic sensors, various functional parts, and so on.
RELATED ART
[0003] Photo irradiation techniques are generally efficient for mass production. In order to continue to improve the efficiency of mass productivity, there has been a demand to use the photo irradiation techniques in processing for preparing smaller and finer products. Therefore, studies have been conducted not only for selecting a far ultraviolet ray having a shorter wavelength than ever as an irradiation light, but also for improving mask patterns, shapes of the light source, and so on. There is a demand to develop an improvement that is easily carried out by a user and that makes it possible to continue to apply such photo irradiation techniques for precisely drawing a finer pattern than ever.
[0004] When irradiating by using a KrF (krypton fluoride) excimer laser, which is generally used in the latest manufacturing process for semiconductor devices, the minimum resolution pattern size of 130 nm is about to be accomplished, and if it is combined with a super resolution technology, a minimum resolution pattern size of less than 130 nm is possible. In the next generation of the photo irradiation techniques in the mass production, the means of the photo irradiation is considered to select an ArF (argon fluoride) excimer laser having a shorter wavelength than ever. When using the ArF (argon fluoride) excimer laser, it may be possible to realize making a pattern in the level of 70 to 80 nm. However, when using a far ultraviolet ray having a shorter wavelength than ever as an irradiating light, edge roughness is unavoidable: that is, the smaller or finer the resist pattern is designed, the more the edge of the resist pattern is waved, although the edge is designed to be formed in a line shape. In other words, when resist pattern is drawn by irradiation of a far ultraviolet ray, a small and fine resist pattern may be expected, and the pattern has a line shape with a very little width. However, as the whole of the device size is reduced and the width of the pattern is narrowed, the edge roughness is relatively increased compared with the total of the width of the pattern. The current devices used in the type of the latest generation on the average have an edge roughness in the amount of ±5%, which is said to be a conspicuous level. It is necessary or essential to consider and create a measure to reduce the amount of the edge roughness. Otherwise, short circuit or disconnection of the pattern may be generated in the next step of the surface preparation step. As a result, the edge roughness will significantly affect the yield of the product. With reference to FIG. 1, this problem is explained more in detail. See FIG. 1.
[0005] [0005]FIG. 1 shows plan views of a pattern in the middle of preparing a semiconductor device, which illustrate the objectives in the conventional process. FIG. 1( a ) shows a plan view of a pattern to be drawn in accordance with the design, and FIG. 1( b ) shows a plan view of an actual drawn pattern, which has an edge roughness as shown.
[0006] In the conventional way, the slashed portions shown in the figures are where a conductive film is formed. At the previous step, not shown in the figures, the conductive film is coated on the whole of the surface thereof. Then, a resist film is formed and patterned by means a photolithographic technique, which is well known in the art. Since the edge roughness is generated in this process as shown, the resist pattern results in waving, which should be a line shape. Then, such a resist pattern is used as a mask. However, such a resist pattern accompanied with the edge roughness is not appropriate for precisely etching the conductive film and patterning by remaining the portion of the slashed portions as shown. The etched pattern of the conductive film is significantly waved as shown in FIG. 1( b ). In the worst case, disconnection or short circuit will occur in the pattern. Recently, the use of copper wiring has become widespread, especially in the latest fine logic devices. However, if a pattern is formed by being transferred by the resist pattern having the edge roughness, it will be difficult to cover a copper diffusion prevention film of such a copper wiring, resulting in significantly affecting the following steps after the lithography step or resulting in loss of reliability of the device.
[0007] Improvement of several resist materials has led to reduction in the edge roughness, and up to now, the issue of the edge roughness has not been raised as an industrial problem. However, the resist pattern has recently been demanded to have a resolution less than the wavelength. Also, there has been a demand to improve other performance parameters, such as sensitivity. These improvements may compromise the reduction of the edge roughness. Therefore, it has been more difficult to reduce the edge roughness while improving the other properties.
[0008] Moreover, in the next generation of the devices, the resist pattern by means of lithography will be demanded to be much smaller and finer than ever. In such applications, the ratio of the edge roughness generated in the resist pattern will be relatively increased, since the size of the resist pattern will be smaller and smaller or finer. As a result, the edge roughness will more affect the quality of the devices than ever, especially at the step after forming the resist pattern, such as, an etching step or wiring step, resulting in causing short circuit of the wiring or disconnection of the pattern.
THE OBJECTIVES OF THE INVENTION
[0009] Therefore, there is an objective to be solved in this invention. That is a reduction of an edge roughness during forming a fine pattern, which was difficult to avoid only by improving a resist material. Such an objective is solved by that after patterning a resist film, a coating film is formed on the resist film, so as to intermix the resist film material with the coating film material at the interface therebetween to reduce the edge roughness. In addition to reducing the edge roughness, there is also an objective to keep or improve etching resistance, not only by using a resist material which is used for irradiation by means of a light source having a wavelength in the field of a deep ultraviolet, such as, an ArF (argon fluoride) excimer laser, but also by using a resist material which is used for irradiation by means of a light source, such as, KrF (krypton fluoride) excimer laser, and which is known to have superior etching resistance.
BRIEF DESCRIPTION OF THE FIGURES
[0010] FIGS. 1 ( a ) and ( b ) show plan views for illustrating processes for preparing a semiconductor devices, to point out the problems in the conventional steps.
[0011] [0011]FIG. 2 shows (first) cross-sectional views of the process, for illustrating the principle of the present invention.
[0012] [0012]FIG. 3 shows (second) cross-sectional views of the process, for illustrating the principle of the present invention.
[0013] FIGS. 4 ( a ), ( b ) and ( c ) show (first) cross-sectional views for illustrating a method for preparing an EEPROM as one of the applications of the present invention.
[0014] FIGS. 5 ( d ), ( e ), and ( f ) show (second) cross-sectional views for illustrating a method for preparing an EEPROM as one of the applications of the present invention.
[0015] FIGS. 6 ( g ), ( h ), and ( i ) show (third) cross-sectional views for illustrating a method for preparing an EEPROM as one of the applications of the present invention.
[0016] FIGS. 7 ( a ) and ( b ) show (fourth) cross-sectional views for illustrating a method for preparing an EEPROM as one of the applications of the present invention.
[0017] FIGS. 8 ( a ), ( b ), and ( c ) show (fifth) cross-sectional views for illustrating a method for preparing an EEPROM as one of the applications of the present invention.
[0018] FIGS. 9 ( a ), ( b ), and ( c ) show plan views from an upper view point for illustrating a method for preparing an EEPROM as one of the applications of the present invention.
[0019] FIGS. 10 ( a ), ( b ), ( c ), and ( d ) generally show cross-sectional views for illustrating a method for preparing a magnetic head by using a resist pattern formed by the positive type resist composition according to the present invention, as an example.
[0020] [0020]FIG. 11 generally shows a (first) cross-sectional view for illustrating a method for preparing a magnetic head by using a resist pattern formed by the positive type resist composition according to the present invention, as an example.
[0021] [0021]FIG. 12 generally shows a (second) cross-sectional view for illustrating a method for preparing a magnetic head by using a resist pattern formed by the positive type resist composition according to the present invention, as an example.
[0022] [0022]FIG. 11 generally shows a (first) cross-sectional view for illustrating a method for
[0023] [0023]FIG. 13 generally shows a (third) cross-sectional view for illustrating a method for preparing a magnetic head by using a resist pattern formed by the positive type resist composition according to the present invention, as an example.
[0024] [0024]FIG. 14 generally shows a (fourth) cross-sectional view for illustrating a method for preparing a magnetic head by using a resist pattern formed by the positive type resist composition according to the present invention, as an example.
[0025] [0025]FIG. 15 generally shows a (fifth) cross-sectional view for illustrating a method for preparing a magnetic head by using a resist pattern formed by the positive type resist composition according to the present invention, as an example.
[0026] [0026]FIG. 16 generally shows a (sixth) cross-sectional view for illustrating a method for preparing a magnetic head by using a resist pattern formed by the positive type resist composition according to the present invention, as an example.
[0027] [0027]FIG. 17 shows a plan view of a magnetic head prepared in accordance with the steps shown in FIG. 11 to FIG. 16.
[0028] [0028]FIG. 18 generally shows an MR element portion in a magnetic head (MR head), as an example.
[0029] [0029]FIG. 19 generally shows (first) process for preparing the MR element portion shown in FIG. 18.
[0030] [0030]FIG. 20 generally shows a (second) process for preparing the MR element portion shown in FIG. 18.
[0031] [0031]FIG. 21 shows a plan view of a situation where a terminal connected to an MR element is formed from two layers of a first resist layer and a second resist layer.
[0032] [0032]FIG. 22 shows cross-sectional views at lines of 50 - 50 and 50 ′- 50 ′ in FIG. 21.
[0033] [0033]FIG. 23 shows process views for forming an MR element which is used for a magnetic head (MR head) by means of lifting off process.
[0034] [0034]FIG. 24 shows process views for forming an MR element which is used for a magnetic head (MR head) by means of lifting off process.
[0035] [0035]FIG. 25 shows (first) process views for forming an MR element which is used for a magnetic head (MR head), by means of milling process.
[0036] [0036]FIG. 26 shows (second) process views for forming an MR element which is used for a magnetic head (MR head), by means of milling process.
[0037] [0037]FIG. 27 shows process views for preparing a T-gate electrode of an HHMT.
[0038] [0038]FIG. 28 shows (first) process views for preparing a partition wall for a plasma display panel.
[0039] [0039]FIG. 29 shows (second) process views for preparing a partition wall for a plasma display panel.
[0040] [0040]FIG. 30 shows an illustrating view of a plasma display panel.
SUMMARY OF THE INVENTION
[0041] In order to solve the objectives described above, there is provided the present invention as follows.
[0042] (1) There is provided a resist pattern-improving material, comprising:
[0043] (a) a water-soluble or alkali-soluble composition, comprising
[0044] (i) at least one resin selected from the group consisting of polyvinyl alcohol, polyvinyl acetal and polyvinyl acetate, and
[0045] (ii) at least one crosslinking agent selected from the group consisting of melamine derivatives, urea derivatives, and uril derivatives,
[0046] wherein the resist pattern-improving material is coated on the surface of the resist pattern to cover it.
[0047] (2) There is provided a resist pattern-improving material in the formula defined in the paragraph (1), further including a water-soluble aromatic compound.
[0048] (3) There is provided a resin pattern-improving material in the formula defined in the paragraph (1) or (2), further including a surfactant selected from the group consisting of polyoxy ethylene-polyoxy propylene copolymer, polyoxy alkylene alkyl ethers, polyoxy ethylene alkyl ethers, polyoxy ethylene derivatives, sorbic fatty acid esters, glycerin fatty acid esters, primary alcohol ethoxylates, and phenol ethoxylates, and phenol ethoxylates.
[0049] (4) There is provided a resin pattern-improving material in the formula defined in any of the paragraphs (1) to (3), further including a solvent which does not easily dissolve a formed resist material placed therebelow.
[0050] (5) There is provided a method for reducing an edge roughness of a resist pattern, wherein after forming the resist pattern, the pattern-improving material defined in any of the paragraphs (1) to (4) is coated to cover the resist pattern. Alternatively, there is provided a method for forming a small and fine pattern by using the method for reducing the edge roughness of the resist pattern. Alternatively, there is provided a method for preparing a small device by means of using the method for reducing the edge roughness of the resist pattern. Alternatively, there is provided a method for preparing a semiconductor device by means of using the method for reducing the edge roughness of the resist pattern.
[0051] (6) There is provided a method for reducing an edge roughness, comprising:
[0052] (a) forming a resist pattern;
[0053] (b) coating a solution including a surfactant selected from the group consisting of polyoxy ethylene-polyoxy propylene copolymer, polyoxy alkylene alkyl ethers, polyoxy ethylene alkyl ethers, polyoxy ethylene derivatives, sorbic fatty acid esters, glycerin fatty acid esters, primary alcohol ethoxylates, and phenol ethoxylates, 328 and
[0054] (c) coating a water-soluble or alkali-soluble composition, comprising:
[0055] (i) at least one resin selected from the group consisting of polyvinyl alcohol, polyvinyl acetal and polyvinyl acetate,
[0056] (ii) at least one crosslinking agent selected from the group consisting of melamine derivatives, urea derivatives, and uril derivatives, and
[0057] (iii) at least one polyphenol compound selected from the group consisting of flavonoids, catechins, anthocyanidins, proanthocyanidins, tannins, quercetins, isoflavones, and derivatives thereof.
[0058] Alternatively, there is provided a method for forming a pattern by means of using the method for reducing the edge roughness of the resist pattern. Alternatively, there is provided a method for preparing a small device by means of using the method for reducing the edge roughness of the resist pattern. Alternatively, there is provided a method for preparing a semiconductor device by means of using the method for reducing the edge roughness of the resist pattern.
[0059] Next, an effect of the present invention and its principle are explained.
[0060] The inventors of the present invention have enthusiastically studied for solving the objectives stated above. In the middle of the research, the inventors of the present invention have tested various formulas while adjusting the kinds of the base resin of the resist, the molecular structures of the protective groups, the balance of hydrophobic and hydrophilic properties, and so on. Finally, the inventors of the present invention have found a formula which is able to control the variation of the resist pattern size within 10% or less, as well as to reduce the issue of the edge roughness into the level not to cause a problem with respect to manufacturing.
[0061] With reference to FIG. 2 and FIG. 3, the mechanisms of the reduction of the edge roughness, and improvement of etching resistance when further adding a water-soluble aromatic compound, according to the present invention, are explained as follows. See FIG. 2.
[0062] [0062]FIG. 2 shows a cross-sectional view of the resist pattern, for illustrating a first embodiment. In the first embodiment, the resist pattern is prepared by the process of forming a resist material on the surface of the base board to form a resist pattern, and then, spin-coating the edge roughness reducing material according to the present invention on the base board including the formed openings.
[0063] In the first embodiment, the resist pattern-improving material includes a polyvinyl acetal resin (KW-3, made by Sekisui Chemical Co., Ltd.) as a base resin, tetramethoxy methyl glycoluril as a crosslinking agent, a nonionic surfactant, pure water (deionized water), and isopropyl alcohol. After making a resist pattern, the resist pattern-improving material according to the present invention is coated, and then, pre-baking is carried out to form a coating film. At the pattern interface therebetween, the resist pattern is mixed with the improving material according to the present invention, and then, baking is carried out for crosslinking at a higher temperature than that for the pre-baking, so as to crosslink in the portion where the resist pattern is mixed with the improving material. Then it is developed in water or a weak alkali solution. The portion having a weak crosslinking or high solubility will be removed, to develop and form a fine pattern having a reduced roughness. When the resist pattern-improving material further includes a water-soluble aromatic compound, the resist pattern-improving material having the water-soluble aromatic compound is mixed with the resist pattern to crosslink each other, so as to significantly improve etching resistance, compared with a conventional material comprising polyvinyl acetal, polyvinyl alcohol, or polyvinyl acetate. See FIG. 3.
[0064] [0064]FIG. 3 shows a cross-sectional view of a resist pattern, for illustrating a second embodiment. In the second embodiment, the resist pattern is prepared by the process of forming a resist material on the surface of the base board to form a resist pattern, and then, spin-coating the edge roughness reducing material on the resist pattern including the formed openings.
[0065] In the second embodiment, the resist pattern-improving material includes a polyvinyl acetal resin (KW-3, made by Sekisui Chemical Co., Ltd.) as a base resin, a nonionic surfactant, pure water (deionized water), and isopropyl alcohol. After forming a resist pattern, the resist pattern-improving material according to the present invention is coated, and then, pre-baking is carried out to form a coating film. At the pattern interface therebetween, the resist is mixed with the improving material according to the present invention, by heating at a higher temperature than that for the pre-baking. Then, it is developed in water or a weak alkali solution. The portion having a high solubility, where the improving material according to the present invention for reducing the edge roughness has not permeated, will be removed and developed so as to form a fine pattern having a reduced roughness.
[0066] As to a resist material useful for the present invention, it is preferable to use resist materials for irradiation by a KrF excimer laser, and alicyclic type resist materials for irradiation by an ArF excimer laser. The alicyclic type resist materials may include resist materials for ArF excimer lithography, such as acrylic type resist materials having an adamantyl group on the side chain, COMA type resist materials, hybrid type (copolymer of an alicyclic acrylic type and COMA type) resist materials, cycloolefin type resist materials, and so on. However, the resist materials, which may be used in the present invention, are not limited thereto. Novolak type resist materials, PHS type chemical amplified resist materials preferably irradiated by an electron beam or EUV light source, main chain decomposing type non-chemical amplified resist materials represented by PMMA, resist materials for F2 laser lithography in which any of the above listed resist is fluorinated may be also used in the present invention. Any of the resist materials necessary for fine working may be used in the present invention. The film thickness of the resist material to be formed may be designed by the surface to be formed and an etching condition therefor, and there is no specific limitation in the present invention. However, it is preferable to form the resist material having a film thickness of 0.05 to 200 nm, which is the same as usual.
[0067] The base resin used in the present invention may include polyvinyl acetal, polyvinyl alcohol, polyvinyl acetate, the polyacrylic acid, polyvinyl pyrrolidone, polyethylene imine, polyethylene oxide, styrene-maleic acid copolymer, polyvinyl amine resin, polyallylamine, water-soluble resin having an oxazoline group, water-soluble melamine resin, water-soluble urea resin, alkyd resin, and sulfonic acid amide resin, and mixture thereof, and so on.
[0068] It is not essential to add the crosslinking agent in the second embodiment. However, the crosslinking agent may be added if necessary, and if so, it may include glycoluril type crosslinking agents; urea type crosslinking agents, such as, urea resin, alkoxy methylene urea, N-alkoxy methylene urea, ethyleneurea, ethylene urea carboxylic acid, and so on; melamine type crosslinking agents, such as, methylene, alkoxy methylene melamine, and so on; amino type crosslinking agents, such as, benzoguanamine, so long as such a crosslinking agent functions in accordance with the present invention when it is added in the material.
[0069] The water-soluble aromatic compound may include, for example, polyphenols. In detail, such polyphenols may preferably include flavonoids, catechins, anthocyanidins, proanthocyanidins, tannins, quercetins, isoflavones, and glycosides or derivatives thereof. In addition to the polyphenols as stated above, it may be also preferable to use polyhydric phenols represented by resorcin, resorcin [4] arene, pyrogallol, gallic acid, and derivatives thereof, aromatic carboxylic acids represented by salicylic acid, phthalic acid, dihydroxybenzoic acid, and derivatives thereof; naphthalene polyhydric alcohols represented by naphthalenediol, naphthalenetriol, and derivatives thereof; and benzophenone derivatives represented by alizarin yellow A. In addition, it is also possible to use various compounds which have been industrially used as a water-soluble pigment having an aromatic group.
[0070] The surfactant is not necessary to be added if the resist pattern-improving material has affinity or compatibility with the resist. However, it may be added in the following cases: the case where the resist pattern-improving material has less affinity or compatibility with the resist, the case to control the variation of the pattern size as little as possible without adding the crosslinking agent, the case to improve the uniformity of the roughness reducing property on the surface to be treated, the case for deforming, and so on. Such a surfactant may preferably be selected from the group consisting of nonionic surfactants, such as, polyoxy ethylene-polyoxy propylene copolymers, polyoxy alkylene alkyl ethers, polyoxy ethylene alkyl ethers, polyoxy ethylene derivatives, sorbic fatty acid esters, glycerin fatty acid esters, primary alcohol ethoxylates, and phenol ethoxylates. In addition, so long as using a nonionic surfactant, any nonionic surfactant other than the listed here may be used, and such alternatives will be expected to accomplish the same effect in a similar manner as stated above.
[0071] In addition to the resin, the crosslinking agent (which is not essential to the present invention), and the water-soluble aromatic compound (which is not essential to the present invention), the resist pattern-improving material according to the present invention may include at least one organic solvent selected from the group consisting of alcohols, linear esters, cyclic esters, ketones, linear ethers, and cyclic ethers If the resist pattern-improving material according to the present invention has an insufficient solubility to dissolve the solute included therein, or has an insufficient property of reducing the edge roughness, it is preferable to add such an organic solvent to the extent not to affect the forming of the resist pattern. In such a case, the organic solvent as the alcohols may include isopropyl alcohol. The organic solvent as the linear esters may include lactic acid ethyl (ethyl lactate), propylene glycol methyl ether acetate (PGMEA). The organic solvent as the cyclic esters may include lactones. In particular, it is preferable to use γ-butyrolactone. The organic solvent as the ketones may include acetone, cyclohexanone, heptanone, and so on. The organic solvent as the linear ethers may include ethylene glycol dimethyl ether, and so on. The organic solvent as the cyclic ethers may include tetrahydrofuran, dioxane, and so on. Especially, it is preferable to use an organic solvent which has a boiling point of 80 to 200° C., approximately. Fine drawing of the resist pattern may be accomplished by using such an organic solvent having the boiling point within this range.
EXAMPLE TEST 1
[0072] (Preparation of a Resist Pattern-Improving Material)
[0073] Various resist pattern-improving materials were prepared in accordance of the formulas shown in the Table 1 below. In Table 1, the numbers encompassed by parentheses are based on parts by weight. KW-3 made by Sekisui Chemical Co., Ltd. is used as polyvinyl acetal resin, and the surfactant used here is made by Asahi Denka Co., Ltd. Pure water (deionized water) and isopropyl alcohol in a ratio of 98 6:0.4, by weight, was mixed as the main solvent. In Table 1, “Uril” means tetramethoxy methyl glycoluril, and “Urea” means N,N′-dimethoxy methyl dimethoxy ethyleneurea, and “Melamine” means hexamethoxy methyl melamine.
TABLE 1 The Name of the Water-soluble Resist Pattern- Crosslinking Aromatic improving Material Agent Compound Surfactant A KW-3 (16) Uril (0.8) Not Included Not Included B KW-3 (16) Urea (1.0) Not Included Not Included C KW-3 (13), Melamine (0.5) Not Included Not Included PVA (3) D KW-3 (16) Uril (1.2) Not Included Not Included E KW-3 (16) Uril (0) Not Included Not included F KW-3 (16) Uril (1.0) Not Included Not Included G KW-3 (16) Uril (1.0) Not Included TN-80 (0.0625) H KW-3 (16) Uril (1.0) Not Included TN-80 (0.125) I KW-3 (16) Urea (1.0) catechin (5) Not Included J KW-3 (16) Urea (1.0) catechin (5) PC-8 (0.05)
[0074] While coating the resist pattern-improving material to form a film, spin-coating is carried out in the process of rotating at a speed of 1000 rpm for a period of 5 seconds followed by rotating at a speed of 3500 rpm for a period of 5 seconds. In the baking step, the sample is heated at a temperature of 85° C. for a period of 70 seconds, followed by heating at a temperature of 90 to 100° C. for a period of 70 seconds. Then, the sample was washed with pure water for a period of 60 seconds so as to remove a non-crosslinked portion.
EXAMPLE TEST 2
[0075] (Test for Reducing the Edge Roughness of the Resist Pattern)
[0076] The various resist pattern-improving materials prepared in accordance with Example 1 were used here. 150 nm space pattern, which were formed by using an alicyclic resist for ArF lithography, were treated in this example. As a result, the patterns which had improved roughness were obtained.
TABLE 2 Roughness Size The Name of the Initial after the Increased Amount Resist Pattern- Roughness Size Treatment of the Size improving Material (3 sigma, nm) (3 sigma, nm) (nm) A 16.0 12.2 10.8 B 16.0 10.0 9.1 C 16.0 8.5 6.5 D 16.0 6.0 6.8 E 16.0 15.0 9.2 F 16.0 11.0 7.4 G 16.0 5.8 9.1 H 16.0 5.5 13.8 I 16.0 11.3 5.8 J 16.0 7.1 10.9
EXAMPLE TEST 3
[0077] (Test for Reducing the Edge Roughness of the Resist Pattern)
[0078] The various resist pattern-improving materials prepared in accordance with Example 1 were used here 150 nm hole patterns, which were formed by using an alicyclic resist for ArF lithography, were treated in this example. As a result, the patterns which had improved roughness were obtained.
TABLE 3 Roughness Size The Name of the Initial after the Increased Amount Resist Pattern- Roughness Size Treatment of the Size improving Material (3 sigma, nm) (3 sigma, nm) (nm) A 8.2 7.5 17.5 B 8.2 6.8 3.0 C 8.2 5.9 11.5 D 8.2 4.0 1.8 E 8.2 8.0 7.3 F 8.2 7.8 16.8 G 8.2 4.2 1.6 H 8.2 4.1 6.8 I 8.2 7.7 4.8 J 8.2 4.5 8.8
[0079] From the results of Example 2 and Example 3, the effect of reducing the edge roughness indicates that the resist pattern-improving material according to the present invention is applicable either for lined patterns and holed patterns
EXAMPLE TEST 4
[0080] (Etching Resisitance)
[0081] The resist films having a thickness of 0.5 micron were formed on a silicon wafer, and then treated by the resist pattern-improving materials D, H, I prepared in the previous Example. For comparison, as a KrF resist, a sample formed from UV-6 made by Shiplay Corporation, and a sample formed from PMMA (polymethyl methacrylate) were prepared. Using an RIE equipment in the type of parallel electrodes, each sample was etched under the conditions of RF power=200 W, at a pressure of 0.02 Torr, using CF 4 gas for a period of 3 minutes. Then, the amounts of reduced film thickness were compared.
TABLE 4 The Material Name Etching Plate (Å/s) Ratio UV-6 627 1.00 PMMA 770 1.23 I 650 1.04 J 662 1.06
[0082] The results listed above show that the etching resistance of the resist pattern-improving material according to the present invention is similar to that of the KrF resist, and significantly improved compared with PMMA.
EXAMPLE TEST 5
[0083] (Application to an Electron Ray
[0084] PMMA (polymethyl methacrylate) was used as a resist material, and 100 nm space patterns were formed by an electron beam exposure apparatus (50 KeV). The resist were treated to obtain patterns having a reduced roughness as follows.
TABLE 5 Initial Roughness Size Increased Amount Roughness Size after the Treatment of the Size Resist Pattern (3 sigma, nm) (3 sigma, nm) (nm) A 18.0 14.5 7.8 B 18.0 12.0 8.0 C 18.0 11.2 4.2 D 18.0 8.0 4.3 E 18.0 16.5 5.9 F 18.0 13.5 9.3 G 18.0 6.3 7.8 H 18.0 6.1 22.3 I 18.0 14.1 4.3 J 18.0 9.1 9.2
[0085] The results show that the resist pattern-improving material according to the present invention does not restrict the selection of the type of the resist material, and may be applicable either to chemical amplified type resist materials and chemical non-amplified type resist materials.
EXAMPLE TEST 6
[0086] (Application to a Two Layers for Irradiating an Electron Ray)
[0087] PMMA (polymethyl methacrylate) was coated to have a thickness of 0.15 micron, to form a first layer as a resist. Then, ZEP-520A was coated thereon to have a thickness of 0.15 micron, to form a second layer. Thereby obtained sample boards were subjected to photo irradiation at the space patterns by electron beam exposure apparatus (50 KeV). Development was performed in MIBK (methyl isobutyl ketone) for 60 seconds, so as to obtain a pattern having a width of 100 nm. Thereby obtained resist was subjected to treatment using the resist pattern-improving materials D, G, H, which had indicated preferable results obtained in Example 7. The results obtained in this Example show that no affect was found on the upper layer, ZEP layer. However, the lower layer, PMMA layer, was affected, and the edge roughness of the pattern is reduced.
[0088] The examples described above show that the resist pattern-improving material according to the present invention may be useful in various applications. Several applications of the present invention stated hereinafter are based on the fact revealed by these Example Tests. The present invention will be explained with respect to a method for preparing a flash type EEEPROM, a method for preparing a magnetic sensors and a method for preparing a PDP (Plasma Display Panel). However, the present invention may be applicable to any other applications in which a fine pattern is necessary, and is not limited thereto. As the other applications, a method for preparing functional parts, such as, mask pattern, rectil pattern, LCD (liquid crystalline display), SAW filter (Surface Acoustic Wave filter), and so on; a method for preparing optical parts used for connecting optical wiring; a method for preparing fine and small parts, such as, micro-actuator, and so on may be included. Also, as an example of a method for preparing semiconductor devices, a process for preparing a flash memory will be explained in detail, but the present invention is not limited thereto. The present invention may be also applicable to a method for preparing a logic device, DRAM, FRAM, and so on, and same effect will be expected in a manner as stated above.
DETAILED DESCRIPTION OF THE INVENTION
[0089] The technology of the resist pattern-improving material according to the present invention may be useful for various applications, among which several methods for preparing various devices are explained here.
[0090] (1) First Application Example of the Present Invention: A Method for Preparing a Flash Memory
[0091] There is provided a method for preparing a flash memory. This is an example for preparing a semiconductor device, which may be preferable to incorporate the step for forming a pattern according to the present invention. For example, the resist pattern-improving material according to the present invention may be used in the step of forming a holed pattern, which may contribute to reduce an edge roughness of the resist pattern, and thereby, the size of the inner diameter of the holed pattern, the width between the linier patterns and/or separated patterns, and the interval between the linear patterns, and so on, may be controlled within the allowable range
[0092] As shown in FIG. 4( a ), a field oxide film 23 of SiO 2 is selectively formed on an element separation region on a p-type silicon wafer. Then, a first gate insulation film 24 a of a MOS transistor located in a memory cell portion (a first element region), is formed by heat oxidation in a step, the first gate insulating film 24 a having a film thickness of 100 to 300 Å, and a second gate insulation film 24 b of a MOS transistor located in a peripheral circuit portion (a second element region) is formed by heat oxidation in another step, the second gate insulating film 24 b having a film thickness of 100 to 500 Å. However, if both of the first and second gate insulation films 24 a, 24 b are designed to have the same thicknesses, those oxidation films may be concurrently formed in one step.
[0093] Then, a MOS transistor having a type of n-type depression channel is formed on the memory cell portion. In order to control a threshold voltage, the peripheral portion is masked by a resist film 26 , and then, phosphorous (P) or arsenic (As) as an n-type impurity is incorporated into a portion to be a channel region which will be located right below a floating gate electrode, by means of ion implantation at a dose amount of 1×10 11 to 1×10 14 cm −2 , and thereby, a first threshold controlling layer 25 a is formed. At that time, the dose amount and the selection of the conductive type of the impurity may be determined according to whether it is a depression type or accumulation type.
[0094] Then, a MOS transistor having a type of n-type depression channel is formed on the peripheral circuit portion. In order to control a threshold voltage, the memory cell portion is masked by a resist film 27 , and then, phosphorous (P) or arsenic (AS) as an n-type impurity is incorporated into a portion to be a channel region which will be located right below a gate electrode, by means of ion implantation at a dose amount of 1×10 11 to 1×10 14 cm −2 , and thereby, a second threshold controlling layer 25 b is formed See FIG. 4( b )
[0095] Following the above, a first polysilicon film (first conductive layer) 28 is formed on the whole of the surface, the first polysilicon film having a film thickness of 500 to 2000 Å. The first polysilicon film will be a floating gate electrode of a MOS transistor in the memory cell portion, and a gate electrode of a MOS transistor in the peripheral circuit portion. See FIG. 4( c ).
[0096] Then, a resist film 29 is used as a mask on the first polysilicon film 28 to make a pattern, and thereby, the floating gate electrode 28 a is formed on the MOS transistor in the memory cell portion. See FIG. 5( d ). At that time, as shown in FIG. 7( a ), the patterning is performed in a manner such that the width in the direction of “X” is a final size, without patterning in the direction of “Y” to continue to cover the region to be a source drain region.
[0097] Then, the resist film 29 is removed, followed by that the floating electrode 28 a is covered by means of heat oxidation so as to form a capacitor insulation film 30 a of SiO 2 having a film thickness of 200 to 500 Å. At that time, the SiO 2 film 30 b of is formed concurrently on the first polysilicon film 28 of the peripheral circuit portion. Optionally, a couple of layers, including SiO 2 and Si 3 N 4 films may be formed as the capacitor insulation film. Then, the floating gate electrode 28 a and the capacitor insulation film 30 a are covered to form a second polysilicon film (second conductive film) 31 having a film thickness of 500 to 2000 Å, which will be a control gate electrode. See FIG. 5( e ).
[0098] Following the above, the memory cell portion is masked by a resist film 32 , and then, the second polysilicon film 31 and the SiO 2 film 30 b in the peripheral circuit portion are continuously removed to reveal the first polysilicon film 28 . See FIG. 5( f ).
[0099] Then, the second polysilicon film 31 , the SiO 2 film 30 b, and the first polysilicon film 28 a patterning only in the direction of “X”, which is located in the memory cell portion, are masked with a resist film 32 , followed by that patterning is performed in the direction of “Y” to have a final size of a first gate portion 33 a. The control gate electrode 31 a, the capacitor insulation film 30 c, and the floating gate electrode 28 c are formed to have a width in the direction of “Y” being about 1 μm. The first polysilicon film 28 in the peripheral portion is masked with a resist 32 , and then, patterning is carried out to have a final size of a second gate portion 33 b, so as to obtain a gate electrode 28 b having a width of about 1 μm. See FIG. 6( g ) and FIG. 7( b ).
[0100] Then, while operating the control gate electrode 31 a, capacitor insulation film 30 a, and floating gate electrode 28 a in the memory cell portion as a mask, phosphorous (P) or arsenic (As) is incorporated into the Si base board 22 of an element forming region at a dose amount of 1×10 14 to 1×10 16 cm −2 , so as to obtain an n-type source drain region 35 a, 35 b. Also, while operating the gate electrode 28 b in the peripheral portion as a mask, phosphorous (P) or arsenic (As) is incorporated into the Si base board 22 of an element forming region at a dose amount of 1×10 14 to 1×10 16 cm −2 , so as to obtain a S/D region layer 36 a, 36 b. See FIG. 6( h ).
[0101] Then, a layer insulation film 37 of a PSG film having a film thickness of 5000 Å, approximately, is formed to cover the first gate portion 33 a in the memory cell portion and the second gate portion 33 b in the peripheral circuit portion. Subsequently, contact holes 38 a, 38 b, 39 a, 39 b are formed on the layer insulation film 37 above the source drain region layers 35 a, 35 b, 36 a, 36 b, and then, S/D electrodes 40 a, 40 b, 41 a, 41 b are formed to complete a flash type EEPROM. See FIG. 6( i ).
[0102] As described above, in the first application example of the present invention, the patterned first polysilicon film 28 a in the memory cell portion is covered with the capacitor insulation film 30 a, as shown in FIG. 5( e ). Then, the second polysilicon film 31 is formed on the memory cell portion and peripheral circuit portion, and then, as shown in FIG. 6( g ), patterning is continuously performed to form the first gate portion 33 a comprising the first gate insulation film, 24 a, floating gate electrode 28 c, and capacitor insulation film 30 c, and control gate electrode 31 a.
[0103] Therefore, the formed capacitor insulation film 30 c is completely protected by the first and second polysilicon films 28 a, 31 . See FIG. 5( e ) and ( f ). Thus, the capacitor insulation film 30 c is prevented from contaminating any particles and the like, so as to form a capacitor insulation film 30 c for covering the floating gate electrode 28 c in a good quality.
[0104] In addition, the formed second gate insulation film 24 b in the peripheral circuit portion, is completely covered with the first polysilicon film 28 See FIG. 4( c ) to FIG. 5( f ). Thus, the second gate insulation film 24 b continues to have the same film thickness since it was formed As a result, it is easy to control the film thickness of the second gate insulation film 24 b. Also, it is easy to adjust the concentration of the conductive impurity for controlling the threshold voltage.
[0105] In the first application example, the first gate portion 33 a is formed by patterning in the direction of the gate width to have a width in the direction thereof, and then, patterning in the direction of the gate length, so as to obtain a final gate width. Alternatively, the first gate portion 33 a is formed by patterning in the direction of the gate length to have a width, and then in the direction thereof, patterning in the direction of the gate width in the direction thereof, so as to obtain a final gate width.
[0106] (2) The Second Application Example: A Method for Preparing a Flash Memory FIGS. 8 ( a ) to ( c ) show cross-sectional views for illustrating a method for preparing a flash type EEPROM referred to as “FLOTOX Type” or “ETOX Type”, as the second application example of the present invention. The left figures show cross-sectional views illustrating a memory cell portions shown in the direction of “X” (gate length), where a MOS transistor is formed having a floating gate electrode. The central figures show cross-sectional views of the memory cell portion in the left figures, shown in the direction of “Y” (that is a gate width direction perpendicular to the “X” direction). The right figures show cross-sectional views of a MOS transistor in a peripheral circuit portion.
[0107] The points of the second application example, which are different from the first application, are as follows. FIG. 5( f ) is for the first application example. After the step shown in FIG. 5( f ), the second application example has a step of forming a metal film 42 having a high melting temperature (fourth conductive film) 42 , such as, a W or Ti film having a film thickness of about 2000 Å, on the first polysilicon film 28 in the peripheral circuit portion and the second polysilicon film 31 in the memory cell portion, and thereby obtaining a polyside film. Subsequent to the above, the second application example includes the similar steps shown in FIGS. 6 ( g ) to ( i ) to complete a flash type EEPROM. That is, while using the resist film 43 as a mask with respect to the high melting temperature metal film 42 , the second polysilicon film 31 , the SiO 2 film 30 b, and the first polysilicon film 28 a pattered only in the direction of “X”. Then, patterning in the direction of “Y” is performed to have a final size of the first gate portion 44 a, so as to form a control gate electrode 42 a, 31 a, capacitor insulation film 30 c, and floating gate electrode 28 c, having a width in the direction of ‘Y” of about 1 μm, on the memory cell portion. In addition, while using the resist film 43 as a mask with respect to the high melting temperature metal film 42 and first polysilicon film 28 , patterning is performed to have a final size of the second gate portion 44 b, so as to form a gate electrode 42 b, 28 b having a width of 1 μm, approximately, on the peripheral circuit portion. See FIG. 8( b ).
[0108] Then, while using the control gate electrode 42 a, 31 a, capacitor insulation film 30 a, and the floating gate electrode 28 a of the memory cell portion as a mask, phosphorous (P) or arsenic (As) is incorporated by means of ion implantation into the Si base board 22 of an element forming region at a dose amount of 1×10 14 to 1×10 16 cm −2 , so as to obtain an n-type source drain region 45 a, 45 b. Also, while using the gate electrode 42 b, 28 b in the peripheral circuit portion as a mask, phosphorous (P) or arsenic (As) is incorporated by means of ion implantation into the Si base board 22 of an element forming region at a dose amount of 1×10 14 to 1×10 16 cm −2 , so as to obtain a source drain region layer 46 a, 46 b.
[0109] Then, a layer insulation film 37 of a PSG film having a film thickness of 5000 Å, approximately, is formed to cover the first gate portion 44 a in the memory cell portion and the second gate portion 44 b in the peripheral circuit portion. Subsequently, contact holes 48 a, 48 b, 49 a, 49 b are formed on the layer insulation film 47 above the source drain region layers 45 a, 45 b, 46 a, 46 b, and then, S/D electrodes 50 a, 50 b, 51 a, 51 b are formed to complete a flash type EEPROM. See FIG. 8( c ). The same portions as described in the first application example are shown by the same symbols as used in the first application example.
[0110] According to the second application example of the present invention, a high melting temperature metal film 42 a and 31 a is formed on the polysilicon film for the control gate electrode 42 a, 31 a, and the gate electrode 42 b, 28 b, resulting in further reducing electrical conductivity.
[0111] In addition, in the second application example described here, a high melting temperature metal films 42 a, 42 b are used as the fourth conductive film on the polysilicon film. However, a high melting temperature metal silicide such as titanium silicide (TiSi) may be used.
[0112] (3) Third Application of the Present Invention: A Method for Preparing a Flash Memory
[0113] FIGS. 9 ( a ) to ( c ) show cross-sectional views of the third application example of the present invention for illustrating a method for preparing a flash type EEPROM referred to as “FLOTOX Type” or “ETOX Type”. The left figures show cross-sectional views of a memory cell portion shown in the direction of “X” (gate length), where a MOS transistor is formed having a floating gate electrode. The central figures show cross-sectional views of the memory cell portion in the left figures, shown in the direction of “Y” (that is the gate width direction perpendicular to the “X” direction). The right figures show cross-sectional views of a MOS transistor in a peripheral circuit portion.
[0114] The points of the third application example, which are different from those of the first application example, are as follows. The second gate portion 33 c in the peripheral circuit portion (the second element region) has a construction of the first polysilicon film (first conductive film) 28 b, the SiO 2 film (capacitor insulation film) 30 d, and the second polysilicon film (second conductive film) 31 b, whose construction is similar to the first gate portion 33 a in the memory cell portion (first element region). By the steps shown in FIG. 9( b ) or FIG. 9( c ), the first and second polysilicon films 28 b, 31 b are short circuited to obtain the gate electrode.
[0115] In other words, an opening portion 52 a, as shown in FIG. 9( b ), is formed to penetrate the second polysilicon film 31 b as the upper layer, the SiO 2 film 30 d, and the first polysilicon film 28 b as the lower layer. The opening portion 52 a is formed on a portion other than the portion to form the second gate portion 33 c as shown in FIG. 9( a ), and for example, the opening portion 52 a is formed on an insulation film 54 . Inside opening portion 52 a, a third conductive film, such as a high melting temperature metal film of W film or Ti film, is buried, so as to generate a short circuit between the first and second polysilicon films 28 b, 31 b.
[0116] Alternatively, an opening portion 52 a, as shown in FIG. 9( c ), is formed to penetrate the second polysilicon film 31 b as the upper layer, and the SiO 2 film 30 d. On the bottom surface of the opening 52 a, the first polysilicon film 28 b as the lower layer is revealed. Thereafter, inside the opening portion 52 a, a third conductive film, such as a high melting temperature metal film of W film or Ti film, is buried, so as to generate a short circuit between the first and second polysilicon films 28 b, 31 b.
[0117] According to the third application example of the present invention, the second gate portion 33 c in the peripheral circuit portion has the same construction as the first gate portion 33 a in the memory cell portion. Thus, the memory cell portion and the peripheral circuit portion may be formed concurrently, resulting in simplifying the manufacturing steps.
[0118] In addition, in the third application example described here, the third conductive film 53 a or 53 b is formed in a step different from the step for forming the fourth conductive film described in the second application example. However, they may be formed concurrently if they are made of the common high melting temperature metal film.
[0119] (4) The Fourth Application Example of the Present Invention: A Method for Preparing a Magnetic Head
[0120] The fourth application example of the present invention relates to a method for preparing a magnetic head, that is one of applications of the resist pattern-improving material having reduced edge roughness. In the fourth application example, the resist pattern-improving material according to the present invention is applied to the resist pattern 302 , 326 formed from a positive type resist.
[0121] FIGS. 10 (A) to (D) show process views stepwise illustrating the method for preparing a magnetic head.
[0122] First of all, a resist film having a thickness of 6 μm, as shown in FIG. 10(A), is formed on a layer insulation layer 300 , followed by being irradiated and developed to form a resist pattern 302 having an opeing pattern which will be used for forming a thin film magnetic coil in a shape of spiral.
[0123] Then, as shown in FIG. 10(B), a plating surface preparation layer 306 is formed either on a portions with the resist pattern 302 and a portion without the resist pattern (the opening portion 304 ), on the layer insulation layer 300 . The plating surface preparation layer 306 is composed of a Ti layer having a thickness of 0.01 μm and a Cu layer having a thickness of 0.05 μm, which are formed by means of deposition.
[0124] Then, as shown in FIG. 10(C), a thin film conductor 308 is formed on a portion without forming the resist pattern 302 , where the plating surface preparation layer 306 is formed on the opening portion 304 . The thin film conductor 308 is made of a Cu plating film having a thickness of 3 μm.
[0125] Then, as shown in FIG. 10(D), the resist pattern 302 is removed or lifted off by means of dissolution from the layer insulation layer 300 , to obtain a thin film magnetic coil 310 made of a thin film conductor 308 having a spiral pattern.
[0126] As described above, the magnetic head is prepared.
[0127] Thereby obtained magnetic head is prepared by using the resist pattern 302 as a mask whose edge roughness is reduced by the resist pattern-improving material according to the present invention, and therefore, it has a spiral shape having reduced edge roughness. The thin film magnetic coil 310 has a very small pattern, but it is made finely, and in addition, it is superior in mass production.
[0128] FIGS. 11 to 16 shows process views for illustrating various magnetic heads.
[0129] As shown in FIG. 11, a gap layer 314 is coated and formed on a non-magnetic base board of a ceramics by means of spattering. On the non-magnetic base board 312 , an insulating layer of silicon oxide and an insulating surface preparation layer of Ni—Fe permalloy are previously coated and formed by means of spattering, which are not shown in the figures. Moreover, a magnetic layer of Ni—Fe permalloy as a lower layer is previously formed. A resin insulating film 316 of a heat curable resin is formed on a predetermined portion of the gap layer 314 other than the portion to be a magnetic tip portion of the magnetic layer as the lower layer, not shown in the figures. Then, a positive type resist composition is coated on the resin insulating film 316 to form a resist film 318 .
[0130] Then, the resist film 318 is irradiated and developed to form a spiral pattern as shown in FIG. 12 Thereafter, the resist film having a spiral shape is subjected to a heat curing treatment at a temperature of a couple of hundreds degree in Celsius for a period of 1 hour, so as to form a first spiral shaped pattern 320 having protrusions. On the surface, a conductive surface preparation layer 322 of Cu is further formed.
[0131] Then, as shown in FIG. 14, a positive type resist composition is spin-coated on the conductive surface preparation layer 322 so as to form a resist film 324 Thereafter, the resist film 324 is patterned on the first spiral shaped pattern 320 , so as to obtain a resist pattern 326 .
[0132] Then, as shown in FIG. 15, a Cu conductive layer 328 is formed, by means of plating, on the revealed surface of the conductive surface preparation layer 322 , that is a portion where the resist pattern 326 is not formed. Thereafter, as shown in FIG. 16, the resist pattern 326 is removed or lifted off, by means of dissolution, from the conductive surface preparation layer 322 to obtain a thin magnetic coil 330 of the Cu conductive layer 328 having a spiral shape.
[0133] As described above, there is prepared a magnetic head having a writable magnetic pole 332 of the magnetic layer formed on a resin insulating layer 316 , and a thin film magnetic coil 330 on its surface, as shown in a plan view of FIG. 17. The pattern of the writable magnetic pole 332 of the magnetic layer is formed in a manner that a positive type resist is located as the upper layer, and a novolac type resist is located as the lower layer. Such an upper layer pattern formed by irradiation and development is vertically transferred on the lower layer by means of an enzyme plasma. Then, a plating film is formed followed by removing the resist and etching the plated base
[0134] Since thereby obtained magnetic head is formed by using a resist pattern 326 whose edge roughness is reduced by the resist pattern-improving material according to the present invention. The spiral pattern of the magnetic head is very small but formed finely. The tip portion of the writable magnetic pole 332 , composed of the thin film magnetic coil 330 and the magnetic layer, has a very small and fine size and a high aspect ratio, and also is superior in mass production.
[0135] An MR element portion 11 is formed to be provided with a terminal 12 of a magnetic head (MR type head) as shown in FIG. 18, as follows. As shown in FIG. 19( a ), an alumina layer 221 is provided on a supporting material 211 , on which a lower shield layer 231 of NiFe and a lower gap layer 241 of alumina are continuously formed. Further, on the lower gap layer 241 , a first resist layer 261 is formed above the surface of the base board having an MR pattern 251 . Then, the base board having the first resist layer 261 formed is subjected to irradiation of a monochromatic light 271 on the whole surface thereof to improve its surface, as shown in FIG. 19( c ). This step is intended to prevent the surface layer from mixing with the second resist layer formed thereon. On the first resist layer 261 whose surface is improved, a second resist layer 29 is formed, as shown in FIG. 19( c ). Thereafter, using a photo-mask having a predetermined pattern, an i ray is selectively irradiated. In FIG. 19( c ), the irradiated portions 311 , 321 are remained. After the irradiation, baking is performed, and then, it is developed.
[0136] As a result, a resist pattern, whose condition is that a pattern 261 ′ of the first resist layer 261 is eroded under the pattern 291 ′ of the second resist layer 291 , is formed, as shown in FIG. 20( d ). As shown in FIG. 20( e ), the lower portion of the resist pattern on the MR element 251 may be formed into a hollow. Thereafter, a terminal forming material 331 is formed into a film on the surface of the base board having the two layer resist pattern, as shown in FIG. 20( f ). Then, the two layer resist pattern is dissolved and selectively removed in a solution for development, so as to form a pattern of the terminal forming material 331 at a portion where the two layer resist pattern is not provided. Here, the MR pattern 251 corresponds to the MR element portion 11 shown in FIG. 18, and the pattern of the terminal forming material 331 corresponds to the terminal 12 shown in FIG. 18.
[0137] Then, see FIG. 21 and FIG. 22. Explanation here is focused on a process of a hollow lifting off. FIG. 21 shows a plan view of a situation where a terminal 421 connected to an MR element 411 is formed by using two layers of the first resist layer 431 and the second resist layer 441 . The first resist layer 431 is eroded under the second resist layer 441 , whose periphery is drawn by a dashed line. The lower figure in FIG. 21 shows a magnified view of the MR element 411 , which corresponds to the portion pointed out by a symbol “A” in the upper figure in FIG. 21. In the lower figure of FIG. 21, the periphery of the first resist layer 431 under the second resist layer 441 is shown by a dashed line. Above the MR element 411 , only the second resist layer 441 exists, between which there is a hollow. As shown by a cross-sectional view of FIG. 22, the upper figure in FIG. 22 shows a cross-sectional view at a line 50 - 50 pointed out in the lower figure of FIG. 21, which illustrates a hollow structure between the MR element 411 and the second resist layer 441 . The lower figure in FIG. 22 shows a cross-sectional view at a line 50 ′- 50 ′ pointed out in the lower figure in FIG. 21, which illustrates the second resist layer 441 formed on the first resist layer 431 provided on the base board 401 . As shown in the upper figure in FIG. 22 and the lower figure in FIG. 22, a film 421 of the terminal forming material on the second resist layer 441 will be removed or lifted off together with the two layers of the first resist layer 431 and the second resist layer 441 , when a lifting off treatment is performed
[0138] For example, there is provided a method for preparing an MR element for a magnetic head (MR head) by means of the lifting off process. As shown in FIG. 23( a ), an alumina layer 62 is provided on a supporting material 61 , on which a lower shield layer 63 of NiFe and a lower gap layer 64 of alumina are continuously formed, so as to prepare a base board having an MR film 65 on the lower gap layer 64 for producing an MR element. Then, the MR film 65 on the surface of the base board is patterned to prepare an MR element 66 as shown in FIG. 23( b ). Continuously, as shown in FIG. 23( c ), a terminal 68 is formed on the lower gap layer 64 on the base board, by using a mask pattern 67 . Then, the mask pattern 67 is removed by means of the lifting off process, as shown in FIG. 23( d ). Thereafter, as shown in FIG. 23( e ), the lower shield layer 63 and the lower gap layer 64 are patterned by means of ion trimming, so as to obtain the lower shield layer 63 ′ and the lower gap layer 64 ′. Alternatively, the lower shield layer 63 ′ and the lower gap layer 64 ′ may be formed by patterning on the base board as shown in FIG. 24( a ), and then, the MR element 66 may be formed and the terminal 68 may be formed by means of lifting off as shown in FIG. 24( b ), and then the lower shield layer 63 ′ and the lower gap layer 64 ′ may be patterned as shown in FIG. 24( c ), and thereby, the final shape of the lower shield layer 63 and the lower gap layer 64 may be obtained.
[0139] Then, there is provided another method for preparing a magnetic head, with reference to FIG. 25 and FIG. 26. As shown in FIG. 25( a ), a base board is prepared which has a lower shield layer 83 of NiFe, a lower gap layer 84 of alumina, and an MR film 85 for an ER element continuously formed on an alumina layer (not shown) provided on a supporting material (not shown) On the base board, polymethyl glutalimide made by Japan Macdermid Corporation as a material for the first resist layer is spin-coated to have a thickness of 0.3 μm, followed by baking at a temperature of 180° C. for a period of 2 minutes, so as to form a first resist layer 86 . Then, the base board is placed on a hot plate inside a chamber for surface treatment, followed by irradiating a light (Xe 2 excimer light) having a wavelength of 172 nm on the whole surface of the base board at an irradiation length of 1 mm for a period of 20 seconds. Then, the base board is moved into a coating cup again, and then, the positive type resist composition according to the present invention is spin-coated thereon to have a thickness of 2.0 nm, followed by baking at a temperature of 110° C. for a period of 2 minutes, so as to form a second resist layer 87 . Continuously, as shown in FIG. 25( c ), an i ray 88 is irradiated through a predetermined mask pattern formed by a g ray spattering. After the irradiation, it is developed by a solution of tetramethyl ammonium hydroxide at a concentration of 2.38% by mass. At the time of development, the first resist layer 86 and the second resist layer 87 are concurrently developed so as to form two layer resist pattern 89 as shown in FIG. 25( d ). Observation of the structure of the two layer resist pattern 89 by an optical microscope shows that the lower layer is eroded under the upper layer. Then, as shown in FIG. 26( e ), the two layer resist pattern 89 is masked to pattern by means of ion milling to form an MR element 85 a, followed by that a metal film 81 to be a terminal is formed by means of spattering as shown in FIG. 26( f ). Then, the two layer resist pattern 89 is removed by a resist removing agent (MS-2001 made by Fuji Hunt Corporation), followed by washing with ethanol and drying to form a terminal 81 .
[0140] (5) The Fifth Application Example of the Present Invention: A Method for Preparing an HEMT
[0141] There is provided a method for preparing an HEMT as an example of the applications for the resist pattern-improving material according to the present invention. In this application example, a resist patterns formed from a positive type resist 91 , 94 are formed by using the resist pattern-improving material according to the present invention for reducing the edge roughness.
[0142] [0142]FIG. 27 shows process views illustrating a method for preparing a T-gate electrode of an HEMT. As shown in FIG. 27( a ), there is prepared a GaAs base board 90 having a buffer epitaxial layer, an epitaxial layer for supplying second electrons, and a cap epitaxial layer formed thereon. On the GaAs base board 90 , a negative type first electron beam resist (SAL-601 made by Shipley Corporation) is coated, followed by baking. Thereafter, an electron beam is irradiated to form a resist pattern 91 having a separated line shape. The resist pattern 91 has a gate length of 0.1 μm and a thickness of 1 μm. After the irradiation, the negative type first electron beam resist is developed, followed by washing and drying to obtain a resist pattern 91 having a separated line shape, the resist pattern 91 having a gate length of 0.1 μm and a thickness of 1 μm. Then, as shown in FIG. 27( b ), the base board is treated by an enzyme plasma (for example, at an electric power of 100 W, at a period of 30 seconds, at an oxygen flow rate of 200 sccm) in order to improve its wettability Then, as shown in FIG. 27( c ), an OCD (made by Tokyo Ohka Kogyo Co, Ltd.), that is an insulate spin-on-glass (SOG) is coated on the GaAs base board 90 at a thickness of 0.5 μm, followed by baking at a temperature of 110° C. for a period of 2 hours. Thus, an insulation film 92 is formed. Thereafter, an O 2 -Assher is used for removing the resist pattern 91 having a separated line shape, so as to form an opening 92 a whose cross-section has a taper shape (the angle of the taper: 60 degree.) Then, as shown in FIG. 27( d ), TiW is coated by means of spattering to have a thickness of 0.1 μm, on the whole surface of the GaAs base board, so as to form a first metal wiring layer 93 which will be used for a lower gate electrode. On the first metal wiring layer 93 , a positive type resist is coated to have a thickness of 0.6 μm, followed by baking to form a resist layer 94 . Thereafter, an irradiation and development of the resist 94 are carried out followed by washing and drying, so as to form an opening 94 a larger than the opening 92 a, whose cross-section has an opposite-taper shape. The opening 94 a has a gate length of 0.5 μm. Thereafter, Ti and Al are continuously deposited to have a thickness of 0.5 μm on the GaAs base board, so as to form a second metal wiring layer 95 which will be used for an upper gate electrode. As shown in FIG. 27( e ), the portion having the second metal wiring layer 95 formed on the opening 92 a is remained, and the other portion of the second metal wiring layer 95 and the resist layer 94 thereunder are removed or lifted off by using an organic solvent. Then, as shown in FIG. 27( f ), the remained portion of the second metal wiring layer 95 is used as a mask. By means of RIE, the first metal wiring layer 93 formed under the second metal wiring layer 95 is remained, and an unnecessary portion of the first metal wiring layer 93 is removed, and the insulation film 92 formed thereunder is removed by using a solution of NH 4 F, so as to form a fine T-gate electrode.
[0143] (6) The Sixth Application Example of the Present Invention: A Method for Preparing a Plasma Display
[0144] There is provided a method for preparing a plasma display as an example of applications of the resist pattern-improving material according to the present invention for reducing the edge roughness. In the fifth application example described here, the resist pattern-improving material according to the present invention is applied to a positive type resist pattern 104 . See FIGS. 28 and 29.
[0145] With reference to FIG. 28 and FIG. 29, a process for forming a partition wall in a plasma display is explained. FIGS. 28 ( a ) to ( d ) and FIGS. 29 ( e ) to ( g ) show cross-sectional views for illustrating processes for forming a partition wall. As shown in FIG. 28( a ), an address electrode 101 is formed on a glass base board 100 . The glass base board 100 is, for example, made of a soda glass or high strain glass having a thickness of 2.8 mm. After forming the address electrode 101 , for example, a surface preparation layer 102 of dielectric glass is formed. In the following explanations, the glass base board 100 , address electrode 101 , and surface preparation layer 102 may be referred to as a base board 103 for convenience. Then, as shown in FIG. 28( b ), a photosensitive coating layer 104 is formed on the base board 103 . The photosensitive coating layer 104 is formed by using a positive type resist material, to have a thickness of 120 nm. Then, as shown in FIG. 28( c ), an i ray is irradiated through a photo mask 105 having a predetermined width and pitch of the pattern. The amount of the irradiation is adjusted according to the width and pitch of the pattern of the photo mask 105 . As shown in FIG. 28( d ), the irradiation is followed by development. A solution of sodium carbonate at a concentrate of 1% by mass is used for the development. The development is subjected for a period of about 3 minutes, followed by washing in water. Thereafter, as shown in FIG. 29( e ), a plasma welding is carried out on the base board 103 , so as to deposit a welding film 107 of a partition wall material at the inside of the grooved portions of the photosensitive layer 104 .
[0146] In detail, the plasma welding torch 108 is provided with a cooling gas port 110 . Welding of the plasma jet 109 is concurrent with flowing of the cooling gas 111 toward the base board 103 . Nitrogen gas is used as the cooling gas 111 . The cooling gas may reduce the damage of the photo sensitive coating layer 104 due to heat under the welding, and thereby, a partition wall may be made finer. In the step of the welding, the welding film 107 is generally deposited inside the grooves of the photosensitive coating layer 104 , in a manner to swell on the surface of the photosensitive layer 104 . However, the photosensitive layer 104 is less deposed on the periphery thereof. Then, as shown in FIG. 29( f ), the welding film 107 over the surface of the photosensitive coating layer 104 is generally removed by means of grinding, so as to flatten the surface of the welding film 107 deposited inside the grooves of the photosensitive coating layer 104 . Then, as shown in FIG. 29( g ), the base board 103 is burned in an atmosphere including oxygen at a high temperature, and thereby, the photosensitive resin of organic components is burned out and changed into gases, such as, carbon dioxide, for removal. Thus, a partition wall 107 having a predetermined shape is formed on the base board 103 . As described here, the partition wall for a plasma display is prepared. See FIG. 30.
[0147] The plasma display panel, as described here as an application example of the present invention, has a front base board 150 and a back base board 151 opposed to the front base board 150 . The front base board 150 is provided with an indication electrode 152 , 153 , a dielectric layer 154 , and an MgO dielectric protective layer 155 formed thereon in such orders. The back base board 151 is provided with an address electrode 156 and a dielectric layer 157 formed thereon, on which a partition wall 158 is formed. The side surface of the partition wall 158 is coated with a fluorescence layer 159 . Between the front base board 150 and the back base board 151 , an electric discharging gas 160 is filled at a specific pressure. The electric discharging gas 160 is discharged between the indication electrodes 152 , 153 to generate an ultraviolet ray, which irradiates the fluorescence layer 159 to make a picture indication, for example, a color picture indication.
[0148] As described above, several application example of the present invention are explained, based on preparation methods for various devices which may be applicable to the present invention. The resist pattern-improving material according to the present invention may reduce the edge roughness in the step of patterning. It would be possible to continue to use photo irradiation techniques for a while, and to easily produce high density devices in mass production. This specification shows several applications, but the invention is not limited to the explanations here, and may be modified on the merit within the scope of the present invention.
[0149] For example, the above description says that the nonionic surfactant is selected from the group consisting of polyoxy ethylene-polyoxy propylene copolymer, polyoxy alkylene alkyl ethers, polyoxy ethylene alkyl ethers, polyoxy ethylene derivatives, sorbic fatty acid esters, glycerin fatty acid esters, primary alcohol ethoxylates, and phenol ethoxylates. Alternatively, another surfactant not listed here may be selected so long as it is a nonionic surfactant. Such an alternative will accomplish a similar effect specific to the present invention.
[0150] Also, the above description says that the alicyclic type resist materials may include resist materials for ArF excimer laser, such as acrylic type resist materials having an adamantyl group on the side chain. Alternatively, resist materials for ArF excimer laser, such as, acrylic type resist materials having a norbornene group on the side chain, and the like, or resist materials for ArF excimer laser, such as, COMA (cycloolefin maleic acid anhydride type) type resist materials, and the like, may be used. Also, a resist materials for ArF excimer laser, such as, alicyclic cycloolefins having an adamantyl group, norbornene group, and the like, on its main chain. Also, these resins listed here may be fluorinated at a part of the main chain or side chain thereof, and if so, it will be possible to work in a fine manner since it makes a resist pattern applicable to irradiation of F 2 excimer laser light.
[0151] The explanations above relate to methods for various semiconductor devices, but the present invention may be applicable to the followings, which need small and fine patterns: for example, functional parts, such as, mask pattern, rectil pattern, LCD (liquid crystalline display), SAW filter (elastic surface wave filter), and so on; optical parts used for connecting optical wiring; fine and small parts, such as, micro actuators, and so on. Also, as an example application of semiconductor devices, a process for preparing a flash memory is explained in detail, but the present invention is not limited thereto. The present invention may be also applicable to a method for preparing a logic device, DRAM, FRAM, and so on.
[0152] Also, the applications described above is focused on explanations of the resist pattern-improving material according to the present invention, especially with respect to manufacturing processes and their applications. However, the explanation described above, such as, the mixing ratio of the composition, must not limit the scope of the invention.
[0153] According to the present invention, it is possible to form a good pattern having a reduced edge roughness, resulting in maintaining a mass production for preparing highly fine devices, without avoiding short circuit and bad condition patterns.
[0154] According to the present invention, several effects are expected. For example, it is possible to form a pattern which is controlled to have less varied sizes. It is possible to use a laser exceeding an irradiation criticality of a deep ultraviolet irradiation, by using, for example, an ArF (argon fluoride) excimer laser (having a wavelength of 193 nm), and so on. Therefore, it may contribute to continue to use photo irradiation working, and also, mass production for devices may be contained to use.
[0155] The symbols used in this specification are summarized below.
[0156] [0156] 1 : photo resist film, 1 a: resist pattern, 2 : resist pattern-improving film, 2 a: resist pattern having improved, 3 : layer insulation film, 4 : improved portion of the resist pattern, 22 : Si base board (semiconductor base board), 23 , field oxidation film, 24 a: first gate insulating film, 24 b: second gate insulating film, 25 a: first threshold controlling layer, 25 b: second threshold controlling layer, 26 , 27 , 29 , 32 , 34 , 43 : resist film, 28 , 28 a. first polysilicon film (first conductive film), 28 b: gate electrode (first polysilicon film), 28 c: floating gate electrode, 30 a, 30 c: capacitor insulating film, 30 b, 30 d. SiO 2 film, 31 , 31 b: second polysilicon film (second conductive film), 31 a: control gate electrode, 33 a, 44 a: first gate portion, 33 b, 33 c, 44 b: second gate portion, 35 a, 35 b, 36 a, 36 b, 45 a, 45 b, 46 a, 46 : source drain region layer, 37 , 47 : layer insulation film, 38 a, 38 b, 39 a, 39 b, 48 a, 48 b, 49 a, 49 b: contact hole, 40 a, 40 b, 41 a, 41 b, 50 a, 50 b, 51 a, 51 b: source drain electrode, 42 : high melting temperature metal film (fourth conductive film), 42 a: control gate electrode (high melting temperature metal film, fourth conductive film), 42 b: gate electrode (high melting temperature metal film, fourth conductive film), 52 a, 52 b: opening portion, 53 a, 53 b: high melting temperature metal film (third conductive film), 54 : insulating film, 11 : MR element portion, 12 : terminal, 211 : supporting material, 221 : alumina layer, 231 : lower shield layer, 241 : lower gap layer, 251 : MR pattern, 261 : first resist layer, 271 monochromatic light, 291 : second resist layer, 301 : i ray, 311 : irradiation portion, 321 : irradiation portion, 331 : terminal forming material, 411 : MR element, 421 , terminal, 431 : first resist layer, 441 : second resist layer, 61 : supporting material, 62 , alumina layer, 63 : lower shield layer, 63 ′: lower shield, 64 : lower gap layer, 64 ′: lower gap, 65 : MR film, 66 : MR element, 67 : mask pattern, 68 : terminal, 81 : metal film, 83 : lower shield layer, 84 : lower gap layer, 85 : MR film, 85 a: MR element, 86 : first resist layer, 87 : second resist layer, 88 : i ray, 89 : two layer resist pattern, 90 : GaAs base board, 91 : resist pattern, 92 : insulating film, 92 a: opening portion, 93 : first metal wiring layer, 94 : resist layer, 94 a: opening portion, 95 : second metal wiring layer, 100 : glass base board, 101 : address electrode, 102 : surface preparation layer, 103 : base board, 104 : photosensitive resin layer, 105 : photo mask, 107 : welding film, 108 : plasma welding torch, 109 : plasma jet, 110 : cooling gas port, 111 : cooling gas, 150 : front base board, 151 : back base board, 152 : indication electrode, 153 : indication electrode, 154 : dielectric layer, 155 : MgO dielectric layer protective layer, 156 : address electrode, 157 : dielectric layer, 158 : partition wall, 159 : fluorescence layer, 160 : electric discharging gas, 300 : layer insulation layer, 302 : resist pattern, 304 : opening portion, 306 : plating surface preparation layer, 308 : thin film conductive layer(Cu plating film), 310 : thin film magnetic coil, 312 : non-magnetic base board, 314 : gap layer, 316 : resin insulating layer, 318 : resist film, 318 a: resist pattern, 320 : first spiral pattern, 322 : conductive surface preparation layer, 324 : resist layer, 326 : resist pattern, 328 : Cu conductive film, 330 : thin film magnetic coil, 332 : writable magnetic pole of a magnetic layer | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a substrate for use in an apparatus for attracting a wafer such as a semiconductor wafer and a manufacturing method thereof.
2. Description of the Related Art
Electrostatic chuck are currently used to attract and hold semiconductor wafers in conveying, exposing, film-forming such as CVD (Chemical Vapor Deposition) and sputtering, micro processing, cleaning, etching or dicing the semiconductor wafers. Attention has been much paid to dense ceramics as materials for such electrostatic chucks. Particularly in the semiconductor manufacturing apparatus, a halogenated corrosive gas such as ClF 3 is often used as an etching gas or a cleaning gas. It is desired that the substrate or susceptor for the electrostatic chuck has high thermal conductivity in order to rapidly heat and cool the semiconductor wafer while holding it. It is further desired that the substrate has such thermal shock resistance as to be broken due to rapid temperature change. For example, dense aluminum nitride and dense alumina are considered promising, because they have good corrosion resistance to the above-stated haloganated corrosive gas and thermal shock resistance.
In the semiconductor manufacturing apparatus, it is necessary to prevent the production of particles which would cause defects in semiconductors. In the actual semiconductor manufacturing apparatus, the semiconductor wafer is attracted and held at its back face by the electrostatic chuck. At that time, particles occur on the back surface side of the semiconductor wafer. If a large amount of particles occur, they spread over the front surface of the semiconductor wafer and into a chamber. As a result, the chamber is contaminated, so that semiconductor failure might occur on surfaces of other semiconductor wafers.
To prevent this problem, there have been proposed the following techniques. When the attracting surface of the ceramic electrostatic chuck comes in contact with a silicon wafer, the uneven attracting surface of the electrostatic chuck contacts with the silicon, and rubs off a part of the silicon having relatively low hardness to produce particles. Considering this, fine protrusions on the attracting surface of the electrostatic chuck are rounded by applying plasma onto this attracting surface, thereby preventing the silicon from being rubbed off and consequently decreasing the number of particles (Japanese Unexamined Patent Application Laid-open No. 7-245336).
According to Japanese Unexamined Patent Application Laid-open No. 8-55900, when a silicon wafer is to be attracted to the electrostatic chuck, voltage to be applied to the electrostatic chuck is gradually increased, thereby to mitigate any shock caused through the contact of the silicon wafer with the chuck. By so doing, the damage to the silicon wafer is suppressed, and the number of particles resulting from silicon wafer having been rubbed off is decreased.
The present inventors have been continuing the study to decrease the number of particles adhering to the back surface of a semiconductor wafer after the wafer has been attracted by the electrostatic chuck. According to prior art stated above, it is possible to decrease the number of particles down to for example, few to several thousands per 8-inch wafer. However, to further improve the yield of the semiconductor wafers in the semiconductor manufacturing process and to cope with more micro-structured semiconductors, it is required to decrease the number of particles furthermore. It has been desired, for example, to decrease the number of particles to a few to several hundreds per 8-inch wafer.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to considerably decrease the number of particles adhering to the back surface of the wafer after the wafer has been attracted to a ceramic substrate of a wafer attracting apparatus.
The present invention relates to a substrate for use in a wafer attracting apparatus which comprises a substrate made of a ceramic material and adapted to attract and hold a wafer onto an attracting surface thereof, wherein said attracting surface is constituted by a ductile worked surface, the ductile worked surface has concave portions, a diameter of each of the concave portions is 0.1 μm or less, and when the wafer is attracted onto the attracting surface of the substrate and released from the attracting surface, the number of particles adhering to that wafer is 9.3 or less per 1 cm 2 . The measurement of the particles adhering to the wafer is effected in the present invention under the following condition, that is, at an attracting force of 50 g/cm 2 at room temperature in clean air. The ductile working is a working which effects working such as polishing of particles themselves at the surface of the substrate without peeling off such particles themselves from the attracting surface of the substrate.
The present invention also relates to a wafer attracting apparatus which comprises a substrate made of a ceramic material and adapted to attract and hold a wafer onto an attracting surface thereof, wherein said attracting surface is constituted by a ductile worked surface having a center line surface roughness height Ra of 0.05 μm or less formed by etching, vertical steps are formed among ceramic particles exposed outside at the attracting surface is 0.5 μm or less, and when the wafer is attracted onto the attracting surface of the substrate, the number of particles adhering to that wafer is 9.3 or less per 1 cm 2 .
The present invention further relates to a method for manufacturing a wafer attracting apparatus having a substrate made of a ceramic material and adapted to attract and hold a wafer on an attracting surface of the substrate, said method comprising the steps of: converting the attracting surface of the substrate to a ductile worked surface, cleaning the ductile-worked attracting surface by a cleaning member in a high purity cleaning agent while rubbing the attracting surface of the substrate with the cleaning member, and conducting an ultrasonically cleaning for the attracting surface in the high purity cleaning agent. The term "rubbing" means that the attracting surface of the substrate is rubbed with the cleaning member, while the attracting surface is not substantially damaged thereby.
The present invention further relates to a method for manufacturing a wafer attracting apparatus having a substrate made of a ceramic material and adapted to attract and hold a wafer on an attracting surface of the substrate, said method comprising the steps of: converting the attracting surface of the substrate to a ductile worked surface having a center line surface roughness height of Ra=0.05 μm, cleaning the ductile-worked attracting surface by a cleaning member in a high purity cleaning agent while rubbing the attracting surface of the substrate with the cleaning member, and conducting an ultrasonically cleaning for the attracting surface in the high purity cleaning agent.
The present invention further relates to a wafer attracting apparatus which comprises a substrate made of a ceramic material and adapted to attract and hold a wafer onto an attracting surface thereof, wherein said attracting surface is constituted by a ductile worked surface, and when the wafer is attracted onto the attracting surface of the substrate, a maximum roughness Rmax of the ductile worked surface of the substrate is 0.1 μm or less, and the number of particles adhering to that wafer is 9.3 or less per 1 cm 2 .
The present inventors have conducted a detailed study as to particles generated after the semiconductor wafer was attracted and held by the ceramic electrostatic chuck. As a result, the inventors made discoveries as follows. Specifically, the mirror finished surface of an 8-inch silicon wafer was mounted and attracted onto an attracting surface of an aluminum nitride electrostatic chuck. Thereafter, the number of particles on the mirror finished surface of the silicon wafer was measured to be 90,000 or more particles.
Next, those particles were subjected to elemental analysis, thereby obtaining an analysis result shown in FIG. 1 where peaks of aluminum, silicon, nitrogen and carbon are observed. It is highly noted that the aluminum peak is particularly quite high. The peak of the silicon is also high. However, since the elemental analysis was conducted while particles were present on the silicon wafer, it is presumed that the peak of the silicon almost is attributable to the silicon in the wafer.
This fact contradicts the conventional assumption that particles are produced when the back surface of the silicon wafer is chipped through the shock occurring through contact between the attracting surface of the ceramic electrostatic chuck and the silicon wafer. Rather, this indicates that a main cause of the particle generation lies in the attracting surface of the electrostatic chuck.
It is not clear why particles occur on the attracting surface of the ceramic electrostatic chuck. The attracting surface of the chuck is normally flattened by grinding process. However, it is considered that fine ground pieces are generated during ordinary grinding which makes the attracting surface of the electrostatic chuck flat, and that the resulting fine ground pieces are retained in very small concave portions at the attracting surface or fixedly attached to the attracting surface.
Based upon that discovery, the present inventors cleaned attracting surfaces of electrostatic chucks in various ways. As a result, the inventors succeeded in greatly decreasing the number of particles adhering to the back surface of the semiconductor wafer to 3000 or less per a back surface of an 8-inch wafer (per 324 cm 2 ) (that is, 9.3 or less per 1 cm 2 ) and further to 1000 or less per a back surface of an 8-inch wafer (per 324 cm 2 ) (that is, 3.1 or less per 1 cm 2 ) by the steps of mirror-finishing the attracting surface to a ductile worked surface through lapping or like, cleaning the attracting surface by using a cleaning member in a high purity cleaning agent while contacting the attracting surface with the cleaning member, and then ultrasonically cleaning the attracting surface of the chuck in pure water.
More specifically, the attracting surface of the ceramic substrate is mirror-finished to a ductile worked surface by lapping or the like until the center line average surface roughness height Ra preferably becomes 0.1 μm or less. In this state, no further ceramic particles will be peeled off. Although small holes of 0.1 μm or less in diameter still remain on the ductile worked surface in this state, no holes of 0.1 μm or more in diameter substantially exist. In other words, the diameters of the concave portions remaining on the ductile worked surface are 0.1 μm or less. Neither ceramic grains or their fragmental particles enter these small holes. None of them adhere to the semiconductor wafer.
In the present invention, that the diameters of the concave portions existing on the ductile surface are 0.1 μm or less or that none of holes of 0.1 μm or more in diameter substantially exist means that the number of holes of 0.1 μm or more in diameter is five or less within a dimensional range of 50 μm×70 μm even when observations are made at 100 visual fields in an image analysis. That is, the above means that no large holes basically exist in the ceramic tissue. This may include a case where very small number of holes of 0.1 μm or more in diameter exist under some quite local conditions.
However, even when the semiconductor wafer was attracted by the electrostatic chuck after the ductile worked surface was ultrasonically cleaned, about 25,000 particles were observed on the surface of the semiconductor wafer. It is considered that the reason is probably that ceramic grains or their fragmental pieces peeled from the ceramic substrate are fixedly attached to portions other than the small holes on the ductile worked surface and that the fixedly attached particles cannot be removed by the ultrasonically cleaning.
Taking this fact into account, the present inventors brush cleaning the substrate in a high purity cleaning agent after the ductile worked surface of the substrate having a center line average height of 0.01 μm or less was formed by lapping or the like. In that case, however, about 20,000 particles were observed on the surface of the semiconductor wafer. It is considered that the reason is that particles are separated from the attracting surface by brushing, remained among bristles of the brush or within the cleaning agent and the remaining particles adhered to the attracting surface of the substrate.
Based on the discovery, the present inventors cleaned the attracting surface of the substrate which was constituted by the ductile worked surface, while bringing the ductile worked surface into contact with a cleaning member. Thereafter, the inventors further ultrasonically cleaned the attracting surface of the substrate within high purity cleaning agent. As a result, the inventors succeeded in decreasing the number of particles adhering to the back surface of the semiconductor wafer, after the wafer is contacted with and released from the attracting surface of the electrostatic chuck, to 3000 or less and further to 1000 or less per a 8-inch wafer. In this way, the present invention has been accomplished.
Moreover, the present inventors polished an attracting surface of a substrate and then cleaned the resulting surface within a high purity cleaning agent while rubbing the surface with a cleaning member. Thereafter, ultrasonically cleaning was further conducted within high purity cleaning agent to the surface. As a result, the inventors also succeeded in greatly decreasing the number of particles adhering to the back surface of the semiconductor wafer after the contact between the wafer and the electrostatic chuck.
The inventors studied the reason for the successful result. If the attracting surface is polished until Ra preferably reaches 0.05 μm or less, no small holes as stated above exist at the ductile worked surface mentioned above. However, a processing agent used for the polishing acts as an etching liquid, and forms steps at the ceramic grains exposed to the attracting surface. This will be explained with reference to a schematic view of FIG. 2.
A lot of ceramic grains 2A, 2B and 2C are exposed outside at the attracting surface 1 of the substrate. Since the ceramic grains differ in the direction of crystallographic axis, they differ in etching rate. As a result, height difference occur among the particles 2A, 2B and 2C after polishing, whereby grain boundaries 3 of the ceramic grains appear at the attracting surface 1.
When viewing the attracting surface having such a structure, particles adhere to the surface of each ceramic grain 2A, 2B, 2C. These particles can be removed by rubbing the ceramic grains with a cleaning member.
A part of the particles caught among bristles of the brush of the cleaning member are attached again to the surfaces of the ceramic grains 2A, 2B and 2C. However, it is considered that since those reattached particles have been already once peeled off from the surfaces of the ceramic grains by the cleaning member, the adhering force of the particles to the ceramic grains is so weak that they could be easily removed in the following cleaning step. It is noted, however, that if the height difference among the grains exceeds 0.5 μm, it becomes difficult to contact the cleaning member with surfaces of the ceramic grains and therefore difficult to remove the particles. It is thus more preferable that the height difference is 0.3 μm or less,
These and other objects, features and advantages of the invention will be appreciated upon reading of the following description of the invention when taken in conjunction with the attached drawings, with the understanding that some modifications, variations and changes of the same could be made by the skilled person in the art to which the invention pertains.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, reference is made to the attached drawings, wherein:
FIG. 1 is a graph showing a result of an elemental analysis for particles on the silicon wafer;
FIG. 2 is a schematic view showing the state of an attracting surface 1 of a substrate polished;
FIG. 3 shows a scanning electron microscopic photograph of the ceramic tissue of an attracting surface of an electrostatic chuck according to Comparison Example 1;
FIG. 4 shows a scanning electron microscopic photograph of a ceramic tissue of an attracting surface of an electrostatic chuck according to the present invention;
FIG. 5 is a distribution diagram showing the particle distribution on a silicon wafer at a mirror-finished surface side as measured by a particle counter by a light scattering type particle counter in the Comparison Example 1; and
FIG. 6 is a distribution diagram showing the particle distribution on a silicon wafer mirror-finished surface side as measured by the light scattering type particle counter by the light scattering method in the Example 1 according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the present invention, the electrostatic chuck is most desirable for the wafer attracting apparatus; however, a vacuum chuck is also available. As the wafer, a semiconductor wafer requiring high purity is most desirable. However, the present invention is also applicable to the iron wafer and the aluminum wafer.
If the present invention is applied to the electrostatic chuck, the shape, etc. of the electrostatic chuck are not limited to specific ones. As a substrate perform of the electrostatic chuck, ordinary substrates to be used for this purpose may be used. That is, the substrate preform may include a ceramic substrate preform prepared by the steps of forming a green molded body preliminarily uniaxially molded in which an electrode is buried and subjecting the green molded body to HP sintering. It is preferable that an electrostatic chuck electrode to be embedded in a ceramic substrate is made of a sheet-shaped bulk metallic material. Here, the "sheet-shaped bulk metallic material" means, for example, a linear bulk body, a planar bulk body or the like in the form of a integrally shaped planar member.
In this case, an electrode for the electrostatic chuck is preferably made of a high melting point metal, since it is fired together with ceramic powder such as alumina powder or aluminum nitride powder. The high melting point metals includes, for example, tantalum, tungsten, molybdenum, platinum, rhenium, hafnium and their alloys. For the viewpoint of preventing the semiconductor wafer from being contaminated, tantalum, tungsten, molybdenum, platinum and their alloys are preferred.
As the above-stated bulk sheet-shaped material, the following can be used:
(1) A sheet-shaped bulk material made of a thin plate.
(2) A sheet-shaped bulk material in which many small void are formed.
The bulk material (2) includes a bulk material made of a planar body having numerous small holes and a net-shaped bulk material. A punched metal may be recited as an example of the planar bulk having numerous small holes. However, if the bulk material is made of a punched metal having a high melting point, it is difficult and highly costly to punch many small holes in the planar high melting point metal because of its high hardness. Compared with this, if the bulk material is to be made of a wire net, wires made of a high melting point metal are so easily available that the metal wire net may be produced by knitting the wires.
The mesh shape, the wire diameter, etc. of such a metal wire are not limited specifically. However, a 150-mesh metal wire net having a wire diameter of 0.03 mm to a 6-mesh metal wire net having a wire diameter of 0.5 mm were practically usable without causing any problem. In addition, the cross-sectional shape in the width direction of the linear material constituting the metal wire net may be circular, elliptical, rectangular or of variously rolled shapes. "One mesh" means one wire per inch.
It is possible to embed a resistive heater and/or a plasma generation electrode as well as an electrostatic chuck electrode in the ceramic substrate constituting the electrostatic chuck.
As the ceramic substrate for constituting a wafer attracting apparatus which is the very target of the present invention, alumna, aluminum nitride, silicon nitride, silicon carbide and the like having a porosity of 95% or more can be recited by way of example. Alumina and aluminum nitride are particularly preferable.
A method for working the attracting surface in the wafer attracting apparatus according to the present invention should not be limited specifically. Preferably, a lapping with abrasive grains made of a hard material, such as diamond, having the average grain diameter or 1 μm or less or preferably 0.5 μm or less may be adopted. By this processing, a ductile worked surface having Ra=0.01 μm or less can be obtained.
The polishing with abrasive grains of silica, cerium oxide or the like having the average grain diameter 2 μm or less in a neutral or alkaline aqueous solution as a processing liquid diameter may be adopted. By this polishing, it is possible to obtain ductile worked surface having Ra=0.05 μm or less. It is also possible to adopt lapping and polishing in combination.
The same or different high purity cleaning agents may be used for cleaning the ductile worked surface while being rubbed with the cleaning member and ultrasonic cleaning. As the high purity cleaning agent, deionized water having a resistivity of 16 MΩ or less with the number of fine particles in the water being 10/ml or less is preferable, however, an aqueous solution of a surface active agent and an alkaline cleaning agent may be used as well. It is particularly preferable that the temperature of the high purity cleaning agent is set in a range from room temperature to 80° C.
As a cleaning member for cleaning the attracting surface of the substrate of the wafer attracting apparatus, a brushing member is particularly desirable. The material for that brush of the brushing member which directly contacts with the attracting surface of the substrate is preferably polyurethane resin, Teflon resin, polyvinyl alcohol resin called "Bellclean (trademark)" (manufactured by Kanebo Co., ltd.) or the like.
The frequency of ultrasonic waves in the ultrasonical cleaning is not specifically limited. However, it is noted that if the frequency of the waves is not less than 100 kHz but not more than 1000 kHz and the output of the ultrasonic waves is 3.0 to 6.0 W/cm 2 , the number of particles can be particularly reduced.
(Embodiments)
More detailed experimental results will be explained hereinafter.
(Manufacture of the electrostatic chucks)
A metal wire net made of molybdenum was used as the electrostatic chuck. The wire net is a net obtained by knitting 0.12 mm-diameter molybdenum wires at a rate of 50/inch. Aluminum nitride powder was uniaxially press molded into a disc-like preform. At that time, the wire net was embedded into the preform.
The preform was installed in a mold and sealed in a carbon foil. The preform was fired by hot pressing at a temperature of 1,950° C. under pressure of 200 kg/cm 2 for a retention time of two hours, thereby obtaining a sintered body. The relative density of the sintered body was 98.0% or more. The resultant electrostatic chuck was 200 mm in diameter and 8 mm in thickness. The hot pressing firing makes it possible to effectively reduce residual pores and to obtain a sintered body having a relative density of 99.8% or more.
COMPARISOM EXAMPLE 1
An attracting surface of the above-stated electrostatic chuck was lapped. More specifically, the electrostatic chuck was first placed on a copper board (trade name: Hyprez copper manufactured by Japan Engis, Co., Ltd.) and lapped with diamond abrasive grains having the average grain diameter of 6 μm. Thereafter, it was lapped by using diamond abrasive grains of 3 μm in the average grain diameter. The center line average surface height Ra of the lapped surface was measured to be 0.080 μm by a surface roughness meter.
The electrostatic chuck was dipped into deionized water inside a Class 1000 clean room, and subjected to ultrasonic cleaning at a frequency of 730 kHz, an ultrasonic output of 3.7 W/cm 2 , and a temperature of 25° C. for 5 minutes. Next, the electrostatic chuck was dried with hot air at 130° C. in a clean oven, and then cooled.
A mirror finished surface of a silicon wafer was attracted onto the attracting surface of the electrostatic chuck at 200° C. in air, and the attracted state of the wafer to the electrostatic chuck was released. The number of particles, 0.2 μm or more in diameter, adhering to the mirror finished surface of the silicon wafer was measured by a light-scattering type particle counter. As a result, the number of the particles attached was 94,400. FIG. 5 is a distribution diagram showing particle distribution measured by the light-scattering type particle counter.
Furthermore, the elemental analysis was made with respect to the particles on the silicon wafer by means of an energy dispersing type spectral analyzer. FIG. 1 shows the analysis result. A scanning electron microscopic photograph of the ceramic tissue of the attracting surface of the electrostatic chuck is shown in FIG. 3. As can be seen from FIG. 3, aluminum nitride particles were separated from the attracting surface. This indicates that the working of the attracting surface is a brittle working involving the separation of aluminum nitride particles.
COMPARISOM EXAMPLE 2
As in the case of Comparison Example 1, an attracting surface of a electrostatic chuck was lapped. Likewise, the attracting surface of the chuck was brushed for 5 minutes in deionized water by using a roll brush made of polyurethane resin inside the Class 1000 clean room. Thereafter, the electrostatic chuck was dried with hot air at 130° C. in the clean oven, and cooled.
With respect to the electrostatic chuck, the number of particles attached to a mirror finished surface of a silicon wafer was measured as in the case of Comparison Example 1. The measurement result was 80,400. The elemental analysis for the particles on the silicon wafer and the ceramic tissue on the attracting surface were similar to those of Comparison Example 1.
COMPARISOM EXAMPLE 3
After manufacturing an electrostatic chuck as described above, the electrostatic chuck was placed on the copper board (trade name: Hyprez copper manufactured by Japan Engis, Co., Ltd.) and lapped with diamond abrasive grains having the average grain diameter of 6 μm. The electrostatic chuck was further lapped with diamond abrasive grains having the average grain diameter of 3 μm. Thereafter, the resulting electrostatic chuck was then placed on a pure tin board and lapped with diamond abrasive grains having the average grain diameter of 0.5 μm. The Ra of the lapped surface was 0.008 μm.
The electrostatic chuck was dipped into deionized water in the Class 1000 clean room, and ultrasonically cleaned at a frequency of 730 kHz, an ultrasonic output of 7 W/cm 2 and a temperature of 25° C. for 5 minutes. Next, the electrostatic chuck was dried with hot air at 130° C. in the clean oven, and then cooled.
With respect to the electrostatic chuck, the number of particles adhering to a mirror finished surface of a silicon wafer was measured as in the case of Comparison Example 1. The number of the particles attached was 24,900. The result of the elemental analysis for the particles on the silicon wafer was the same as that of Comparison Example 1.
COMPARISOM EXAMPLE 4
An electrostatic chuck was manufactured as described above, which had a worked surface with the center line average height Ra=0.008 was obtained. The attracting surface of the chuck was brushed in deionized water for 5 minutes with a roll brush of polyurethane resin inside the Class 1000 clean room. Thereafter, the electrostatic chuck was dried with hot air at 130° C. in the clean oven, and then cooled.
With respect to the electrostatic chuck, the number of particles attached to a mirror finished surface of a silicon wafer was measured as in the case of Comparison Example 1. The number of the particles attached was 19,500. The result of the elemental analysis for particles on the silicon wafer was the same as that of Comparison Example 1.
EXAMPLE 1
After manufacturing an electrostatic chuck as described above, the chuck was placed on the copper board (trade name: Hyprez copper manufactured by Japan Engis, Co., Ltd.) and lapped with diamond abrasive grains having the average particle diameter of 6 μm. The chuck was then lapped with diamond abrasive grains having the average particle diameter of 3 μm. Furthermore, the electrostatic chuck was placed on a pure tin board and lapped with diamond abrasive grains of 0.5 μm. The Ra of the lapped surface was 0.008 μm. The ductile worked surface of the chuck was subjected to image analysis, which revealed that no holes having diameters of 0.1 μm or more existed in a range of 50 μm×70 μm although observed at 100 visual fields.
The attracting surface of the electrostatic chuck was brushed with a roll brush of polyurethane resin in deionized water for 5 minutes inside the Class 1000 clean room. Thereafter, the electrostatic chuck was dipped into deionized water and to ultrasonically cleaned at a frequency of 730 kHz, an ultrasonic output of 3.7 W/cm 2 , a temperature of 25° C. for 5 minutes. The electrostatic chuck was then dried with hot air at 130° C. in a clean oven, and then cooled.
With respect to the electrostatic chuck, the number of particles attached to a mirror finished surface of a silicon wafer was measured as in the case of Comparison Example 1. The number of the particles attached was 720. As can be understood from this, according to the present invention, the number of particles attached to the mirror finished surface of the silicon wafer could be successfully reduced by about 99% from that of Comparison Example 1. FIG. 6 is a distribution diagram showing the particle distribution measured by the light-scattering type particle counter.
A scanning electron microscopic photograph of a ceramic tissue of the attracting surface of the electrostatic chuck is shown in FIG. 4. As is clear from FIG. 4, separation of aluminum nitride grains from the attracting surface was not observed and the ductile surface was seen. The diameters of small holes in the ductile surface were 0.07 μm or less. It is noted that the small holes are portions in the vicinity of bottom surfaces of holes at which aluminum nitride grains were separated prior to final lapping. The holes could be made smaller thanks to the final lapping.
EXAMPLE 2
Example 2 was the same as Example 1 except that the frequency was 28 kHz and the ultrasonic output was 0.8 W/cm 2 at the time in ultrasonic cleaning. As in the case of Example 1, holes having diameters greater than 0.1 μm did not exist. As a result, the number of particles attached to a mirror finished surface of a silicon wafer was 2,900. Moreover, a scanning electron microscopic photograph of a ceramic tissue of the attracting surface of the electrostatic chuck was the same as that of Example 1.
EXAMPLE 3
Example 3 was the same as Example 1 except that the temperature of deionized water was 80° C. at the time of ultrasonically cleaning. As a result, the number of particles attached to the mirror finished surface of the silicon wafer was 650.
EXAMPLE 4
Example 4 was the same as Example 1 except that an attracting surface of an electrostatic chuck was polished with a solution of cerium oxide abrasive grains having the average grain diameter of 1.8 μm in Aqueous Lubricant (trade name) manufactured by Nippon Engis Co. Ltd. The Ra of the attracting surface of the electrostatic chuck after polishing was 0.03 μm. The height difference among ceramic grains at the attracting surface was 0.3 μm or less. No small holes in the ductile worked surface were present. As a result, the number of particles attached to a mirror finished surface of a silicon wafer was 860.
As can be seen from the above description, the wafer attracting apparatus according to the present invention, which includes the ceramic substrate, can largely decrease the number of particles attaching to the back surface of the wafer after the wafer has been attracted onto the attracting surface of the substrate. | 4y
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/438,216 entitled “Nitrogen Reaction Sputtering Copper-Indium-Gallium for Solar Cells” and filed Jan. 31, 2011, which is herein incorporated by reference
FIELD OF THE INVENTION
[0002] The present invention relates in general to solar cells, and more particularly to copper-indium-gallium-nitride (CIGN) solar cells and a method for manufacturing CIGN solar cells.
BACKGROUND OF THE INVENTION
[0003] Solar cells have been developed as clean, renewable energy sources to meet growing demand. Currently, crystalline silicon solar cells (both single crystal and polycrystalline) are the dominant technologies in the market. Crystalline silicon solar cells must use a thick substrate (>100 um) of silicon to absorb the sunlight since it has an indirect band gap. Also, the absorption coefficient is low for crystalline silicon because of the indirect band gap. The use of a thick substrate also means that the crystalline silicon solar cells must use high quality material to provide long carrier lifetimes to allow the carriers to diffuse to the contacts. Therefore, crystalline silicon solar cell technologies lead to increased costs. Thin film solar cells based on amorphous silicon (a-Si), copper indium gallium (sulfide) selenide (CIGS), cadmium telluride (CdTe), and copper zinc tin (sulfide) selenide (CZTS), etc. provide an opportunity to increase the material utilization since only thin films (<10 um) are generally required. CdTe and CZTS films have band gaps of about 1.5 eV and therefore, are efficient absorbers for wavelengths shorter than about 800 nm. The absorption coefficient for CdTe is about 10 5 /cm and the absorption coefficient for CZTS is about 10 4 /cm. CIGS films have bandgaps in the range of 1.0 eV (CIS) to 1.65 eV (CGS) and are also efficient absorbers across the entire visible spectrum. The absorption coefficient for CIGS is about 10 5 /cm. Additionally, thin film solar cells can be fabricated at the module level, thus further decreasing the manufacturing costs. Furthermore, thin film solar cells may be fabricated on inexpensive substrates such as glass, plastics, and thin sheets of metal. Among the thin film solar cells, CIGS has demonstrated the best lab cell efficiency (close to 20%) and the best large area module efficiency (>12%).
[0004] The increasing demand for environmentally friendly, sustainable and renewable energy sources is driving the development of large area, thin film photovoltaic (TFPV) devices. With a long-term goal of providing a significant percentage of global energy demand, there is a concomitant need for Earth-abundant, high conversion efficiency materials for use in photovoltaic devices. A number of Earth abundant direct-bandgap semiconductor materials now seem to show evidence of the potential for both high efficiency and low cost in Very Large Scale (VLS) production (e.g. greater than 100 gigawatt (GW)), yet relatively little attention has been devoted to their development and characterization.
[0005] Among the TFPV technologies, CIGS and CdTe are the two that have reached volume production with greater than 10% stabilized module efficiencies. Solar cell production volume must increase tremendously in the coming decades to meet sharply growing energy needs. However, the supply of In, Ga and Te may impact annual production of CIGS and CdTe solar panels. Moreover, price increases and supply constraints in In and Ga could result from the aggregate demand for these materials used in flat panel displays (FPD) and light-emitting diodes (LED) along with CIGS TFPV. Also, there are concerns about the toxicity of Cd throughout the lifecycle of the CdTe TFPV solar modules. Efforts to develop devices that leverage manufacturing and R&D infrastructure related to TFPV using more widely available and more environmentally friendly raw materials should be considered a top priority for research.
[0006] The immaturity of TFPV devices exploiting Earth abundant materials represents a daunting challenge in terms of the time-to-commercialization. That same immaturity also suggests an enticing opportunity for breakthrough discoveries. A quaternary system such as CIGS or CZTS requires management of multiple kinetic pathways, thermodynamic phase equilibrium considerations, defect chemistries, and interfacial control. The vast phase-space to be managed includes process parameters, source material choices, compositions, and overall integration schemes. Traditional R&D methods are ill-equipped to address such complexity, and the traditionally slow pace of R&D could limit any new material from reaching industrial relevance when having to compete with the incrementally improving performance of already established TFPV fabrication lines.
[0007] However, due to the complexity of the material, cell structure and manufacturing process, both the fundamental scientific understanding and large scale manufacturability are yet to be improved for CIGS and CZTS solar cells. As the photovoltaic industry pushes to achieve grid parity, much faster and broader investigation is needed to explore the material, device, and process windows for higher efficiency and a lower cost of manufacturing process. Efficient methods for forming different types of CIGS and CZTS solar cells that can be evaluated are necessary.
[0008] The efficiency of TFPV solar cells depends on many properties of the absorber layer and the buffer layer such as crystallinity, grain size, composition uniformity, density, defect concentration, doping level, surface roughness, etc.
[0009] The manufacture of TFPV modules entails the integration and sequencing of many unit processing steps. As an example, TFPV manufacturing typically includes a series of processing steps such as cleaning, surface preparation, deposition, patterning, etching, thermal annealing, and other related unit processing steps. The precise sequencing and integration of the unit processing steps enables the formation of functional devices meeting desired performance metrics such as efficiency, power production, and reliability.
[0010] As part of the discovery, optimization and qualification of each unit process, it is desirable to be able to i) test different materials, ii) test different processing conditions within each unit process module, iii) test different sequencing and integration of processing modules within an integrated processing tool, iv) test different sequencing of processing tools in executing different process sequence integration flows, and combinations thereof in the manufacture of devices such as integrated circuits. In particular, there is a need to be able to test i) more than one material, ii) more than one processing condition, iii) more than one sequence of processing conditions, iv) more than one process sequence integration flow, and combinations thereof, collectively known as “combinatorial process sequence integration”, on a single monolithic substrate without the need of consuming the equivalent number of monolithic substrates per material(s), processing condition(s), sequence(s) of processing conditions, sequence(s) of processes, and combinations thereof. This can greatly improve both the speed and reduce the costs associated with the discovery, implementation, optimization, and qualification of material(s), process(es), and process integration sequence(s) required for manufacturing.
[0011] Systems and methods for High Productivity Combinatorial (HPC) processing are described in U.S. Pat. No. 7,544,574 filed on Feb. 10, 2006, U.S. Pat. No. 7,824,935 filed on Jul. 2, 2008, U.S. Pat. No. 7,871,928 filed on May 4, 2009, U.S. Pat. No. 7,902,063 filed on Feb. 10, 2006, and U.S. Pat. No. 7,947,531 filed on Aug. 28, 2009 which are all herein incorporated by reference. Systems and methods for HPC processing are further described in U.S. application Ser. No. 11/352,077 filed on Feb. 10, 2006, claiming priority from Oct. 15, 2005, U.S. application Ser. No. 11/419,174 filed on May 18, 2006, claiming priority from Oct. 15, 2005, U.S. application Ser. No. 11/674,132 filed on Feb. 12, 2007, claiming priority from Oct. 15, 2005, and U.S. application Ser. No. 11/674,137 filed on Feb. 12, 2007, claiming priority from Oct. 15, 2005 which are all herein incorporated by reference.
[0012] HPC processing techniques have been successfully adapted to wet chemical processing such as etching and cleaning. HPC processing techniques have also been successfully adapted to deposition processes such as physical vapor deposition (PVD), atomic layer deposition (ALD), and chemical vapor deposition (CVD).
[0013] The manufacturing of solar cells, such as CIGS solar cells, often involves the use of toxic materials, such as those used in selenization processes. The handling and removal of the materials related to selenization processes significantly affects the manufacturing costs of such solar cells. Additionally, the use of selenization typically results in the cells being sensitive to exposure to the atmosphere, which is often the case between various manufacturing steps (i.e., “queue time”). Further, there is a need to improve the adhesion between the CIGS layers and the molybdenum back contact layer.
SUMMARY OF THE DISCLOSURE
[0014] In some embodiments of the present invention, reactive sputtering is used to form Cu—In—Ga—N (CIGN) materials to be used as the absorber layer in thin film solar panels. This material can be used with or without a selenization process typically used to form CIGS materials. In some embodiments, a nitridation process is implemented before the formation of CIGN or CIGS materials. In some embodiments, a nitridation process is implemented after the formation of CIGN or CIGS materials. In some embodiments, a nitridation process is implemented during the formation of CIGN or CIGS materials.
[0015] In some embodiments, a nitrogen reactive sputtering process is used in place of a selenization process. One advantage of such a method is that the nitrogen reactive sputtering process may be less toxic than the selenization process, while still allowing a band gap of between 0.7 electron-volts (eV) and 1.7 eV, which is suitable for solar cells.
[0016] In some embodiments, a Cu—In—Ga—N protective nitride layer is formed over CIG layers (i.e., after the formation of the CIG layers) before the CIG layers are exposed to the atmosphere. One advantage of such embodiments is that the nitride layer may protect the CIG layers from oxygen and water vapor, which may reduce any adverse effects from such exposure during “queue” time (i.e., before subsequent processing steps).
[0017] In some embodiments, a nitridation process is performed before the formation of the CIG layers on a Mo back contact layer. One advantage of such embodiments is that the adhesion between the CIG layers and the Mo layer may be improved.
[0018] A further advantage of some embodiments described herein is that manufacturing costs may be reduced, as the removal of the selenization may eliminate some of the costs incurred to remove toxic materials used in solar cell processing. Additionally, product quality may be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The drawings are not to scale and the relative dimensions of various elements in the drawings are depicted schematically and not necessarily to scale.
[0020] The techniques of the present invention can readily be understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
[0021] FIG. 1 is a schematic diagram for implementing combinatorial processing and evaluation.
[0022] FIG. 2 is a schematic diagram for illustrating various process sequences using combinatorial processing and evaluation.
[0023] FIGS. 3A and 3B illustrate schematic diagrams of a simple CIGS TFPV stack according to some embodiments described herein.
[0024] FIG. 4 illustrates a schematic diagram of a combinatorial PVD system according to an embodiment described herein.
[0025] FIG. 5 illustrates a schematic diagram of a substrate that has been processed in a combinatorial manner.
[0026] FIGS. 6A-6C illustrate schematic diagrams of a simple TFPV stack according to some embodiments described herein.
[0027] FIGS. 7A-7C illustrate schematic diagrams of a simple TFPV stack according to some embodiments described herein.
[0028] FIGS. 8A-8C illustrate schematic diagrams of a simple TFPV stack according to some embodiments described herein.
[0029] FIGS. 9A-9C illustrate schematic diagrams of a simple TFPV stack according to some embodiments described herein.
[0030] FIGS. 10A-10B present data for the refractive index, n, and extinction coefficient, k, for Cu—In—Ga films at 633 nm.
[0031] FIGS. 11A-110 present data for the band gap, refractive index, n, and extinction coefficient, k, for Cu—In—Ga—N films at 633 nm.
DETAILED DESCRIPTION
[0032] A detailed description of one or more embodiments is provided below along with accompanying figures. The detailed description is provided in connection with such embodiments, but is not limited to any particular example. The scope is limited only by the claims and numerous alternatives, modifications, and equivalents are encompassed. Numerous specific details are set forth in the following description in order to provide a thorough understanding. These details are provided for the purpose of example and the described techniques may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the embodiments has not been described in detail to avoid unnecessarily obscuring the description.
[0033] As used herein, “CIGS” will be understood to represent the entire range of related alloys denoted by Cu(In x Ga 1-x )(S y Se 2-y ) where 0≦x≦1 and 0≦y≦2. As used herein, “CZTS” will be understood to represent the entire range of related alloys denoted by Cu 2 ZnSn(S y Se 1-y ) 4 where 0≦y≦1.
[0034] In FIGS. 3 and 6 - 9 below, a TFPV material stack is illustrated using a simple planar structure. Those skilled in the art will appreciate that the description and teachings to follow can be readily applied to any simple or complex TFPV solar cell morphology. The drawings are for illustrative purposes only and do not limit the application of the present invention.
[0035] FIG. 1 illustrates a schematic diagram, 100 , for implementing combinatorial processing and evaluation using primary, secondary, and tertiary screening. The schematic diagram, 100 , illustrates that the relative number of combinatorial processes run with a group of substrates decreases as certain materials and/or processes are selected. Generally, combinatorial processing includes performing a large number of processes during a primary screen, selecting promising candidates from those processes, performing the selected processing during a secondary screen, selecting promising candidates from the secondary screen for a tertiary screen, and so on. In addition, feedback from later stages to earlier stages can be used to refine the success criteria and provide better screening results.
[0036] For example, thousands of materials are evaluated during a materials discovery stage, 102 . Materials discovery stage, 102 , is also known as a primary screening stage performed using primary screening techniques. Primary screening techniques may include dividing substrates into coupons and depositing materials using varied processes. The materials are then evaluated, and promising candidates are advanced to the secondary screen, or materials and process development stage, 104 . Evaluation of the materials is performed using metrology tools such as electronic testers and imaging tools (i.e., microscopes).
[0037] The materials and process development stage, 104 , may evaluate hundreds of materials (i.e., a magnitude smaller than the primary stage) and may focus on the processes used to deposit or develop those materials. Promising materials and processes are again selected, and advanced to the tertiary screen or process integration stage, 106 , where tens of materials and/or processes and combinations are evaluated. The tertiary screen or process integration stage, 106 , may focus on integrating the selected processes and materials with other processes and materials.
[0038] The most promising materials and processes from the tertiary screen are advanced to device qualification, 108 . In device qualification, the materials and processes selected are evaluated for high volume manufacturing, which normally is conducted on full substrates within production tools, but need not be conducted in such a manner. The results are evaluated to determine the efficacy of the selected materials and processes. If successful, the use of the screened materials and processes can proceed to pilot manufacturing, 110 .
[0039] The schematic diagram, 100 , is an example of various techniques that may be used to evaluate and select materials and processes for the development of new materials and processes. The descriptions of primary, secondary, etc. screening and the various stages, 102 - 110 , are arbitrary and the stages may overlap, occur out of sequence, be described and be performed in many other ways.
[0040] This application benefits from High Productivity Combinatorial (HPC) techniques described in U.S. patent application Ser. No. 11/674,137 filed on Feb. 12, 2007 which is hereby incorporated for reference in its entirety. Portions of the '137 application have been reproduced below to enhance the understanding of the present invention. The embodiments described herein enable the application of combinatorial techniques to process sequence integration in order to arrive at a globally optimal sequence of TFPV manufacturing operations by considering interaction effects between the unit manufacturing operations, the process conditions used to effect such unit manufacturing operations, hardware details used during the processing, as well as materials characteristics of components utilized within the unit manufacturing operations. Rather than only considering a series of local optimums, i.e., where the best conditions and materials for each manufacturing unit operation is considered in isolation, the embodiments described below consider interactions effects introduced due to the multitude of processing operations that are performed and the order in which such multitude of processing operations are performed when fabricating a TFPV device. A global optimum sequence order is therefore derived and as part of this derivation, the unit processes, unit process parameters and materials used in the unit process operations of the optimum sequence order are also considered.
[0041] The embodiments described further analyze a portion or sub-set of the overall process sequence used to manufacture a TFPV device. Once the subset of the process sequence is identified for analysis, combinatorial process sequence integration testing is performed to optimize the materials, unit processes, hardware details, and process sequence used to build that portion of the device or structure. During the processing of some embodiments described herein, structures are formed on the processed substrate that are equivalent to the structures formed during actual production of the TFPV device. For example, such structures may include, but would not be limited to, contact layers, buffer layers, absorber layers, or any other series of layers or unit processes that create an intermediate structure found on TFPV devices. While the combinatorial processing varies certain materials, unit processes, hardware details, or process sequences, the composition or thickness of the layers or structures or the action of the unit process, such as cleaning, surface preparation, deposition, surface treatment, etc. is substantially uniform through each discrete region. Furthermore, while different materials or unit processes may be used for corresponding layers or steps in the formation of a structure in different regions of the substrate during the combinatorial processing, the application of each layer or use of a given unit process is substantially consistent or uniform throughout the different regions in which it is intentionally applied. Thus, the processing is uniform within a region (inter-region uniformity) and between regions (intra-region uniformity), as desired. It should be noted that the process can be varied between regions, for example, where a thickness of a layer is varied or a material may be varied between the regions, etc., as desired by the design of the experiment.
[0042] The result is a series of regions on the substrate that contain structures or unit process sequences that have been uniformly applied within that region and, as applicable, across different regions. This process uniformity allows comparison of the properties within and across the different regions such that the variations in test results are due to the varied parameter (e.g., materials, unit processes, unit process parameters, hardware details, or process sequences) and not the lack of process uniformity. In the embodiments described herein, the positions of the discrete regions on the substrate can be defined as needed, but are preferably systematized for ease of tooling and design of experimentation. In addition, the number, variants and location of structures within each region are designed to enable valid statistical analysis of the test results within each region and across regions to be performed.
[0043] FIG. 2 is a simplified schematic diagram illustrating a general methodology for combinatorial process sequence integration that includes site isolated processing and/or conventional processing in accordance with one embodiment of the invention. In one embodiment, the substrate is initially processed using conventional process N. In one exemplary embodiment, the substrate is then processed using site isolated process N+1. During site isolated processing, an HPC module may be used, such as the HPC module described in U.S. patent application Ser. No. 11/352,077 filed on Feb. 10, 2006. The substrate can then be processed using site isolated process N+2, and thereafter processed using conventional process N+3. Testing is performed and the results are evaluated. The testing can include physical, chemical, acoustic, magnetic, electrical, optical, etc. tests. From this evaluation, a particular process from the various site isolated processes (e.g. from steps N+1 and N+2) may be selected and fixed so that additional combinatorial process sequence integration may be performed using site isolated processing for either process N or N+3. For example, a next process sequence can include processing the substrate using site isolated process N, conventional processing for processes N+1, N+2, and N+3, with testing performed thereafter.
[0044] It should be appreciated that various other combinations of conventional and combinatorial processes can be included in the processing sequence with regard to FIG. 2 . That is, the combinatorial process sequence integration can be applied to any desired segments and/or portions of an overall process flow. Characterization, including physical, chemical, acoustic, magnetic, electrical, optical, etc. testing, can be performed after each process operation, and/or series of process operations within the process flow as desired. The feedback provided by the testing is used to select certain materials, processes, process conditions, and process sequences and eliminate others. Furthermore, the above flows can be applied to entire monolithic substrates, or portions of monolithic substrates such as coupons.
[0045] Under combinatorial processing operations the processing conditions at different regions can be controlled independently. Consequently, process material amounts, reactant species, processing temperatures, processing times, processing pressures, processing flow rates, processing powers, processing reagent compositions, the rates at which the reactions are quenched, deposition order of process materials, process sequence steps, hardware details, etc., can be varied from region to region on the substrate. Thus, for example, when exploring materials, a processing material delivered to a first and second region can be the same or different. If the processing material delivered to the first region is the same as the processing material delivered to the second region, this processing material can be offered to the first and second regions on the substrate at different concentrations. In addition, the material can be deposited under different processing parameters. Parameters which can be varied include, but are not limited to, process material amounts, reactant species, processing temperatures, processing times, processing pressures, processing flow rates, processing powers, processing reagent compositions, the rates at which the reactions are quenched, atmospheres in which the processes are conducted, an order in which materials are deposited, hardware details of the gas distribution assembly, etc. It should be appreciated that these process parameters are exemplary and not meant to be an exhaustive list as other process parameters commonly used in TFPV manufacturing may be varied.
[0046] As mentioned above, within a region, the process conditions are substantially uniform, in contrast to gradient processing techniques which rely on the inherent non-uniformity of the material deposition. That is, the embodiments, described herein locally perform the processing in a conventional manner, e.g., substantially consistent and substantially uniform, while globally over the substrate, the materials, processes, and process sequences may vary. Thus, the testing will find optimums without interference from process variation differences between processes that are meant to be the same. It should be appreciated that a region may be adjacent to another region in one embodiment or the regions may be isolated and, therefore, non-overlapping. When the regions are adjacent, there may be a slight overlap wherein the materials or precise process interactions are not known, however, a portion of the regions, normally at least 50% or more of the area, is uniform and all testing occurs within that region. Further, the potential overlap is only allowed with material of processes that will not adversely affect the result of the tests. Both types of regions are referred to herein as regions or discrete regions.
[0047] FIGS. 3A and 3B illustrate a simple CIGS TFPV material stack consistent with some embodiments of the present invention. The convention will be used wherein light is assumed to be incident upon the top of the material stack. A back contact layer, 304 , (typically Mo) is formed above a substrate, 302 , (typically soda lime glass (SLG)). The back contact layer is typically between about 0.2 um and 1.0 um in thickness. The back contact layer is typically formed using a physical vapor deposition (PVD) process but may also be formed using an evaporation process. A CIGS absorber layer, 306 , is formed above the back contact layer. The absorber layer is typically between about 0.5 um and 3.0 um in thickness. The absorber layer may be formed using a variety of techniques such as PVD, co-evaporation, printing or spraying of inks, CVD, etc. The different shading of the absorber layer, 306 , in FIG. 3B is an indication that development activities on this layer can be accomplished using HPC techniques as will be discussed below. Advantageously, the absorber layer is deficient in Cu. The Cu deficiency may be controlled by managing the deposition conditions. Advantageously, a small amount of Na is contained in the absorber layer. The Na may be added by out-diffusion from the SLG substrate or may be purposely added in the form of Na 2 Se after the deposition of the absorber layer. Optionally, the absorber layer undergoes a selenization process after formation to fill the Se vacancies within the matrix. The selenization process involves the exposure of the absorber layer to H 2 Se, Se vapor, or diethylselenide (DESe) at temperatures between about 400C and 600C as shown in FIG. 3B . During the selenization process, a layer of MoSe 2 forms at the back contact/absorber layer interface and forms a good ohmic contact between the two layers. A buffer layer, 308 , (typically CdS) is then formed above the absorber layer. The buffer layer is typically between about 30 nm and 80 nm in thickness. The buffer layer is typically formed using a chemical bath deposition (CBD) technique or by PVD. Optionally, an intrinsic ZnO (iZnO) layer, 310 , is then formed above the buffer layer. The iZnO layer is a high resistivity material and forms part of the transparent conductive oxide (TCO) stack that serves as part of the front contact structure. The TCO stack is formed from transparent conductive metal oxide materials and collects charge across the face of the TFPV solar cell and conducts the charge to the opaque metal grids used to connect the solar cell to external loads. The iZnO layer makes the TFPV solar cell less sensitive to lateral non-uniformities caused by differences in composition or defect concentration in the absorber and/or buffer layers. The iZnO layer is typically between about 30 nm and 80 nm in thickness. The iZnO layer is typically formed using a reactive PVD technique or CVD technique. A low resistivity top TCO layer, 312 , (examples include Al:ZnO (AZO), InSnO (ITO), InZnO, B:ZnO, Ga:ZnO, F:ZnO, F:SnO 2 , etc.) is formed above the iZnO layer. The top TCO layer is typically between about 0.3 um and 2.0 um in thickness. The top TCO layer is typically formed using a reactive PVD technique or CVD technique. An opaque metal grid, 314 , (typically Al or Ni:Al) is formed on top to collect the current and make connections to the balance of the system. The metal grid is typically between about 0.5 um and 2.0 um in thickness.
[0048] FIG. 4 illustrates a schematic diagram of a combinatorial PVD system according to an embodiment described herein. Details of the combinatorial PVD system are described in U.S. patent application Ser. No. 12/027,980 filed on Feb. 7, 2008 and claiming priority to Sep. 5, 2007 and U.S. patent application Ser. No. 12/028,643 filed on Feb. 8, 2008 and claiming priority to Sep. 5, 2007.Substrate, 400 , is held on substrate support, 402 . Substrate support, 402 , has two axes of rotation, 404 and 406 . The two axes of rotation are not aligned. This feature allows different regions of the substrate to be accessed for processing. The substrate support may be moved in a vertical direction to alter the spacing between the PVD targets and the substrate. The combinatorial PVD system comprises multiple PVD assemblies configured within a PVD chamber (not shown). In FIG. 4 , three PVD assemblies are shown, 408 a - 408 c. Those skilled in the art will appreciate that any number of PVD assemblies may be used, limited only by the size of the chamber and the size of the PVD assemblies. Typically, four PVD assemblies are contained within the chamber. Advantageously, the multiple PVD assemblies contain different target materials to allow a wide range of material and alloys compositions to be investigated. Additionally, the combinatorial PVD system will typically include the capability for reactive sputtering in reactive gases such as O 2 , NH 3 , N 2 , etc. The PVD assemblies may be moved in a vertical direction to alter the spacing between the PVD targets and the substrate and may be tilted to alter the angle of incidence of the sputtered material arriving at the substrate surface. The combinatorial PVD system further comprises a process kit shield assembly, 410 . The process kit shield assembly includes an aperture, 412 , used to define isolated regions on the surface. The portion of the process kit shield assembly that includes the aperture may have both rotational and translational capabilities. The combination of the substrate support movement, PVD assembly movement, and process kit shield assembly aperture movement allows multiple regions of the substrate to be processed in a site isolated manner wherein each site can be processed without interference from adjacent regions. Advantageously, the process parameters among the multiple site isolated regions can be varied in a combinatorial manner.
[0049] FIG. 5 illustrates a schematic diagram of a substrate that has been processed in a combinatorial manner. Although the substrate in FIG. 5 is illustrated as being a generally square shape, those skilled in the art will understand that the substrate may be any useful shape such as round, rectangular, etc. FIG. 5 illustrates a substrate, 500 , with nine site isolated regions, 502 a - 502 i , illustrated thereon. The lower portion of FIG. 5 illustrates a top down view while the upper portion of FIG. 5 illustrates a cross-sectional view taken through the three site isolated regions, 502 g - 502 i. The shading of the nine site isolated regions illustrates that the process parameters used to process these regions have been varied in a combinatorial manner. The substrate may then be processed through a next step that may be conventional or may also be a combinatorial step as discussed earlier with respect to FIG. 2 .
[0050] FIGS. 6A-6C illustrate a simple CIGS TFPV material stack consistent with some embodiments of the present invention. The convention will be used wherein light is assumed to be incident upon the top of the material stack. FIG. 6A illustrates the basic TFPV stack as described in the discussion of FIGS. 3A and 3B . Referring to FIG. 6B , a back contact layer, 604 , (typically Mo) is formed above a substrate, 602 , (typically soda lime glass (SLG)). The back contact layer is typically between about 0.2 um and 1.0 um in thickness. The back contact layer is typically formed using a physical vapor deposition (PVD) process but may also be formed using an evaporation process. A CIG(N) absorber layer, 606 , is formed above the back contact layer. The absorber layer is typically between about 0.5 um and 3.0 um in thickness. The absorber layer may be formed using a variety of techniques such as PVD, co-evaporation, printing or spraying of inks, CVD, etc. The different shading of the absorber layer, 606 , in FIG. 6B is an indication that development activities on this layer can be accomplished using HPC techniques as discussed previously.
[0051] In some embodiments of the present invention, a nitrogen containing gas such as N 2 or NH 3 is used during the PVD deposition of the Cu—In—Ga material. Thus, the CIG layer(s) is infused with nitrogen to form a CIGN absorber layer. The performance of the CIGN absorber layer will depend upon composition, structure, grain size, grain orientation, surface roughness, etc. These parameters can be affected by varying deposition conditions such as PVD source power, pressure, nitrogen containing gas flow, PVD source to substrate distance, substrate temperature, etc. The composition and deposition conditions can be varied in a combinatorial manner to develop CIGN absorber films with increased performance. One of the benefits of developing a high performance CIGN absorber film is that it eliminates the need for the selenization step as indicated in FIG. 6B . This benefit lowers the cost of the TFPV solar panel manufactured using CIGN and reduces the toxicity and hazards of the manufacturing process. The substrate/back contact/absorber stack portion of the final TFPV solar panel is indicated in FIG. 6C wherein there is no Se component.
[0052] FIGS. 7A-7C illustrate a simple CIGS TFPV material stack consistent with some embodiments of the present invention. The convention will be used wherein light is assumed to be incident upon the top of the material stack. FIG. 7A illustrates the basic TFPV stack as described in the discussion of FIGS. 3A and 3B . Referring to FIG. 7B , a back contact layer, 704 , (typically Mo) is formed above a substrate, 702 , (typically soda lime glass (SLG)). The back contact layer is typically between about 0.2 um and 1.0 um in thickness. The back contact layer is typically formed using a physical vapor deposition (PVD) process but may also be formed using an evaporation process. A CIG absorber layer, 706 , is formed above the back contact layer. The absorber layer is typically between about 0.5 um and 3.0 um in thickness. The absorber layer may be formed using a variety of techniques such as PVD, co-evaporation, printing or spraying of inks, CVD, etc. The different shading of the absorber layer, 706 , in FIG. 7B is an indication that development activities on this layer can be accomplished using HPC techniques as discussed previously.
[0053] As mentioned previously, the CIG layers are sensitive to exposure to oxygen or water vapor between the end of the deposition step and the selenization step. In some embodiments of the present invention, a nitrogen containing gas such as N 2 or NH 3 is used at the end of the PVD deposition of the Cu—In—Ga material to form a protective CIGN layer, 716 . Thus, the surface of the CIG layer(s) is infused with nitrogen to form a CIGN layer at the surface. Therefore, the CIGN layer will protect the underlying CIG layers from degradation due to oxygen or water vapor exposure while the substrate is waiting for the selenization step. The thickness of the CIGN protective layer is about 10 nm. The performance of the CIGN protective layer will depend upon composition, structure, grain size, grain orientation, surface roughness, etc. These parameters can be affected by varying deposition conditions such as PVD source power, pressure, nitrogen containing gas flow, PVD source to substrate distance, substrate temperature, etc. The deposition conditions can be varied in a combinatorial manner to develop CIGN protective layers with increased performance. The substrate/back contact/absorber stack portion of the final TFPV solar panel is indicated in FIG. 7C .
[0054] FIGS. 8A-8C illustrate a simple CIGS TFPV material stack consistent with some embodiments of the present invention. The convention will be used wherein light is assumed to be incident upon the top of the material stack. FIG. 8A illustrates the basic TFPV stack as described in the discussion of FIGS. 3A and 3B . Referring to FIG. 8B , a back contact layer, 804 , (typically Mo) is formed above a substrate, 802 , (typically soda lime glass (SLG)). The back contact layer is typically between about 0.2 um and 1.0 um in thickness. The back contact layer is typically formed using a physical vapor deposition (PVD) process but may also be formed using an evaporation process. A CIGN layer, 816 , is deposited above the back contact prior to the deposition of the non-nitrided CIG absorber layer. A CIG absorber layer, 806 , is formed above the CIGN layer. The absorber layer is typically between about 0.5 um and 3.0 um in thickness. The absorber layer may be formed using a variety of techniques such as PVD, co-evaporation, printing or spraying of inks, CVD, etc. The different shading of the absorber layer, 806 , in FIG. 8B is an indication that development activities on this layer can be accomplished using HPC techniques as discussed previously.
[0055] It is desirable for the CIG layers to have good adhesion to the back contact layer. The adhesion at this interface can be improved by depositing a thin layer of CIGN between the back contact layer and the bulk of the CIG absorber layer. In some embodiments of the present invention, a nitrogen containing gas such as N 2 or NH 3 is used at the beginning of the PVD deposition of the Cu—In—Ga material to form a CIGN adhesion layer, 816 . Thus, the surface of the CIG layer(s) is infused with nitrogen to form a CIGN layer at the initial interface. The flow of the nitrogen containing gas would then be stopped and the remaining portion of the CIG absorber layer deposited without nitrogen. The thickness of the CIGN adhesion layer is about 10 nm. The performance of the CIGN adhesion layer will depend upon composition, structure, grain size, grain orientation, surface roughness, etc. These parameters can be affected by varying deposition conditions such as PVD source power, pressure, nitrogen containing gas flow, PVD source to substrate distance, substrate temperature, etc. The deposition conditions can be varied in a combinatorial manner to develop CIGN adhesion layers with increased performance. The substrate/back contact/absorber stack portion of the final TFPV solar panel is indicated in FIG. 8C .
[0056] FIGS. 9A-9C illustrate a simple CIGS TFPV material stack consistent with some embodiments of the present invention. The convention will be used wherein light is assumed to be incident upon the top of the material stack. FIG. 9A illustrates the basic TFPV stack as described in the discussion of FIGS. 3A and 3B . Referring to FIG. 9B , a back contact layer, 904 , (typically Mo) is formed above a substrate, 902 , (typically soda lime glass (SLG)). The back contact layer is typically between about 0.2 um and 1.0 um in thickness. The back contact layer is typically formed using a physical vapor deposition (PVD) process but may also be formed using an evaporation process. A CIGN adhesion layer, 916 , is deposited above the back contact prior to the deposition of the non-nitrided CIG absorber layer as discussed with respect to FIGS. 8A-8C . A CIG absorber layer, 906 , is formed above the CIGN layer. The absorber layer is typically between about 0.5 um and 3.0 um in thickness. The absorber layer may be formed using a variety of techniques such as PVD, co-evaporation, printing or spraying of inks, CVD, etc. The different shading of the absorber layer, 906 , in FIG. 9B is an indication that development activities on this layer can be accomplished using HPC techniques as discussed previously.
[0057] As mentioned previously, the CIG layers are sensitive to exposure to oxygen or water vapor between the end of the deposition step and the selenization step. In some embodiments of the present invention, a nitrogen containing gas such as N 2 or NH 3 is used at the end of the PVD deposition of the Cu—In—Ga material to form a protective CIGN layer, 918 as discussed with respect to FIGS. 7A-7C . Thus, the surface of the CIG layer(s) is infused with nitrogen to form a CIGN layer at the surface. Therefore, the CIGN layer will protect the underlying CIG layers from degradation due to oxygen or water vapor exposure while the substrate is waiting for the selenization step. The thickness of the CIGN protective layer is about 10 nm.
[0058] The performance of the CIGN adhesion layer and the CIGN protective layer will depend upon composition, structure, grain size, grain orientation, surface roughness, etc. These parameters can be affected by varying deposition conditions such as PVD source power, pressure, nitrogen containing gas flow, PVD source to substrate distance, substrate temperature, etc. The deposition conditions can be varied in a combinatorial manner to develop CIGN adhesion layers with increased performance. The deposition conditions may be different for the two different types of CIGN layers. The substrate/back contact/absorber stack portion of the final TFPV solar panel is indicated in FIG. 9C .
[0059] FIGS. 10A-10B present data for the refractive index, n, and extinction coefficient, k, for Cu—In—Ga films at 633 nm. FIG. 10A presents data for the refractive index, n, of a range of Cu x —In—Ga y ternary alloys measured at 633 nm. The refractive index for the pure metallic system is low and ranges from about 0 to about 1. FIG. 10B presents data for the extinction coefficient, k, of a range of Cu x —In—Ga y ternary alloys measured at 633 nm. The extinction coefficient for the pure metallic system is high and ranges from about 3 to about 6. The samples may be formed by varying composition, pressure, power, target to substrate spacing, etc. These process parameters may be varied in a combinatorial manner as discussed previously.
[0060] FIGS. 11A-11D presents data for the band gap, refractive index, n, and extinction coefficient, k, for Cu x —In—Ga y —N films at 633 nm. FIG. 11A illustrates the range of compositions used to generate the data presented in FIGS. 11B-11D . FIG. 11B indicates that the band gap is dependent on the composition, x,y, and varies between about 0.6 eV and about 1.6 eV. FIG. 11C indicates the refractive index for the nitrided system is higher than that for the metallic system and ranges from about 2 to about 3. FIG. 11D indicates the extinction coefficient for the nitrided system is lower than that for the metallic system and ranges from about 0 to about 2. The samples may be formed by varying composition, Ar/N-species ratio, pressure, power, target to substrate spacing, etc. These process parameters may be varied in a combinatorial manner as discussed previously.
[0061] Although the foregoing examples have been described in some detail for purposes of clarity of understanding, the invention is not limited to the details provided. There are many alternative ways of implementing the invention. The disclosed examples are illustrative and not restrictive. | 4y
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CROSS REFERENCE TO RELATED APPLICATION
This application is based on and claims priority to United States Provisional Patent Application No. 60/049,356, filed Jun. 11, 1997, entitled SINGLE ENDED FORWARD CONVERTER WITH SYNCHRONOUS RECTIFICATION AND RELAY CIRCUIT IN PHASE-LOCKED LOOP.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a synchronizing and driving circuit for a forward converter employing a synchronous rectifier and, more particularly, to a driving circuit utilizing a phase-locked loop to control the switch timing of the synchronous rectifiers.
2. Related Art
In known forward switching power supply circuits employing synchronous rectifiers, the secondary side diodes are replaced by transistors to obtain a lower on-state voltage drop. The transistors must be biased to conduct from source to drain (for an N-channel power MOSFET) when a diode would have been conducting from anode to cathode, and conversely, must be gated to block voltage from drain to source when a diode would have been blocking from cathode to anode.
The timing of turn on/off of the transistors is critical and may become problematic because practical transistors (such as MOSFETs, IGBTs, and the like) exhibit non-zero switching times. While such transistors are turning on and/or off, the current is diverted through parallel or integral diodes, which diodes are more lossy than certain power transistors and, therefore, reduce overall converter efficiency. This problem is exacerbated when the switching frequency is increased and the transistor switching times become a larger part of the overall switching period.
With reference to FIG. 1, a known apparatus for producing the signals for gating on and off the transistors in a synchronous rectifier is shown. In FIG. 1, the synchronous rectifier transistors, Q1 and Q2, are MOSFETs which include anti-parallel diodes thereacross. As is known in the art, Q1 and Q2 are coupled to the secondary winding of a transformer, XFRMR, which drives an output LC circuit. The transistors Q1 and Q2 are connected as so-called cross-coupled switches (i.e., the gates are connected to opposite sides of the XFRMR secondary winding).
FIG. 2 shows an alternative known apparatus for gating the transistors Q1 and Q2, which transistors are connected as so-called two terminal switches. In this arrangement, each power MOSFET, Q1 and Q2, is coupled to a gate circuit, CKT1 and CKT2, respectively, which detects the voltage across the transistor and gates the transistor accordingly.
Other methods of producing the gating signals for the synchronous rectifiers include stand alone linear circuits to sense changes in transformer output voltage and, as described in related U.S. Pat. No. 5,818,704 filed on Apr. 17, 1997 and assigned to the International Rectifier Corporation, circuits which sense inductor signals to produce the gating signals.
The circuits of FIGS. 1 and 2 and the stand alone circuits to sense changes in transformer output voltage suffer from the disadvantage that transformer delays (due to leakage inductance), noise (due to transformer resetting) and limits on device switching times reduce the precision in switching the synchronous rectifiers and, therefore, reduce converter efficiency.
Accordingly, there is a need in the art for a new method and apparatus for producing the gating signals for the synchronous rectifiers in a power converter which does not exhibit the deficiencies as the prior art.
SUMMARY OF THE INVENTION
In order to overcome the disadvantages of the prior art, the power converter of the present invention includes a switching transformer having a primary winding and a secondary winding, the secondary winding having first and second voltage nodes across which a winding voltage having a variable duty cycle and phase is impressed; a first synchronous rectifier transistor coupled from the first voltage node to a common node; a second synchronous rectifier transistor coupled from the second voltage node to the common node; and a driver circuit operable to receive the winding voltage and produce first and second drive signals to the first and second synchronous rectifier transistors, respectively, the first and second drive signals leading the phase of the winding voltage.
Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawing forms which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a schematic diagram of a prior art power converter employing a synchronous rectifier circuit;
FIG. 2 is a schematic diagram of another prior art power converter employing a synchronous rectifier circuit;
FIG. 3 is a schematic diagram of a power converter employing a synchronous rectifier circuit in accordance with one aspect of the present invention;
FIG. 4 is a detailed schematic diagram of the gate driving circuit of the power converter of FIG. 3;
FIG. 5 is a schematic diagram of the duty cycle rate change detector of the gate driving circuit of FIG. 4;
FIG. 6 is a timing diagram showing certain signals of the duty cycle rate change detector of FIG. 5;
FIG. 7 is a schematic diagram of a power converter employing a synchronous rectifier circuit in accordance with another aspect of the present invention;
FIG. 8 is a schematic diagram of a power converter employing an alternative embodiment of the synchronous rectifier of FIG. 7;
FIG. 9 are schematic diagrams of two filter circuits suitable for use in the power converter of FIGS. 7 and 8;
FIG. 10 is a block diagram of the gate driving circuit of the power converter of FIGS. 7 and 8; and
FIG. 11 is a detailed schematic diagram of the gate driving circuit of FIG. 10.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein like numerals indicate like elements, there is shown in FIG. 3 a schematic diagram of a power converter 1 employing a synchronous rectifier circuit in accordance with a first aspect of the present invention. The converter 1 includes a pair of MOSFET transistors, Q1 and Q2, used as synchronous rectifiers which are connected to the secondary winding of a transformer, XFRMR. It is noted that other types of transistors Q1, Q2 may be employed (for example, IGBTs) which still fall within the scope of the invention.
The converter 1 also includes a gate driving circuit, IC1, which has IN, CL1, CL2, GND, Vdd, Q1g, CF, and Q2g terminals and is preferably in integrated form. IC1 takes input from the XFRMR winding through R2 to the IN terminal and ground. Capacitors C3 and C4 are used in adjusting for certain switching frequencies of the converter 1. IC1 takes operating power from the XFRMR winding through R1 and employs C1 as an energy storage device. Terminals Q1g and Q2g are coupled to the gates of Q1 and Q2, respectively, for providing gate signals thereto. Capacitor C2 may be provided to adjust the amount of phase lead of a phase-locked loop (described below).
Reference is now made to FIG. 4 which is a more detailed schematic diagram of the gate driving circuit IC1 of the power converter 1. The gate driving circuit IC1 includes a Schmitt Trigger circuit 100, a frequency divider circuit 200, a phase-locked loop circuit 300, and a duty cycle reconstruction circuit 400. IC1 also includes a Vdd power supply circuit comprising external resistor R1, zener diode VR1, and external capacitor C1, where R1 is not needed if the signal at the input terminal (IN) is below about 20 VDC.
The Schmitt Trigger circuit 100 is used as a buffer circuit and includes a pair of series coupled inverting amplifiers 101 and a feedback resistor Rf. The trip point of the Schmitt Trigger 100 is set to about 1/2 of the operating supply voltage (Vdd) and includes a noise margin.
The frequency divider circuit 200 includes two amplifier circuits, one non-inverting 201 and the other inverting 202. The amplifiers receive their inputs from the output of the Schmitt Trigger 100 and are connected to flip-flop circuits 203 and 204, respectively. The flip-flop circuits 203, 204 produce output signals which have frequencies 1/2 that of the signals from amplifiers 201, 202. The flip-flop outputs have a duty cycle of about 50%. It is important to note that the duty cycle information which was contained in the signal at the IN terminal is transferred to a phase difference between the output signals of the flip-flop circuits 203, 204.
The flop-flop circuits 203, 204 drive the phase-locked loop circuits (PLL) 300. The PLL circuits 300 each respectively include phase comparators 301, 302, voltage controlled oscillators 303, 304, and delay elements 305, 306. The delay elements 305, 306 are formed using amplifiers with diode feedback elements, but other suitable types of delay elements will be apparent to those skilled in the art from the above teaching and are considered within the scope of the invention.
The delay elements 305, 306 in the feedback path of the PLL circuits 300 cause the outputs of the PLL circuits 300 to lead the input signals from the flip-flop circuits 202, 203. The amount of phase lead at the outputs of the PLL circuits 300 may be manually adjusted by changing the number of delay elements 305, 306 or may be automatically and/or externally adjusted using the external capacitor C2 (FIG. 3).
In FIG. 4, the delay elements 305, 306 are shown as buffer circuits having opposing diode feedback circuits. In order to adjust the number of delay elements, the diode feedback circuits may be internally or externally fusible to disable particular delay elements 305, 306.
The duty cycle reconstruction circuit 400 includes exclusive OR (XOR) gates and exclusive NOR (XNOR) gates, shown as a single element 401, and a pair of output amplifiers, one non-inverting 402 and the other inverting 403. The duty cycle reconstruction circuit 400 operates to re-introduce the duty cycle information contained in the phase difference between the output signals from the PLL circuits 300 into the pulse widths of the output signals from the amplifiers 402, 403.
Thus, the duty cycle of the signal on terminal V1A of the frequency divider circuit 200 is the same as the duty cycle of the signal on terminal V1B of the duty cycle reconstruction circuit 400. Similarly, the duty cycle of the signal on terminal V2A of the frequency divider circuit 200 is the same as the duty cycle of the signal on terminal V2B of the duty cycle reconstruction circuit 400.
There is, however, a very important difference between the signals on V1A versus V1B and between the signals on V2A versus V2B. Indeed, the signals on V1B and V2B lead the signals on V1A and V2A, respectively. Thus, when V1B and V2B (as opposed to V1A and V2A) are used to gate the transistors Q1 and Q2, respectively, the transformer delays, noise effects and device switching delays may be compensated for and the precision in switching the synchronous rectifiers may be maintained without reducing converter efficiency.
The gate driving chip IC1 has three modes of operation, namely, the normal mode, the cross coupled mode, and the off mode. In the normal mode, the gate driving signals at Q1g and Q2g (FIG. 3) are derived from the signals on V1B and V2B, respectively. Thus, in the normal mode, the gate driving signals at Q1g and Q2g lead the input signal (IN), i.e., the gate driving circuit IC1 predicts the voltage transitions at the XFRMR secondary winding.
In the cross coupled mode, the gate driving signals at Q1g and Q2g (FIG. 3) are derived from the signals on V1A and V2A, respectively. Thus, in the cross coupled mode, the gate driving signals at Q1g and Q2g do not lead (and may in fact lag) the input signal IN as in the prior art. In the off mode, the transistors Q1 and Q2 are biased off and any commutation currents are conducted by the anti-parallel diodes of the transistors. The off mode is usually invoked during power up of the converter 1 and/or under very low load conditions (like no load).
Details of the transitions between the above-discussed modes are now presented with particular attention paid to the transition between the normal mode and the cross coupled mode.
The PLL circuits 300 have a limited ability to track fast changes in the phase of the input signals from the flip-flop circuits 203, 204. Thus, when the duty cycle of the IN signal changes relatively slowly, the PLL circuits 300 may readily track the change and accurately predict the transitions in the voltage at the XFRMR secondary winding. When the duty cycle of the IN signal changes relatively quickly, however, the PLL circuits 300 may not track the change and may lose phase lock therewith.
Consequently, the gate driving circuit IC1 is designed to transition from the normal mode to the cross coupled mode when the rate of change of the duty cycle of the IN signal exceeds a predetermined threshold. When the rate of change of the duty cycle of the IN signal falls below the predetermined threshold, IC1 transitions back to the normal mode of operation.
Turning again to FIG. 4, in order to accommodate the transitions between operating modes, the gate driving circuit IC1 employs a duty cycle rate change detector circuit 600, a timing circuit 700, and a multiplexing circuit 800. The duty cycle rate change detector circuit 600 operates to produce an output pulse when the rate of change of the duty cycle on the IN terminal exceeds a predetermined threshold. Details on the operation of the duty cycle rate change detector circuit 600 are discussed later.
The output pulse from the duty cycle rate change detector circuit 600 triggers the timing circuit 700 to provide a timed pulse (say 20 μs) to the multiplexing circuit 800. The timing circuit 700 includes a one-shot circuit 701, but other suitable types of timing elements will be apparent to those skilled in the art from the above teaching and are considered within the scope of the invention.
It is noted that the timing circuit 700 includes another one shot circuit 702 which also may trigger the multiplexing circuit 800. The one-shot circuit 702 is driven by an undervoltage lockout circuit 500 which operates to cause the gate driving circuit IC1 to enter the cross coupled mode while the peak amplitude of the voltage on the IN terminal is below a predetermined limit. The undervoltage lockout circuit 500, includes diode D501, storage capacitor C502, resistor divider circuit R503, resistors R504 and R505, diode D502, amplifier 507, and inverting buffer 506. As shown, the undervoltage lockout circuit 500 resets the flip-flops 203, 204 of the frequency divider circuit 200. The operation of the undervoltage lockout circuit 500 is well known in the art and, therefore, is not discussed in more detail herein.
The outputs of the one-shot circuits 701, 702 are combined by way of a so-called glue logic circuit (employing NOR gates 703, 704) such that either circuit 701, 702 may drive the multiplexing circuit 800.
The multiplexing circuit 800 includes a pair of multiplexers 801, 802 and buffer amplifiers 803, 804. The multiplexers 801, 802 receive input signals from the V1A, V1B terminals and the V2A, V2B terminals, respectively. The Q1g and Q2g terminals of IC1 will receive either the signals on terminals V1A, V2A or the signals on terminals V1B, V2B depending on a voltage level and/or edge presented on the select pins of the multiplexers 801, 802. Thus, the gate driving circuit IC1 will enter the cross coupled mode from the normal mode when one or both of the one-shot circuits 701, 702 present a timed pulse to the multiplexers 801, 802 (i.e., the multiplexers 801, 802 select the signals on terminals V1A, V2A in favor of the signals on terminals V1B, V2B). When one or both of the one-shot circuits 701, 702 time out, they will present a voltage level and/or edge to the select pins of the multiplexers 801, 802 which will cause them to select the signals on terminals V1B, V2B in favor of the signals on terminals V1A, V2A (i.e., IC1 will again operate in the normal mode).
Reference is now made to FIG. 5 which shows a schematic diagram of the duty cycle rate change detector 600 of the gate driving circuit IC1. The duty cycle rate change detector 600 includes a low pass filter circuit 30, a differentiator circuit 40 and a window comparator circuit 50.
The low pass filter circuit 30 includes resistor R44, capacitor C200, and buffer amplifier X2. The corner frequency of the low pass filter 30 is preferably set to 1/10 of the switching frequency of the converter 1 (although other corner frequencies may be selected and still fall within the scope of the invention). The low pass filter produces an output at NODE1 which is proportional to the duty cycle of the waveform at the IN terminal of IC1.
The signal at NODE1 is input to the differentiator circuit 40, which circuit includes the following components: high pass filter circuit elements R55 and C33, offset circuit elements R70 and R80, amplifier X3, and feedback components R66 and C440. The operation of the differentiator circuit 40 is well known to those skilled in the art and, therefore, will not be presented herein. The differentiator, however, outputs a signal at NODE2 which is proportional to the rate of change of the voltage at NODE1. In other words, the voltage at NODE2 is proportional to the rate of change of the duty cycle at the XFRMR secondary winding.
The window comparator circuit 50 includes resistor divider circuit elements R100, R110, and R120, comparators X4 and X5, and pull-up resistor R90. The window comparator circuit 50 outputs a pulse on NODE3 when the absolute value of the amplitude of the voltage at NODE2 exceeds predetermined thresholds.
Turning to FIG. 6, the timing waveforms of the voltages on the IN terminal, NODE1, NODE2, and NODE3 are shown. As may readily be seen, as the duty cycle of the voltage waveform on the IN terminal rapidly drops (at time=10 μs) the low pass filter circuit 30 responds by lowering the amplitude of the voltage on NODE1 (time=13 μs). The differentiator circuit 40 detects the rate at which the voltage on NODE1 drops and responds by outputting a voltage spike on NODE2 (time=15 μs) having an amplitude proportional to the rate at which the voltage on NODE1 drops. The window circuit 50 detects the amplitude of the voltage on NODE2 and outputs a negatively going square wave pulse on NODE3 corresponding to the voltage spike on NODE2.
It may be seen from FIG. 6 that the window circuit 50 detects a positively going spike on NODE2 (time=15 μs) and a negatively going spike (time=24 μs) which occurs when the duty cycle of the waveform on the IN terminal rapidly increases (time=20 μs). Thus, the absolute value of the amplitude of the voltage spike on NODE2 is detected by the window comparator circuit 50. It is the pulse on NODE3 which triggers the one-shot 701 to produce a timed pulse to the multiplexing circuit 800 described above.
Reference is now made to FIGS. 7 and 8 which show schematic diagrams of the secondary side circuits of power converters 10 and 11, respectively, which employ synchronous rectifier circuits in accordance with another aspect of the present invention. Power converters 10 and 11 include a pair of MOSFET transistors, Q1 and Q2, used as synchronous rectifiers, which are connected to the secondary windings of a transformer, XFRMR. Each of power converters 10 and 11 also include a gate driving circuit IC2 which has IN1, IN2, CL1, CL2, CL3, CL4, GND, Vdd, CD1, CD2, RF, G1, and G2 terminals and is preferably in integrated form. An integrated circuit suitable for use as IC2 in the power converters of FIGS. 7 and 8 is the IR7501 gate drive circuit which may be obtained from the International Rectifier Corporation, El Segundo, Calif.
Gate drive circuit IC2 receives inputs from the XFRMR windings at nodes X10 and X20 through resistors R2 and R4, respectively, to the IN1, and IN2 terminals. Thus, the power converter circuits 10 and 11 of FIGS. 7 and 8 differ from the power converter circuit 1 of FIG. 3 in that they receive inputs from both ends of the XFRMR windings rather than only one end.
Power converter circuits 10 and 11 operate in substantially the same manner except for how the respective gate drive circuits IC2 receive operating power. Power converter 10 of FIG. 7 receives operating power from the output Vout of the circuit to terminal Vdd, where capacitor C1 provides decoupling and local energy storage for IC2. This configuration is particularly suited for output voltages Vout of between about 2.5 to 5 volts (although even higher output voltages are contemplated, e.g., to 10 volts, 15 volts or higher). IC2 of power converter 11 (FIG. 8) receives operating power from node X10 of the XFRMR winding. The voltage at terminal VDD of IC2 is obtained by rectifying the voltage at node X10 using resistor RVdd and diode DVdd. This configuration is particularly suited to output voltages Vout of between about 1.5 to 2.5 volts.
Circuit components labelled CN1 and CN2 in power converter circuits 10 and 11 represent passive loop filter configurations which may be varied depending on the desired transient response of the circuit. Referring to FIG. 9, two passive loop filter configurations are shown, one being a lag-lead configuration and the other being a lag configuration. It is apparent to those skilled in the art how the circuit component values for R9, R8 and C5 may be adjusted to select a particular transient response for the power converter circuit 10 and/or 11.
Referring again to FIGS. 7 and 8, capacitor C2 is used for adjusting the respective switching frequencies of the power converters 10 and 11. While capacitors C3 and C4 may be provided to adjust an amount of phase lead of the phase-locked loop (described below).
Reference is now made to FIG. 10 which shows a circuit block diagram of the gate drive circuit IC2. The gate driving circuit IC2 includes a pair of Schmitt Trigger circuits 101 and 102, a pair of edge detector circuits 220 and 222, a phase-locked loop circuit 300, and an output regeneration circuit 410. In order to accommodate transitions between operating modes (i.e., the normal mode, off mode, and cross coupled mode), the gate drive circuit IC2 also employs a multiplexing circuit (or output select circuit) 800, a transient control circuit 750, and an undervoltage lock-out circuit 500. IC2 also includes a Vdd and Vcc power supply circuit 900 for providing operating power voltage levels for the various circuits in the system.
Reference is also made to FIG. 11 which shows a detailed circuit diagram corresponding with the block diagram of FIG. 10. The detailed circuits shown in FIG. 11 are suitable for use in the Schmitt Trigger circuits 101 and 102, the edge detector circuits 220 and 222, the phase-lock loop circuit 300, the output regeneration circuit 410, the output select circuit 800, the transient control circuit 750, the undervoltage lock-out circuit 500, and the power supply circuit 900. It is apparent to those skilled in the art that the specific circuit configurations shown in FIG. 11 are suitable for use in the gate drive circuit IC2 of FIG. 10 but are not the only circuit configurations possible, indeed many other modifications and variations are contemplated and considered within the scope of the invention.
The Schmitt Trigger circuits 101 and 102 receive the XFRMR winding voltages from nodes X10 and X20, respectively, through resistors R2 and R4 and are used as buffer circuits having trip points set to about 1/2 of the operating supply voltage Vcc. The outputs A5 and A6 of the respective Schmitt Triggers 101 and 102 are input to the edge detector circuits 220 and 222 as well as the multiplexer circuit 800. A suitable circuit implementation for Schmitt Triggers 101 and 102 is shown in FIG. 11.
The edge detector circuits 220 and 222 receive the A5 and A6 outputs, respectively, and convert them into relatively narrow pulses which coincide with the rising edge of the XFRMR winding voltages at nodes X10 and X20, respectively. It is preferred that the pulse widths of the narrow pulses produced by the edge detector circuits 220 and 222 be approximately 50 to 100 nano seconds. The pulse signals from the edge detector circuits 220 and 222 are input to respective phase comparator circuits 301 and 302 of the phase-locked loop circuit 300. The duty cycle information contained in the voltages at nodes X10 and X20 of the XFRMR winding is represented in a phase shift (or time delay) between the pulse signals produced by the respective edge detector circuits 220 and 222. A suitable circuit implementation for the edge detector circuits 220 and 222 is shown in FIG. 11.
The phase-locked loop circuit 300 includes at least two and preferably a pair of phase comparators 301 and 302, voltage controlled oscillators 301 and 304, and delay circuits 305 and 306. As previously discussed, passive loop filters 310 and 312 may be included to adjust the transient response of the phase-locked loop circuits. The respective outputs of the phase-locked loop circuits (i.e., the nodes at the respective right sides of the voltage controlled oscillators 303, 306) are signals having duty cycles of about 50% and having frequencies substantially the same as the respective frequencies of the voltages at nodes X10 and X20 of the XFRMR winding.
Each of the delay circuits 305 and 306 is in a respective feedback path of one of the phase-locked loop circuits and, therefore, cause the outputs of the voltage controlled oscillators 303 and 306 to lead the pulse signals produced by the edge detector circuits 220 and 222. The amount of phase lead at the outputs of the phase-locked loop circuits may be adjusted by the delay circuits 305 and 306. With reference to FIG. 11, the amount of phase lead may be adjusted via potentiometer P2, capacitor C4, potentiometer P3, and/or capacitor C7. It is apparent to those skilled in the art that the delay circuits 305 and 306 may alternatively be implemented using circuits substantially similar to those shown in FIG. 4 if desired. Indeed, other suitable types of delay circuits will be apparent to those skilled in the art from the above teaching and are considered within the scope of the invention.
The output regeneration circuit 410 includes edge detector circuits 224 and 226 coupled to a flip flop circuit 228. Edge detector circuits 224 and 226 sense the respective rising edges of the outputs from the voltage controlled oscillators circuits 303 and 306, respectively, and produce respective pulse signals for input to the flip flop circuit 228. The flip flop circuit 228 reintroduces the duty cycle information contained in the phase difference between the respective pulse signals from the edge detector circuits 224 and 226 into complimentary output signals A50 and A60. Thus, the duty cycle of the signal on line A5 is the same as the duty cycle of the signal on line A50. Similarly, the duty cycle of the signal on line A6 is the same as the duty cycle of the signal on line A60. There is, however, a difference between the signals on lines A5 and A50 and between the signals on line A6 and line A60, namely, the signals on lines A50 and A60 lead the signals on lines A5 and A6, respectively. Thus, when the signals on lines A50 and A60 are used to gate the transistors Q1 and Q2, respectively, the transformer delays, noise effects and device switching delays may be compensated for and the precision in switching the synchronous rectifiers may be maintained without reducing converter efficiency.
The gate driver circuit IC2 has three modes of operation, namely, the normal mode, the cross coupled mode, and the off mode which are the same as the modes of operation of the circuit of FIG. 3. Thus, in the normal mode, the signals on lines A50 and A60 are used to drive transistors Q1 and Q2. In the cross coupled mode, the signals on lines A5 and A6 are used to drive transistors Q1 and Q2, respectively. In the off mode, transistors Q1 and Q2 are biased off.
Transitions between the above modes of operation are facilitated using the multiplexer circuit 800 which receives control signals from the transient control circuit 750 and the undervoltage lock-out circuit 500. The transient control circuit 750 receives signals PCP1 and PCP2 from the respective phase comparator circuits 301 and 302 of the phase-locked loop circuit 300. Signals PCP1 and PCP2 represent the phase difference between the inputs to the phase comparator circuits 301 and 302, respectively, and are relatively narrow pulses (approximately 20 nano seconds) when the phase-locked loop circuits are locked. When the power converter circuit 10, 11 receives a transient (e.g., a rapid duty cycle change) the phase-locked loop circuits become unlocked and the widths of the PCP1 and PCP2 signals increase significantly. The transient control circuit 750 monitors the widths of the PCP1 and PCP2 pulse signals and produces an output which transitions when the width of one or both of the PCP1 and PCP2 pulses exceeds a predetermined value (e.g., approximately 100 to 200 nano seconds). This output controls a select input of the multiplexer circuit 800. Thus, in response to the transitioning output signal from the transient control circuit 750, the multiplexer circuit 800 selects either the signals on lines A50 and A60 or the signals on lines A5 and A6 to drive transistors Q1 and Q2. It is noted that the transient control circuit 750 transitions during a transient condition for only one switching cycle such that transitions between the normal mode and cross coupled mode may be made on a cycle-by-cycle basis. So long as the transient condition persists, however, the transient control circuit 750 will drive the multiplexer circuit 800 such that the power converter 10 or 11 remains in the cross coupled mode. Once the transient condition has cleared, the transient control circuit 750 will control the multiplexer circuit 800 such that the normal operating mode is engaged.
The undervoltage lock-out circuit 500 produces an output signal which enables or disables the multiplexer circuit 800 such that when there is insufficient power to operate the gate driver circuit IC2, the multiplexer circuit 800 is disabled and transistors Q1 and Q2 are biased off (i.e., the power converter 10 or 11 is in the off mode).
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims. | 4y
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[0001] This application is based on and claims the benefit of priority from Japanese Patent Application No. 2008-161673, filed on 20 Jun. 2008, the content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an amorphous siliceous powder, a method for production thereof and a use thereof.
[0004] 2. Related Art
[0005] With rising demand for environmental conservation in recent years, it has been desired to impart flame retardancy to semiconductor sealing materials used for sealing semiconductor elements without using harmful flame retardants such as antimony compounds and brominated epoxy resins which have considerable environmental impact, and impart heat resistance to lead-free solders containing no lead. Semiconductor sealing materials are mainly composed of epoxy resins, phenol resin curing agents, curing accelerators, inorganic fillers and the like, In order to satisfy the requirements described above, semiconductor sealing materials including epoxy resins and the phenol resins having structures with abundant aromatic rings, and which are high flame retardant and heat resistant, and high inorganic filler loading have been employed. Thus, viscosity of the semiconductor sealing material upon sealing tends to increase.
[0006] Meanwhile, in response to demand for smaller, lighter and more sophisticated electronic devices, rapid development has been seen in thinning of electronic components, reducing the diameter of and lengthening spans of gold wire, and increasing the density of wiring pitch in an internal structure of a semiconductor. When a semiconductor is sealed using a semiconductor sealing material having a high viscosity, problems result, such as gold wire is deformed and cut, the semiconductor element is inclined, and narrow spaces are not filled. Thus, there is demand for a semiconductor sealing material that is flame retardant and which has reduced viscosity to allow correct sealing and reduce improper molding.
[0007] To satisfy these demands, semiconductor sealing materials having a reduced viscosity and enhanced molding property have been obtained by improving the epoxy resin and the phenol resin curing agent used therein (Patent Documents 1 and 2). Improvements in curing accelerators have been achieved with a technique referred to as ‘making a latent state’, where a reactive substrate is protected using a component which inhibits a curing property for the purpose of raising a temperature when curing of the epoxy resin is initiated (Patent Documents 3 and 4). Improvements in inorganic fillers have been achieved with controlling the particle size distribution thereof, such that the viscosity of the sealing material, which contains an inorganic filler, does not increase even at high inorganic filler loading (Patent Documents 5 and 6). However, these sealing materials do not have sufficiently reduced viscosity and enhanced molding property, and thus, prior to the present invention, no semiconductor sealing material having a reduced viscosity upon sealing with high inorganic filler loading, and enhanced molding property was available.
[0008] [Patent Document 1] Japanese Unexamined Patent Application, First Publication No. 2007-231159
[0009] [Patent Document 2] Japanese Unexamined Patent Application, First Publication No. 2007-262385
[0010] [Patent Document 3] Japanese Unexamined Patent Application, First Publication No. 2006-225630
[0011] [Patent Document 4] Japanese Unexamined Patent Application, First Publication No. 2002-284859
[0012] [Patent Document 5] Japanese Unexamined Patent Application, First Publication No. 2005-239892
[0013] [Patent Document 6] WO2007/132771
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide a resin composition, and particularly a semiconductor sealing material having a reduced viscosity upon sealing and a further enhanced molding property even with high loading of an inorganic filler, and to provide an amorphous siliceous powder that is suitable for preparation thereof.
[0015] In a first aspect of the present invention, provided is an amorphous siliceous powder comprising Si and Al in a combined content thereof in the powder is 99.5% by mass or more in terms of their oxides; a content of Al in a first portion of the powder, having a particle size range of 15 μm or more to less than 70 μm, is 100 to 30000 ppm in terms of its oxide; a content of Al in a second portion of the powder, having a particle size range of 3 μm or more to less than 15 μm, is 100 to 7000 ppm in terms of its oxide; and a content of Al in the powder including the entire particle size range is 100 to 25000 ppm in terms of its oxide. In the present invention, it is preferable that a ratio (A/B) of (A) the content of Al in the first portion of the powder to (B) the content of Al in the second portion of the powder, is 1.0 to 20. It is also preferable that the powder has a multimodal particle size distribution with at least two peaks in a frequency particle size distribution, in which a maximum frequency value of a first peak is located between a particle size range of 15 to 70 μm, a maximum frequency value of a second peak is located between a particle size range of 3 to 10 μm and an average particle diameter is 5 to 50 μm.
[0016] In a second aspect of the present invention, provided is a method for producing the amorphous siliceous powder of the first aspect of the present invention, the method including spraying from separate burners a first raw material siliceous powder having an average particle diameter of 15 to 70 μm and a content of Al of a first Al source material of 100 to 30000 ppm in terms of its oxide, and a second raw material siliceous powder having an average particle diameter of 3 to 10 μm and a content of Al of a second Al source material of 100 to 7000 ppm in terms of its oxide, into a high temperature flame formed from a flammable gas and a supporting gas.
[0017] In third aspect of the present invention, provided is a resin composition containing the amorphous siliceous powder of the first aspect of the present invention, and a resin. The resin used for the composition preferably comprises an epoxy resin. In a fourth aspect of the present invention, provided is a semiconductor sealing material including the composition.
[0018] According to the present invention, it is possible to provide a resin composition, in particular a semiconductor sealing material, which is excellent in fluidity, viscosity property and molding property. It is also possible to provide an amorphous siliceous powder suitable for preparing the composition.
DETAILED DESCRIPTION OF THE INVENTION
[0019] In the amorphous siliceous powder of the present invention, the content of Al in a first portion of the powder, having a particle size range of 15 μm or more to less than 70 μm, is 100 to 30000 ppm in terms of its oxide, the content of Al in a second portion of the powder, having a particle size range of 3 μm or more to less than 15 μm, is 100 to 7000 ppm in terms of its oxide, and the content of Al in the powder including the entire particle size range is 100 to 25000 ppm in terms of its oxide. By adjusting the content of Al in each particle size range and in the entire particle size range to the aforementioned range, it becomes possible to prepare a sealing material which is excellent in fluidity, viscosity property and molding property.
[0020] The effects of the present invention are obtained via the mechanism explained below. When a Si atom in a silica structure is replaced with an Al atom, such that —O—Si—O—Al—O—Si—O—, the site where replacement has occurred becomes a strong solid acid site due to a difference between the coordination number of Si and the coordination number of Al. An epoxy rein, a phenol resin curing agent and a curing accelerator in addition to an amorphous siliceous powder are used in a semiconductor sealing material. When a semiconductor sealing material is heated to a general thermal cure temperature (molding temperature) of about 150 to 200° C., a proton in the phenol resin curing agent is drawn out by the curing accelerator, an anion polymerization chain reaction of the epoxy resin with the phenol resin curing agent progresses and the sealing material is thermally cured. When the amorphous siliceous powder of the present invention is used, the proton coordinated at the solid acid site is released by heating. This proton then binds to an anion polymerization end, and the polymerization chain reaction is suspended. As a result, thermal cure reaction in the sealing material is delayed. That is, by the amorphous siliceous powder of the present invention, it becomes possible to delay the thermal cure reaction of the resin in the sealing material, and the sealing material which is excellent in fluidity and viscosity property upon molding can be prepared.
[0021] When the content of Al in the first portion of the amorphous siliceous powder, having a particle size range of 15 μm or more to less than 70 μm, is less than 100 ppm in terms of its oxide, an amount of the formed solid acid sites is reduced, and thus, the effect of delaying the thermal cure reaction of the resin becomes insufficient. Meanwhile, when the content of Al in the first portion exceeds 30000 ppm in terms of its oxide, the surfaces of the particles constituting the amorphous siliceous powder become almost completely covered with Al 2 O 3 . Thus, the amount of the formed solid acid sites is reduced, and the effect of delaying the thermal cure reaction of the resin becomes insufficient. The content of Al in the first portion having a particle size range of 15 μm or more to less than 70 μm, is preferably 500 to 20000 ppm and more preferably 1000 to 15000 ppm in terms of its oxide.
[0022] When the content of Al in the second portion of the amorphous siliceous powder, having a particle size range of 3 μm or more to less than 15 μm, is less than 100 ppm in terms of its oxide, the amount of the formed solid acid sites is reduced, and thus, the effect of delaying the thermal cure reaction of the resin becomes insufficient. Meanwhile, when the content of Al in the second portion exceeds 7000 ppm, the number of epoxy chains coordinated to the surfaces of the particles that constitute the amorphous siliceous powder is increased. Thus, a rolling resistance of the amorphous siliceous powder increases, and the fluidity and the viscosity property upon molding deteriorate. The epoxy chains are also coordinated to the surfaces of the particles that constitute the amorphous siliceous powder in the particle size range of 15 μm or more to less than 70 μm, but the mass of each particle is large, and thus an influence of the rolling resistance due to the coordination of the epoxy chains is negligible. On the contrary, in the particle size range of 3 μm or more to less than 15 μm, the mass of the particle is small, and thus the influence of the rolling resistance due to the coordination of the epoxy chains is large. That is, it is important that the content of Al in the second portion having a particle size range of 3 μm or more to less than 15 μm, is 100 to 7000 ppm in terms of its oxide so that the effect of delaying the thermal cure reaction of the resin due to solid acid formation is exhibited more largely than the influence of the increased rolling resistance due to the coordination of the epoxy chains. The content of Al in the second portion having a particle size range of 3 μm or more to less than 15 μm, is preferably 200 to 5000 ppm and more preferably 350 to 3000 ppm in terms of its oxide.
[0023] When the content of Al in the amorphous siliceous powder is less than 100 ppm in terms of its oxide, the amount of the formed solid acid sites is reduced, and thus, the effect of delaying the thermal cure reaction of the resin becomes insufficient. When the content of Al in the amorphous siliceous powder exceeds 25000 ppm, the viscosity increase at high filler loading in the resin and the like, and the fluidity and the molding property deteriorates. Further, a kneader and a roll used when mixing the resin and a die used when molding undergo sever wear. The content of Al in the amorphous siliceous powder is preferably 300 to 18000 ppm and more preferably 500 to 12000 ppm.
[0024] In the amorphous siliceous powder of the present invention, a combined content of Si and Al in terms of their oxides is 99.5% by mass or more. When the content of Si and Al in terms of their oxides is less than 99.5% by mass, i.e., the content of components other than SiO 2 and Al 2 O 3 exceeds 0.5% by mass, unnecessary substances which are impurities are increased when the semiconductor sealing material is made. Thus, this is not preferable. For example, a part of the impurities may convert to their ionic form, which is then potentially eluted to harmfully affect the molding property. The content of Si and Al in terms of their oxides is preferably 99.6% by mass or more and more preferably 99.7% by mass or more.
[0025] The content of Si and Al in terms of their oxides in the amorphous siliceous powder of the present invention can be measured, for example, by a fluorescent X ray analysis method. That is, 5 g of lithium tetraborate and 30 μL of a release agent (aqueous solution of 50% lithium bromide) are added to 1 g of the amorphous siliceous powder, which is then melted at 1100° C. for 20 minutes to prepare glass beads. Measured is then performed using a fluorescent X ray apparatus (e.g., “Primus 2” supplied from Rigaku Denki Kogyo Co., Ltd.), and each content was quantified using a standard curve prepared from standard samples of SiO 2 or Al 2 O 3 . The measurement was performed by using an X ray tube made of Rhodium (Rh), and an irradiation diameter of 30 mm and an output power of 3.0 kW. When the content of Al in each portion of different particle size range was measured, the portions of the amorphous siliceous powder having a particle size range of 15 μm or more to less than 70 μm, and a particle size range of 3 μm or more to less than 15 μm, were collected by combining sieving using a sieve having an opening size of 70 μm and a sieve having an opening size of 15 μm and filtration using a membrane filter having a pore size of 3 μm, and the powder in each particle size range was quantified.
[0026] In the amorphous siliceous powder of the present invention, it is more preferable that the ratio (A/B) of (A) the content of Al in the first portion of the amorphous siliceous powder, having a particle size range of 15 μm or more to less than 70 μm, to (B) the content of Al in the second portion of the amorphous siliceous powder, having a particle size range of 3 μm or more to less than 15 μm, is 1.0 to 20. When the ratio (A/B) is less than 1.0, the content of Al in the second portion having a particle size range of 3 μm or more to less than 15 μm, is higher than the content of Al in the first portion having a particle size range of 15 μm or more to less than 70 μm. In this case, the influence of the increased rolling resistance due to the coordination of the epoxy chains of the particles in the particle size range of 3 μm or more to less than 15 μm described above becomes remarkable. Thus, this is not preferable. When the ratio (A/B) exceeds 20, the content of Al in the first portion having a particle size range of 15 μm or more to less than 70 μm, is more than 20 times higher than the content of Al in the second portion having the particle size range of 3 μm or more to less than 15 μm. Due to segregation of the solid acid sites in each particle size range, dispersibility of the amorphous siliceous powder deteriorates and the molding property thereof potentially deteriorates when making the semiconductor sealing material. Thus, this is not preferable. The ratio (A/B) is preferably 1.5 to 17 and more preferably 2.0 to 15.
[0027] It is more preferable that the amorphous siliceous powder of the present invention has a multimodal particle size distribution having at least two peaks in the frequency particle size distribution. That is, it is preferable that the particle size distribution is a multimodal particle size distribution having at least two peaks, the maximum frequency value of the first peak is located between a particle size range of 15 to 70 μm and the maximum frequency value of the second peak is located between a particle size range of 3 to 10 μm, when the particle sizes are measured using a laser diffraction scattering particle size distribution analyzer (“model LS-230” supplied from Beckman Coulter). This makes it easy to form a densely filled structure of the amorphous siliceous powder and makes it easier to enhance the fluidity and the viscosity property upon molding. The amorphous siliceous powder of the present invention preferably has an average particle diameter of 5 to 50 μm. When the average particle diameter is less than 5 μm, the molding property deteriorates. Thus, this is not preferable. Meanwhile, when the average particle diameter exceeds 50 μm, damage to semiconductor chips, severing of wires, clogging of die gates and the like are likely to result. The preferable average particle diameter is 8 to 40 μm and more preferably 10 to 35 μm. A maximum particle diameter is preferably 213 μm or less and more preferably 134 μm or less.
[0028] A sample for measuring a laser diffraction scattering particle size distribution was prepared by using water as a medium, adjusting a PIDS (polarization intensity differential scattering) concentration to 45 to 55% by mass and subjecting to an ultrasonic homogenizer with an output power of 200 W for one minute. The particle size distribution was analyzed by dividing into 116 in the range of 0.04 to 2000 μm using a particle diameter channel of log (μm)=0.04 width. A refractive index of 1.33 was used for water, and a refractive index of 1.46 was used for the amorphous siliceous powder. The particle diameter corresponding to a cumulative mass of 50% is the average particle diameter, and the particle diameter corresponding to a cumulative mass of 100% is the maximum particle diameter in the measured particle size distribution.
[0029] It is preferable that an amorphous rate measured by the following method is 95% or more in the amorphous siliceous powder of the present invention. The amorphous rate was determined by using a powder X ray diffraction apparatus (e.g., a brand name “Model Mini Flex” supplied from RIGAKU), performing an X ray diffraction analysis in the range of CuKα ray where 2θ was 26 to 27.5° and calculating from an intensity ratio of certain diffraction peaks. In the case of siliceous powder, crystal silica has a major peak at 26.7°, but amorphous silica has no peak. When the amorphous silica and the crystal silica are present as a mixture, a peak height at 26.7° depending on the ratio of crystal silica is obtained. Thus, a mixed ratio of the crystal silica is calculated from the ratio of the X ray intensity of the sample to the X ray intensity of a crystal silica standard sample (X ray diffraction intensity of sample/X ray diffraction intensity of crystal silica). Then, the amorphous rate is calculated from a formula, Amorphous rate (%)=(1−Mixed ratio of crystal silica)×100.
[0030] An average sphericity of the amorphous siliceous powder of the present invention is preferably 0.80 or more. This makes it possible to reduce the rolling resistance of the semiconductor sealing material to enhance the fluidity and the molding property. For obtaining the average sphericity, a particle image photographed using a stereoscopic microscope (e.g., the brand name of “Model SMZ-10 type” supplied from Nikon Corporation) is loaded in an image analyzer (e.g., the brand name of “MacView” supplied from Mountec), and a projected area (A) and a perimeter (PM) of the particle are measured on the photograph. When an area of a perfect circle corresponding to the perimeter (PM) is (B), a sphericity of that particle is (A)/(B). Thus, when the perfect circle having the same boundary length as the perimeter (PM) of the sample is assumed, B=π×(PM/2π) 2 is derived since PM=2πr and B=πr 2 . Thus, the sphericity of the individual particle is Sphericity=A/B=A×4π/(PM) 2 . The sphericity of 200 particles randomly obtained in this way was calculated, and their mean was squared to obtain the average sphericity. Another example of a method for obtaining sphericity is a conversion based upon an equation Sphericity=Circularity 2 , using circularity of an individual particle that is automatically measured quantitatively using a particle image analyzer (e.g., the brand name of “Model FPIA-3000” supplied from Sysmex).
[0031] Subsequently, the method of producing the amorphous siliceous powder of the present invention will be described. The method for producing the amorphous siliceous powder of the present invention includes the step of spraying from separate burners a first raw material siliceous powder having an average particle diameter of 15 to 70 μm and a content of Al of a first Al source material of 100 to 30000 ppm in terms of its oxide, and a second raw material siliceous powder having an average particle diameter of 3 to 10 μm and a content of Al of a second Al source material of 100 to 7000 ppm in terms of its oxide, into a high temperature flame formed from a flammable gas and a supporting gas. The average particle diameter of the amorphous siliceous powder obtained by the method of the present invention and the content of Al of the Al source material in the powder are almost the same as the average particle diameter and the Al content in the raw material siliceous powder, respectively. Thus, if the average particle diameter of the raw material siliceous powder and the content of Al of the Al source material in the powder depart from the aforementioned ranges, it becomes difficult to produce the amorphous siliceous powder of the present invention. Even when the first and second raw material siliceous powders respectively having an average particle diameter of 15 to 70 μm and 3 to 10 μm includes the Al source material in the aforementioned Al content, if they are sprayed from the same burner, it becomes difficult due to the diffusion of the Al source material to satisfy the requirement of the amorphous siliceous powder of the present invention where the content of Al in the first portion of the amorphous siliceous powder, having a particle size range of 15 μm or more to less than 70 μm, is 100 to 30000 ppm in terms of its oxide and the content of Al in the second portion of the amorphous siliceous powder, having a particle size range of 3 μm or more to less than 15 μm, is 100 to 7000 ppm in terms of its oxide.
[0032] Powders of minerals containing silica naturally produced such as high purity silica rock, high purity silica sand, quartz and berg crystal, and high purity silica powders produced by synthesis method such as precipitation silica and silica gel can be used for the raw material siliceous powder, but the silica rock powder is the most preferable in consideration of cost and availability. The silica rock powders having various particle diameters obtained by being pulverized by a pulverizer such as a vibrating mill or a ball mill are commercially available, and the silica rock powder having the desired average particle diameter could be selected appropriately.
[0033] In the present invention, it is preferable that the Al source material is aluminium oxide powder. The Al source material includes aluminium oxide, aluminium hydroxide, aluminium sulfate, aluminium chloride and aluminium organic compounds, but aluminium oxide is the most preferable because it has a melting point close to that of the raw material siliceous powder, thus it is easily fusion-bonded to the surface of the raw material siliceous powder when sprayed from the burner and an impurity content is low. The average particle diameter of the aluminium oxide powder is preferably 0.01 to 10 μm. When the average particle diameter is less than 0.01 μm, the powder is easily aggregated and a composition tends to become heterogeneous when fusion-bonded with the siliceous powder. Likewise when it exceeds 10 μm, the composition also becomes heterogeneous when fusion-bonded with the siliceous powder. The range of the average particle diameter is preferably 0.03 to 8 μm and more preferably 0.05 to 5 μm.
[0034] As an apparatus in which the raw material siliceous powder including the Al source material is sprayed into the high temperature flame formed from the flammable gas and the supporting gas, for example, one in which a trapping device is connected to a furnace casing comprising the burner is used. The furnace casing may be any of an open type or a closed type, or a vertical type or a horizontal type. The trapping device is provided with one or more of a gravity-setting chamber, a cyclone, a bag filter and an electric dust collector. The produced amorphous siliceous powder can be trapped by controlling its trapping condition. By way of example, Japanese Unexamined Patent Application, First Publication No. H11-57451 and Japanese Unexamined Patent Application, First Publication No. H11-71107 are included.
[0035] The resin composition of the present invention contains the amorphous siliceous powder of the present invention and a resin. The content of the amorphous siliceous powder in the resin composition is 10 to 95% by mass and more preferably 30 to 90% by mass.
[0036] As the resin, it is possible to use epoxy resins, silicone resins, phenol resins, melamine resins, unsaturated polyester, fluorine resins, polyamide such as polyimide, polyamideimide and polyether imide, polyester such as polybutylene terephthalate and polyethylene terephthalate, polyphenylene sulfide, aromatic polyester, polysulfone, liquid crystal polymers, polyether sulfone, polycarbonate, maleimide-modified resins, ABS resins, AAS (acrylonitrile-acryl rubber styrene) resins and AES (acrylonitrile ethylene propylene diene rubber-styrene) resins.
[0037] Among them, an epoxy resin having two or more epoxy groups in one molecule is preferable for formulating the semiconductor sealing material. Examples thereof include phenol novolak type epoxy resins, ortho cresol novolak type epoxy resins, those obtained by epoxidizing novolak resins from phenols and aldehydes, glycidyl ether such as bisphenol A, bisphenol F and bisphenol S, glycidyl ester acid epoxy resins obtained by reacting polybasic acid such as phthalic acid or dimer acid with epochlorohydrin, linear aliphatic epoxy resins, alicyclic epoxy resins, heterocyclic epoxy resins, alkyl-modified polyfunctional epoxy resins, β-naphthol novolak type epoxy resins, 1,6-dihydroxynaphthalene type epoxy resins, 2,7-dihydroxynaphthalene type epoxy resins, bishydroxybiphenyl type epoxy resins, and further epoxy resins in which halogen such as bromine is introduced for imparting the flame retardancy. Among them, the ortho cresol novolak type epoxy resin, the bishydroxybiphenyl type epoxy resin and the epoxy resin having a naphthalene skeleton are suitable in terms of moisture resistance and solder reflow resistance.
[0038] The resin composition of the present invention includes the curing agent for the epoxy resin, or the curing agent for the epoxy resin and the curing accelerator for the epoxy resin. The curing agent for the epoxy resin can include novolak type resins obtained by reacting one or a mixture of two or more selected from a group of phenol, cresol, xylenol, resorcinol, chlorophenol, t-butylphenol, nonylphenol, isopropylphenol and octylphenol with formaldehyde, paraformaldehyde or paraxylene in the presence of an oxidation catalyst, polyparahydroxystyrene resins, bisphenol compounds such as bisphenol A and bisphenol S, trifunctional phenols such as pyrogallol and phloroglucinol, acid anhydride such as maleic anhydride, phthalic anhydride and pyromellitic anhydride, and aromatic amine such as methaphenylenediamine, diaminodiphenylmethane and diaminodiphenylsulfone. The curing accelerator, e.g., triphenylphosphine, benzyldimethylamine or 2-methylimidazole described above can be used in order to accelerate the reaction of the epoxy resin with the curing agent.
[0039] The following components can further be combined if necessary in the resin composition of the present invention. That is, as a stress relaxation agent, rubber-like materials such as silicone rubbers, polysulfide rubbers, acrylic rubbers, butadiene-based rubbers, styrene-based block copolymers and saturated elastomers, various thermoplastic resins, resin-like materials such as silicone resins, and further epoxy resins and phenol resins partially or entirely modified with amino silicone, epoxy silicone or alkoxy silicone can be combined. As a silane coupling agent, epoxy silane such as γ-glycidoxypropyl trimethoxysilane and β-(3,4-epoxycyclohexyl)ethyl trimethoxysilane, amino silane such as aminopropyl triethoxysilane, ureidopropyl triethoxysilane and N-phenylaminopropyl trimethoxysilane, hydrophobic silane compounds such as phenyl trimethoxysilane, methyl trimethoxysilane and octadecyl trimethoxysilane, and mercaptosilane can be combined. As a surface treating agent, Zr chelate, titanate coupling agents and aluminium-based coupling agents can be combined. As a flame retardant aid, Sb 2 O 3 , Sb 2 O 4 and Sb 2 O 5 can be combined. As a flame retardant, halogenated epoxy resins and phosphorous compounds can be combined. Carbon black, iron oxide, dyes and pigments can be combined as a coloring agent. Further, natural waxes, synthetic waxes, metal salts of straight fatty acids, acid amides, esters and paraffin can be combined as a mold releasing agent.
[0040] The resin composition of the present invention can be produced by blending the above materials in predetermined amounts using a blender or Henschel mixer, subsequently kneading them using a heat roll, a kneader, a uniaxial or biaxial extruder, cooling them and then pulverizing them.
[0041] The semiconductor sealing material of the present invention is obtained by containing the epoxy resin in the resin composition, and is composed of the composition including the curing agent for the epoxy resin and the curing accelerator for the epoxy resin. A common practice such as a transfer molding method or a vacuum print molding method is employed to seal the semiconductor using the semiconductor sealing material of the present invention.
EXAMPLES
Examples 1 to 28 and Comparative Examples 1 to 12
[0042] Various amorphous siliceous powders were produced by preparing various raw material siliceous powders (silica rock powders) having a different particle diameter, adding various Al source materials in various amounts, mixing them, subsequently spraying the raw material siliceous powder having the average particle diameter of 10 to 72 μm (raw material 1) from one burner and spraying the raw material siliceous powder having the average particle diameter of 2 to 16 μm (raw material 2) from the other burner using an apparatus in which two burners is disposed in an apparatus described in Japanese Unexamined Patent Application, First Publication No. H11-57451, then melting them in a flame and giving a spherodization treatment to them. In the amorphous siliceous powder, the content of Al in the first portion having a particle size range of 15 μm or more to less than 70 μm, the content of Al in the second portion having the particle size range of 3 μm or more to less than 15 μm, and the content of Al in the amorphous siliceous powder, were controlled by controlling the amount of the Al source material to be added in the raw material siliceous powder in each particle size range and the amount of the raw material siliceous powder having various average particle diameter to be supplied in the flame. The average particle diameter and the particle size distribution of the amorphous siliceous powder were controlled by controlling the average particle diameter and the amount of each raw material siliceous powder to be supplied in the flame. The average sphericity and the amorphous rate were controlled by controlling the amount of the raw material siliceous powder to be supplied in the flame and a flame temperature. LPG and oxygen gas were used for forming the flame, and the oxygen gas is also used as a carrier gas for feeding the raw material powder to the burner. Those conditions and characteristics of the obtained amorphous siliceous powders are shown in Tables 1 to 6.
[0043] The amorphous rate of any of the obtained amorphous siliceous powders was 99% or more, and the average sphericity thereof was 0.80 or more. In order to evaluate the characteristics of these amorphous siliceous powders as a filler of the semiconductor sealing material, the components in combination rates shown in Tables 1 to 6 were combined, dry-blended using the Henschel mixer, and subsequently heated and kneaded using a same direction engaged biaxial extrusion kneader (screw diameter D=25 mm, L/D=10.2, paddle rotation frequency: 50 to 120 rpm, discharged amount: 3.0 kg/hr, temperature of kneaded product: 98 to 100° C.). The kneaded product (discharged product) was pressed using a pressing machine, then cooled and subsequently pulverized to produce the semiconductor sealing material. Viscosity property (curelastometer torque), molding property (wire transformation ratio) and fluidity (spiral flow) thereof were evaluated according to the following. Their results are shown in Tables 1 to 3. The epoxy resin 1: biphenyl aralkyl type epoxy resin (NC-3000P supplied from Nippon Kayaku Co., Ltd.) and the epoxy resin 2: biphenyl type epoxy resin (YX-4000H supplied from Japan Epoxy Resin Co., Ltd.) were used as the epoxy resin. The phenol resin 1: biphenyl aralkyl resin (MEH-7851SS supplied from Nippon Kayaku Co., Ltd.) and the phenol resin 2: phenol aralkyl resin (MILEX XLC-4L supplied from Mitsui Chemicals Inc.) were used as the phenol resin. The coupling agent 1: epoxy silane (KBM-403 supplied from Shin-Etsu Chemical Co., Ltd.) and the coupling agent 2: phenylaminosilane (KBM-573 supplied from Shin-Etsu Chemical Co., Ltd.) were used as the coupling agent. The curing accelerator 1: triphenylphosphine (TPP supplied from Hokko Chemical Industry Co., Ltd.) and the curing accelerator 2: tetraphenyl phosphonium tetraphenyl borate (TPP-K supplied from Hokko Chemical Industry Co., Ltd.) were used as the curing accelerator. Carnauba wax (supplied from Clariant) was used as the mold releasing agent.
(1) Viscosity Property (Curelastometer Torque)
[0044] The viscosity property of the semiconductor sealing material obtained above was determined as follows. A torque 30 seconds after heating the semiconductor sealing material to 110° C. was a viscosity index using a curelastometer (e.g., a brand name “Curelastometer Model 3P-S type” supplied from JSR Trading Co., Ltd.). A smaller value of the torque indicates a better viscosity property.
(2) Molding Property (Wire Transformation Ratio)
[0045] The molding property of the semiconductor sealing material obtained above was determined as follows. Two mock semiconductor elements having a size of 8 mm×8 mm×0.3 mm were overlapped via a die attach film on a substrate for BGA, connected with a gold wire, and subsequently molded into a package size of 38 mm×38 mm×1.0 mm using each semiconductor sealing material and a transfer molding machine. The molded product was cured at 175° C. for 8 hours to produce a BGA type semiconductor. A portion of the gold wire in the semiconductor was observed using a soft X ray transmission apparatus, and the transformation ratio of the gold wire was determined. The transformation ratio of the gold wire was obtained by measuring the shortest distance X of the wire before sealing and the maximum change amount Y of the wire after sealing and calculating (Y/X)×100 (%). This value was obtained as the mean of the transformation ratios of 12 gold wires. In the gold wire, its diameter is 30 μm and an average length is 5 mm. In the transfer molding condition, a die temperature was 175° C., a molding pressure was 7.4 MPa and a pressure preservation time was 90 seconds. The smaller the value, the smaller the transformation amount of the wire and the better the molding property.
(3) Fluidity (Spiral Flow)
[0046] A spiral flow value of each semiconductor sealing material was measured using a transfer molding machine provided with a die for measuring the spiral flow in accordance with EMMI-I-66 (Epoxy Molding Material Institute; Society of Plastic Industry). In the transfer molding condition, the die temperature was 175° C., the molding pressure was 7.4 MPa and the pressure preservation time was 120 seconds. The larger the value, the better the fluidity.
[0000]
TABLE 1
Item
Example 1
Example 2
Example 3
Example 4
Example 5
Example 6
Example 7
Raw material
Type of Al source material
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
siliceous powder
Average particle diameter (μm) of Al
0.5
0.5
0.5
0.5
0.5
0.5
0.5
source material
Average particle diameter (μm) of raw
42
42
42
42
42
42
42
material 1
Average particle diameter (μm) of raw
4
4
4
4
4
4
4
material 2
Al content (ppm) in terms of its oxide in raw
3650
130
410
560
930
1190
8710
material 1
Al content (ppm) in terms of its oxide in raw
510
130
200
260
360
450
1960
material 2
Burners for spraying raw materials 1 and 2
Separate
Separate
Separate
Separate
Separate
Separate
Separate
Condition for
Flow rate (m 3 /hr) of LPG for forming flame
16
16
16
16
16
16
16
dissolution
Flow rate (m 3 /hr) of oxygen for forming flame
96
96
96
96
96
96
96
Amount (kg/hr) of raw material 1 supplied
15
15
15
15
15
15
15
into flame
Amount (kg/hr) of raw material 2 supplied
8
8
8
8
8
8
8
into flame
Amorphous
Content (ppm) of Al in a first portion of
3610
130
370
520
900
1080
8600
siliceous powder
amorphous siliceous powder, having a particle
size range of 15 μm or more and less than
70 μm, in terms of its oxide
Content (ppm) of Al in a second portion of
490
110
190
260
340
390
1850
amorphous siliceous powder, having particle
size range of 3 μm or more and less than
15 μm, in terms of its oxide
Content (ppm) of Al in amorphous siliceous
2730
130
250
340
480
590
6330
powder including the entire particle size range,
in terms of its oxide
Combined content (% by mass) of Si and Al
99.8
99.9
99.9
99.9
99.9
99.9
99.7
in terms of their oxides
Content ratio of Al (A)/(B)
7.4
1.2
1.9
2.0
2.6
2.8
4.6
Maximum value of first peak (μm)
44
48
44
44
44
48
44
Maximum value of second peak (μm)
5
5
5
6
5
6
6
Average particle diameter (μm)
31
33
31
33
32
33
32
Maximum particle diameter (μm)
194
213
213
194
177
177
134
Amorphous rate (%)
99.7
99.9
99.9
99.8
99.6
99.7
99.8
Average sphericity (—)
0.92
0.92
0.91
0.90
0.92
0.90
0.90
Combination ratio
Epoxy resin 1 (% by mass)
—
—
—
—
—
—
—
of semiconductor
Epoxy resin 2 (% by mass)
5.7
5.7
5.7
5.7
5.7
5.7
5.7
sealing material
Phenol resin 1 (% by mass)
6.0
6.0
6.0
6.0
6.0
6.0
6.0
Phenol resin 2 (% by mass)
—
—
—
—
—
—
—
Coupling agent 1 (% by mass)
—
—
—
—
—
—
—
Coupling agent 2 (% by mass)
0.4
0.4
0.4
0.4
0.4
0.4
0.4
Curing accelerator 1 (% by mass)
0.2
0.2
0.2
0.2
0.2
0.2
0.2
Curing accelerator 2 (% by mass)
—
—
—
—
—
—
—
Mold releasing agent (% by mass)
0.3
0.3
0.3
0.3
0.3
0.3
0.3
Amorphous siliceous powder (% by mass)
87.4
87.4
87.4
87.4
87.4
87.4
87.4
Curelastometer torque (N · m)
3.7
4.5
4.6
4.3
4.2
3.9
3.8
Wire transformation ratio (%)
0
2
2
1
1
0
0
Spiral flow (cm)
130
121
120
125
124
133
129
[0000]
TABLE 2
Example
Example
Example
Example
Example
Item
Example 8
Example 9
10
11
12
13
14
Raw material
Type of Al source material
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
siliceous powder
Average particle diameter (μm) of Al
0.5
0.5
0.5
0.5
0.5
0.5
0.5
source material
Average particle diameter (μm) of raw
42
42
42
42
42
42
10
material 1
Average particle diameter (μm) of raw
4
4
4
4
4
4
2
material 2
Al content (ppm) in terms of its oxide in raw
14920
15960
19880
23220
29730
3650
3490
material 1
Al content (ppm) in terms of its oxide in raw
2870
3330
4880
5170
6790
510
1210
material 2
Burners for spraying raw materials 1 and 2
Separate
Separate
Separate
Separate
Separate
Separate
Separate
Condition for
Flow rate (m 3 /hr) of LPG for forming flame
16
16
16
16
16
12
14
dissolution
Flow rate (m 3 /hr) of oxygen for forming flame
96
96
96
96
96
72
84
Amount (kg/hr) of raw material 1 supplied
15
15
15
15
15
24
7
into flame
Amount (kg/hr) of raw material 2 supplied
8
8
8
8
8
13
16
into flame
Amorphous
Content (ppm) of Al in a first portion of
14890
15680
19100
22450
28700
3670
3510
siliceous powder
amorphous siliceous powder, having a particle
size range of 15 μm or more and less than
70 μm, in terms of its oxide
Content (ppm) of Al in a second portion of
2880
3460
4820
5220
6830
530
1320
amorphous siliceous powder, having particle
size range of 3 μm or more and less than
15 μm, in terms of its oxide
Content (ppm) of Al in amorphous siliceous
11780
12470
16480
18080
23450
2800
2070
powder including the entire particle size range,
in terms of its oxide
Combined content (% by mass) of Si and Al
99.8
99.8
99.8
99.8
99.7
99.9
99.9
in terms of their oxides
Content ratio or Al (A)/(B)
5.2
4.5
4.0
4.3
4.2
6.9
2.7
Maximum value of first peak (μm)
44
48
44
44
44
48
12
Maximum value of second peak (μm)
7
5
6
5
7
7
2
Average particle diameter (μm)
33
32
32
31
31
35
4
Maximum particle diameter (μm)
161
194
161
134
194
213
58
Amorphous rate (%)
99.7
99.7
99.6
99.5
99.5
99.5
99.9
Average sphericity (—)
0.90
0.91
0.92
0.90
0.92
0.83
0.92
Combination ratio
Epoxy resin 1 (% by mass)
—
—
—
—
—
—
—
of semiconductor
Epoxy resin 2 (% by mass)
5.7
5.7
5.7
5.7
5.7
5.7
5.7
sealing material
Phenol resin 1 (% by mass)
6.0
6.0
6.0
6.0
6.0
6.0
6.0
Phenol resin 2 (% by mass)
—
—
—
—
—
—
—
Coupling agent 1 (% by mass)
—
—
—
—
—
—
—
Coupling agent 2 (% by mass)
0.4
0.4
0.4
0.4
0.4
0.4
0.4
Curing accelerator 1 (% by mass)
0.2
0.2
0.2
0.2
0.2
0.2
0.2
Curing accelerator 2 (% by mass)
—
—
—
—
—
—
—
Mold releasing agent (% by mass)
0.3
0.3
0.3
0.3
0.3
0.3
0.3
Amorphous siliceous powder (% by mass)
87.4
87.4
87.4
87.4
87.4
87.4
87.4
Curelastometer torque (N · m)
3.6
4.3
4.2
4.4
4.5
4.0
4.2
Wire transformation ratio (%)
1
1
1
2
1
1
1
Spiral flow (cm)
128
125
123
117
118
125
116
[0000]
TABLE 3
Example
Example
Example
Example
Example
Example
Example
Item
15
16
17
18
19
20
21
Raw material
Type of Al source material
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al(OH) 3
siliceous powder
Average particle diameter (μm) of Al
0.5
0.5
0.5
0.5
12
0.03
0.5
source material
Average particle diameter (μm) of raw
42
50
15
62
42
42
42
material 1
Average particle diameter (μm) of raw
4
16
3
12
4
4
4
material 2
Al content (ppm) in terms of its oxide in raw
8710
12070
9590
26770
4810
4950
8480
material 1
Al content (ppm) in terms of its oxide in raw
420
620
420
1260
350
1110
3130
material 2
Burners for spraying raw materials 1 and 2
Separate
Separate
Separate
Seperate
Separate
Seperate
Separate
Condition for
Flow rate (m 3 /hr) of LPG for forming flame
16
16
14
18
16
16
16
dissolution
Flow rate (m 3 /hr) of oxygen for forming flame
96
96
84
108
96
96
96
Amount (kg/hr) of raw material 1 supplied
15
15
15
14
15
15
15
into flame
Amount (kg/hr) of raw material 2 supplied
8
8
8
9
8
8
8
into flame
Amorphous
Content (ppm) of Al in a first portion of
8530
10440
9360
24520
4730
4750
8150
siliceous powder
amorphous siliceous powder, having a particle
size range of 15 μm or more and less than
70 μm, in terms of its oxide
Content (ppm) of Al in a second portion of
410
950
500
1570
360
1240
3190
amorphous siliceous powder, having particle
size range of 3 μm or more and less than
15 μm, in terms of its oxide
Content (ppm) of Al in amorphous siliceous
5790
6980
6510
15930
2320
3630
6710
powder including the entire particle size range,
in terms of its oxide
Combined content (% by mass) of Si and Al
99.7
99.7
99.8
99.9
99.8
99.8
99.8
in terms of their oxides
Content ratio of Al (A)/(B)
21
11
19
16
13
3.8
2.6
Maximum value of first peak (μm)
44
53
16
63
48
44
48
Maximum value of second peak (μm)
5
16
3
13
6
5
6
Average particle diameter (μm)
31
39
11
43
32
30
33
Maximum particle diameter (μm)
194
213
70
234
194
161
194
Amorphous rate (%)
99.8
99.8
99.8
99.7
99.8
99.8
99.7
Average sphericity (—)
0.91
0.89
0.89
0.88
0.88
0.90
0.90
Combination
Epoxy resin 1 (% by mass)
—
—
—
—
—
—
—
ratio of
Epoxy resin 2 (% by mass)
5.7
5.7
5.7
5.7
5.7
5.7
5.7
semiconductor
Phenol resin 1 (% by mass)
6.0
6.0
6.0
6.0
6.0
6.0
6.0
sealing material
Phenol resin 2 (% by mass)
—
—
—
—
—
—
—
Coupling agent 1 (% by mass)
—
—
—
—
—
—
—
Coupling agent 2 (% by mass)
0.4
0.4
0.4
0.4
0.4
0.4
0.4
Curing accelerator 1 (% by mass)
0.2
0.2
0.2
0.2
0.2
0.2
0.2
Curing accelerator 2 (% by mass)
—
—
—
—
—
—
—
Mold releasing agent (% by mass)
0.3
0.3
0.3
0.3
0.3
0.3
0.3
Amorphous siliceous powder (% by mass)
87.4
87.4
87.4
87.4
87.4
87.4
87.4
Curelastometer torque (N · m)
4.4
4.2
3.9
4.3
4.4
4.1
4.2
Wire transformation ratio (%)
1
2
1
2
1
1
0
Spiral flow (cm)
123
120
129
116
122
128
125
[0000]
TABLE 4
Example
Example
Example
Example
Example
Example
Example
Item
22
23
24
25
26
27
28
Raw material
Type of Al source material
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
siliceous powder
Average particle diameter (μm) of Al
10
8
0.5
0.5
0.5
0.5
0.5
source material
Average particle diameter (μm) of raw
72
42
42
42
15
15
30
material 1
Average particle diameter (μm) of raw
7
4
4
4
3
3
5
material 2
Al content (ppm) in terms of its oxide in raw
1360
1090
3650
410
13940
5920
28110
material 1
Al content (ppm) in terms of its oxide in raw
200
1770
510
200
5300
4300
5030
material 2
Burners for spraying raw materials 1 and 2
Separate
Separate
Separate
Separate
Separate
Separate
Separate
Condition for
Flow rate (m 3 /hr) of LPG for forming flame
18
16
16
16
14
14
16
dissolution
Flow rate (m 3 /hr) of oxygen for forming flame
108
96
96
96
84
84
96
Amount (kg/hr) of raw material 1 supplied
16
15
15
15
12
10
16
into flame
Amount (kg/hr) of raw material 2 supplied
7
8
8
8
11
13
7
into flame
Amorphous
Content (ppm) of Al in a first portion of
1330
1180
3610
370
13380
5780
27330
siliceous powder
amorphous siliceous powder, having a particle
size range of 15 μm or more and less than
70 μm, in terms of its oxide
Content (ppm) of Al in a second portion of
210
1650
490
190
5510
4310
5380
amorphous siliceous powder, having particle
size range of 3 μm or more and less than
15 μm, in terms of its oxide
Content (ppm) of Al in amorphous siliceous
1020
1410
2730
250
9770
5610
21140
powder including the entire particle
size range, in terms of its oxide
Combined content (% by mass) of Si and Al
99.9
99.9
99.8
99.9
99.8
99.9
99.8
in terms of their oxides
Content ratio of Al (A)/(B)
6.3
0.7
7.4
1.9
2.4
1.3
5.1
Maximum value of first peak (μm)
76
44
44
44
15
15
31
Maximum value of second peak (μm)
9
7
5
5
3
3
6
Average particle diameter (μm)
54
32
31
31
9
7
24
Maximum particle diameter (μm)
234
213
194
213
70
70
111
Amorphous rate (%)
99.5
99.7
99.7
99.9
99.8
99.8
99.7
Average sphericity (—)
0.86
0.90
0.92
0.91
0.93
0.90
0.92
Combination ratio
Epoxy resin 1 (% by mass)
—
—
6.7
6.7
—
1.2
—
of semiconductor
Epoxy resin 2 (% by mass)
5.7
5.7
—
—
5.3
4.3
5.7
sealing material
Phenol resin 1 (% by mass)
6.0
6.0
—
6.0
—
—
6.0
Phenol resin 2 (% by mass)
—
—
5.3
—
5.1
5.1
—
Coupling agent 1 (% by mass)
—
—
0.4
0.4
—
—
0.4
Coupling agent 2 (% by mass)
0.4
0.4
—
—
0.4
0.4
—
Curing accelerator 1 (% by mass)
0.2
0.2
0.2
0.1
0.2
0.2
0.2
Curing accelerator 2 (% by mass)
—
—
—
0.2
—
—
—
Mold releasing agent (% by mass)
0.3
0.3
0.3
0.3
0.3
0.3
0.3
Amorphous siliceous powder (% by mass)
87.4
87.4
87.1
86.3
88.7
88.5
87.4
Curelastometer torque (N · m)
4.7
4.4
3.5
4.3
4.5
4.4
4.3
Wire transformation ratio (%)
2
2
0
2
1
1
1
Spiral flow (cm)
114
119
133
122
118
123
122
[0000]
TABLE 5
Com-
Com-
Com-
Com-
Com-
Com-
Com-
parative
parative
parative
parative
parative
parative
parative
Item
Example 1
Example 2
Example 3
Example 4
Example 5
Example 6
Example 7
Raw material
Type of Al source material
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
siliceous powder
Average particle diameter (μm) of Al
0.5
0.5
0.5
0.5
0.5
0.5
8
source material
Average particle diameter (μm) of raw
42
42
42
42
42
72
10
material 1
Average particle diameter (μm) of raw
4
4
4
4
4
7
2
material 2
Al content (ppm) in terms of its oxide in raw
70
34140
14870
8510
90
70
430
material 1
Al content (ppm) in terms of its oxide in raw
70
7360
2700
7360
120
60
80
material 2
Burners for spraying raw materials 1 and 2
Separate
Separate
same
Separate
Separate
Separate
Separate
Condition for
Flow rate (m 3 /hr) of LPG for forming flame
16
16
16
16
16
18
14
dissolution
Flow rate (m 3 /hr) of oxygen for forming flame
96
96
96
96
96
108
84
Amount (kg/hr) of raw material 1 supplied
15
15
15
15
15
16
7
into flame
Amount (kg/hr) of raw material 2 supplied
8
8
8
8
8
7
16
into flame
Amorphous
Content (ppm) of Al in a first portion of
70
31810
12080
8410
80
60
410
siliceous powder
amorphous siliceous powder, having a particle
size range of 15 μm or more and less than
70 μm, in terms of its oxide
Content (ppm) of Al in a second portion of
60
7190
11210
7390
130
70
70
amorphous siliceous powder, having particle
size range of 3 μm or more and less than
15 μm, in terms of its oxide
Content (ppm) of Al in amorphous siliceous
70
25910
11980
8250
110
60
170
powder including the entire particle size
range, in terms of its oxide
Combined content (% by mass) of Si and Al
99.9
99.7
99.8
99.7
99.9
99.9
99.9
in terms of their oxides
Content ratio of Al (A)/(B)
1.2
4.4
1.1
1.1
0.6
0.9
5.9
Maximum value or first peak (μm)
44
48
48
44
44
76
12
Maximum value of second peak (μm)
5
6
8
6
4
8
2
Average particle diameter (μm)
31
33
33
32
30
52
4
Maximum particle diameter (μm)
194
177
213
194
177
234
58
Amorphous rate (%)
99.7
99.3
99.7
99.8
99.7
99.6
99.8
Average sphericity (—)
0.90
0.88
0.90
0.91
0.89
0.88
0.91
Combination ratio
Epoxy resin 1 (% by mass)
—
—
—
—
—
—
—
of semiconductor
Epoxy resin 2 (% by mass)
5.7
5.7
5.7
5.7
5.7
5.7
5.7
sealing material
Phenol resin 1 (% by mass)
6.0
6.0
6.0
6.0
6.0
6.0
6.0
Phenol resin 2 (% by mass)
—
—
—
—
—
—
—
Coupling agent 1 (% by mass)
—
—
—
—
—
—
—
Coupling agent 2 (% by mass)
0.4
0.4
0.4
0.4
0.4
0.4
0.4
Curing accelerator 1 (% by mass)
0.2
0.2
0.2
0.2
0.2
0.2
0.2
Curing accelerator 2 (% by mass)
—
—
—
—
—
—
—
Mold releasing agent (% by mass)
0.3
0.3
0.3
0.3
0.3
0.3
0.3
Amorphous siliceous powder (% by mass)
87.4
87.4
87.4
87.4
87.4
87.4
87.4
Curelastometer torque (N · m)
7.0
6.8
7.2
6.0
6.7
7.2
5.6
Wire transformation ratio (%)
5
7
8
4
5
7
5
Spiral flow (cm)
101
98
112
118
105
90
107
[0000]
TABLE 6
Comparative
Comparative
Comparative
Comparative
Comparative
Item
Example 8
Example 9
Example 10
Example 11
Example 12
Raw material
Type of Al source material
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
Al 2 O 3
siliceous powder
Average particle diameter (μm) of Al source material
0.5
0.5
0.5
0.5
0.5
Average particle diameter (μm) of raw material 1
15
42
42
42
50
Average particle diameter (μm) of raw material 2
3
4
4
4
16
Al content (ppm) in terms of its oxide in raw material 1
33890
29730
34140
14870
35900
Al content (ppm) in terms of its oxide in raw material 2
1560
6790
7360
2700
1210
Burners for spraying raw materials 1 and 2
Separate
Separate
Separate
same
Separate
Condition for
Flow rate (m 3 /hr) of LPG for forming flame
14
16
16
16
16
dissolution
Flow rate (m 3 /hr) of oxygen for forming flame
84
96
96
96
96
Amount (kg/hr) of raw material 1 supplied into flame
14
15
15
15
15
Amount (kg/hr) of raw material 2 supplied into flame
9
8
8
8
8
Amorphous
Content (ppm) of Al in a first portion of amorphous
32110
27900
31810
12080
33140
siliceous powder
siliceous powder, having a particle size range of
15 μm or more and less than 70 μm, in
terms of its oxide
Content (ppm) of Al in a second portion of amorphous
1910
6910
7190
11210
1610
siliceous powder, having particle size range of 3 μm
or more and less than 15 μm, in terms of its oxide
Content (ppm) of Al in amorphous siliceous powder
21370
23050
25910
11980
22870
including the entire particle size range,
in terms of its oxide
Combined content (% by mass) of Si and Al in terms
99.7
98.1
99.7
99.8
99.7
of their oxides
Content ratio of Al (A)/(B)
17
4.0
4.4
1.1
21
Maximum value or first peak (μm)
15
44
48
48
51
Maximum value of second peak (μm)
3
5
6
8
16
Average particle diameter (μm)
10
31
33
33
38
Maximum particle diameter (μm)
70
213
177
213
213
Amorphous rate (%)
99.8
99.7
99.3
99.7
99.8
Average sphericity (—)
0.90
0.91
0.88
0.90
0.90
Combination ratio
Epoxy resin 1 (% by mass)
6.7
6.8
6.7
—
—
of semiconductor
Epoxy resin 2 (% by mass)
—
—
—
5.3
5.3
sealing material
Phenol resin 1 (% by mass)
—
6.0
—
—
—
Phenol resin 2 (% by mass)
5.3
—
5.3
5.1
5.1
Coupling agent 1 (% by mass)
—
—
0.4
—
0.4
Coupling agent 2 (% by mass)
0.4
0.4
—
0.4
—
Curing accelerator 1 (% by mass)
0.2
0.2
0.2
0.2
0.2
Curing accelerator 2 (% by mass)
—
—
—
—
—
Mold releasing agent (% by mass)
0.3
0.3
0.3
0.3
0.3
Amorphous siliceous powder (% by mass)
87.1
86.3
87.1
88.7
88.7
Curelastometer torque (N · m)
7.0
6.1
6.9
6.7
6.3
Wire transformation ratio (%)
6
4
5
7
7
Spiral flow (cm)
110
117
105
110
103
[0047] As is evident from the comparison of Examples with Comparative Examples, according to the amorphous siliceous powder of the present invention, it is possible to prepare the resin composition, in particular the semiconductor sealing material which is more excellent in fluidity, viscosity property and molding property than Comparative Examples.
INDUSTRIAL APPLICABILITY
[0048] The amorphous siliceous powder of the present invention is used in semiconductor sealing materials used for automobiles, portable electronic devices, personal computers, electrical home appliances and the like, and as a filler for laminated sheets on which semiconductors are mounted. The resin composition of the present invention can also be used for prepregs for print substrates impregnating and curing in a glass fabric, a glass nonwoven or another organic substrate, and as various engineered plastics, in addition to use in a semiconductor sealing material. | 4y
|
The present invention is generally in the field of assays for apoliproteins in saliva.
This application claims priority to U.S. Ser. No. 60/124,562 filed Mar. 16, 1999.
BACKGROUND OF THE INVENTION
Coronary artery disease (CAD) is the leading cause of morbidity and mortality in most developed countries. Numerous markers and tests for identifying individuals at risk are available, among them blood tests for lipid markers such as total cholesterol and cholesterol bound to various circulating proteins. Based on the outcome of such testing, appropriate prophylactic or therapeutic measures including dietary modification and exercise can be initiated to forestall or reverse progression to more severe CAD.
Plasma lipoproteins are carriers of lipids from the sites of synthesis and absorption to the sites of storage and/or utilization. Lipoproteins are spherical particles with triglycerides and cholesterol esters in their core and a layer of phospholipids, nonesterified cholesterol and apolipoproteins on the surface. They are categorized into five major classes based on their hydrated density as very large, triglyceride-rich particles known as chylomicrons (less than 0.95 g/ml), very low density lipoproteins (VLDL, 0.95 to 1.006 g/ml), intermediate-density lipoproteins (IDL, 1.006 to 1.019 g/ml), low-density lipoproteins (LDL, 1.019 to 1.063 g/ml) and, high-density lipoproteins (HDL, 1.063 to 1.210 g/ml). (Osborne and Brewer, Adv. Prot. Chem . 31:253-337 (1977); Smith, L. C. et al. Ann Rev. Biochem ., 47:751-777 (1978)).
Apolipoproteins are protein components of lipoproteins with three major functions: (1) maintaining the stability of lipoprotein particles, (2) acting as cofactors for enzymes that act on lipoproteins, and (3) removing lipoproteins from circulation by receptor-mediated mechanisms. The four groups of apolipoproteins are apolipoproteins A (Apo A), B (Apo B), C (Apo C) and E (Apo E). Each of the three groups A, B and C consists of two or more distinct proteins. These are for Apo A: Apo A-I, Apo A-II, and Apo A-IV, for Apo B: Apo B-100 and Apo B-48; and for Apo C: Apo C-I, Apo C-II and Apo C-III. Apo E includes several isoforms. Each class of lipoproteins includes a variety of apolipoproteins in differing proportions with the exception of LDL, which contains Apo B-100 as the sole apolipoprotein. Apo A-I and Apo A-II constitute approximately 90 percent of the protein moiety of HDL whereas Apo C and Apo E are present in various proportions in chylomicrons, VLDL, IDL and HDL. Apo B-100 is present in LDL, VLDL and IDL. Apo B-48 resides only in chylornicrons and so called chylomicron remnants (Kane, J. P., Method. Enzymol . 129:123-129 (1986)).
Total plasma or serum cholesterol (C) has traditionally been the primary screening and indicator of CAD, but the emphasis has recently shifted to serum lipoprotein profiles including HDL, LDL, VLDL, lipoprotein A and particularly to the LDL/HDL or Total C/HDL ratios which have shown better correlations with incidence and severity of CAD. In contrast to the atherogenic potential of LDL, VLDL and VLDL remnants, HDL are inversely correlated with CHD, so that individuals with low concentrations of HDL-C have an increased incidence of CHD (Gordon, T. et al., Am. J. Med ., 62:707-714 (1977); Miller, N. E. et al., Lancet , 1:965-968 (1977); Miller, G. J. and Miller, N. E., Lancet , 1:16-19 (1975)).
A large number of manual and automated methods are available for screening and monitoring of these markers. All of these tests, however, require either venous blood drawn by syringe or, in some cases, capillary blood obtained by needle prick. Both methods are invasive and unpleasant to many individuals and are best performed by trained professional personnel, preferably in doctor's office, to minimize erroneous results. Handling and disposal of blood products also involves potential hazards from infectious agents and pathogens.
It is thus highly desirable to provide safer alternative specimens not requiring invasive procedures. Furthermore, the ideal analytical method or device should provide rapid and reliable results for point of collection (“POC”) diagnosis at low cost.
Most analytes that appear in serum also appear in saliva, but at levels that are a fraction of their level in serum. The transport of an analyte into saliva can be by intracellular (diffusion or passive transport) or extracellular (active transport) transport. Materials that are lipid soluble enter saliva by diffusion through cellular compartments. Haekcel, Ann. N.Y. Acad. Sci. 694, 128-142 (1993).
Saliva has not been exploited as a diagnostic fluid because of the many problems associated with adapting it to assay form. For example, it is difficult to collect sufficient sample: Most tests require collection of at least 1 ml of saliva because there is considerable loss during filtration and handling. This requires an average of 3-5 minutes of salivation, which most people are not willing to do. The average flow rate for 95% of young men is 0.35-0.38 ml/min. (K. Diem, et al (ed) Scientific Tables (Ciba-Geigy Pharmaceuticals 1970) p. 643. Moreover, the handling of saliva samples to prepare them for assay is both tedious and unpleasant. Saliva generally has to be filtered to remove the mucopolysaccharides and allow flow and handling. Available collection devices utilize cotton pads to absorb saliva in the mouth. The pad thus acts to collect and process the saliva, preparing it for assay. The pad is then placed in a volume of fluid containing preservatives and shipped to the laboratory for analysis. The preservative fluid prevents quantitation by making it impossible to know how much saliva, if any, was collected and added to the preservative. When the device reaches the lab the technicians must remove the pad and mucopolysaccharides either by centrifugation or filtration. This is a time consuming and unpleasant job. The small amount of saliva sample and low level of analyte in saliva usually means that the saliva sample cannot be analyzed by an autoanalyzer, but must be assayed in a high sensitivity Elisa or RIA, both of which are labor-intensive tests.
Many studies of saliva have shown that the levels of analytes vary with the secreting gland and the method of collection (e.g. stimulated flow versus normal flow). For reviews see Saliva as a Diagnostic Fluid (D. Malmud and L. Tobak, Eds., Ann. N.Y. Acad. Sci. Vol. 694 D (1993) and J. O. Tenuvuo (ed) Human Saliva: Clinical Chemistry and Microbiology (CRC Press Inc. 1989) vol. I and II). Thus, one presumes that the significant variations in lipid levels reported in saliva are in large part due to collection method. Levels of cholesterol are also low, with cholesterol levels of about 1/400 and about 1/50 of that seen in serum. Bronislaw, et al., “Lipids of Saliva and Salivary Concretions,” in Human Saliva: Clinical Chemistry and Microbiology (CRC Press Inc. 1989) vol. II, 121-145). Thus the level in an individual sample is too low for conventional serum assays in the routine assay of lipids in saliva, therefore either requiring the use of sensitive immunoassays or a larger quantity of saliva. J. C Touchstone, et al., “Quantitation of Cholesterol in Biological.” in Adv. Thin Layer Chromatogr., Proc. Bienn. Symp. Meeting Date 1980, (Wiley & Sons 2 nd ed. 1982) measured total cholesterol and lipids. Moreover, there is a variation in levels depending on the time of day and from day to day (less than 8%), with levels highest in morning specimens and lower throughout the day, suggesting that saliva testing of cholesterol be done at the same time of the day.
Another problem with using saliva is that saliva is heavily contaminated with the oral flora. Available collection devices provide high levels of preservatives to retard growth of bacteria but, unless the sample is carefully preserved (e.g. by freezing), samples often become putrefied and laboratory technicians avoid processing saliva. Furthermore, high levels of preservatives can interfere in many assays. Saliva also contains many proteins and enzymes of both salivary and bacterial origins. Over time these enzymes and proteins can interact with the analytes of interest and make the assay of some analytes impossible. Thus, as a rule, stored samples cannot be expected to yield accurate results unless the storage additives and conditions are optimized for the analyte.
The literature reports that, while cholesterol is present in saliva, the levels vary greatly. For example, 5.6 mg/L average was reported by B. Larsson, et al, “Lipids in Human Saliva” in Archs. Oral. Biol. 41(1), 105-110 (1996); 15 mg/L average was reported for both the parotid and submandibular glands saliva output by Slomiany, et al, J. Dent. Res. 61(1), 24-27 (1983); and 69 mg/L was reported by Rabinowitz, et al, Arch. Oral. Biol. 20(7), 403-406 (1975).
As noted above, the ratio of LDL:HDL ratio is an established predictor of the risk of coronary artery disease. The recent NCEP guidelines call for use of ratio rather than total cholesterol. It has been reported that men with acceptable total cholesterol levels but ratios of LDL:HDL above 3.5 were 50% more likely to have coronary heart disease than their counterparts with lower ratios. It is a matter of time before total cholesterol is supplanted by ratios.
Immunoassays for lipoproteins associated with HDL and LDL have been shown to correlate with the measurement of cholesterol ratios in these two fractions. N. Rifai, et al (ed) Laboratory Measurement of Lipids, Lipoproteins and Apolipoproteins (AACC Press 1994) p. 114. The results correlate with the methods where HDL and LDL fractions are physically separated and measured (Laboratory Measurement of Lipids, Lipoproteins and Apolipoproteins. 1994. N. Rifai and R. Warnick Eds. AACC Press.)
It is not known if the proteins with which salivary cholesterol is associated are the same as those in serum, i.e. ApoAI and ApoBII. It is clear from all studies (Belmont) (Mandel, et al, Arch. Oral. Biol. 14(2), 231-233 (1969)) that salivary lipids are secreted by the glands in conjunction with lipoproteins(s). Slomiany et al also demonstrated that the lipids in saliva are associated with proteins. There is no published literature, however, on the origin of the lipids or their physical state in saliva” (Larsson et al). Thus, from the early literature, it is not clear whether the salivary lipids are synthesized de novo in the salivary glands or are derived from serum; and, if they are serum derived, if the salivary apolipoproteins are the same as the apolipoproteins associated with LDL and HDL in serum. There are other salivary glycoproteins also associated with the lipid. It is not clear from the literature whether the structure of the lipid particles in saliva is the same as those in serum and whether the conformation of the apolipoproteins is the same in saliva as in serum. Rabinowitz suggests that lipids secreted by the glands are secreted associated with lipoprotein. He demonstrated that the lipid levels drop in stimulated saliva but retain the same ratio to one another. Larsson reports that salivary lipoprotein fractions are of much higher density than serum lipoproteins and concludes that the salivary lipids are differently aggregated.
Various studies have indicated that the saliva levels of cholesterol show a gross correlation with serum cholesterol levels (Lochner, A. Dissertation Abstract International (1985) Vol. 46, #5B). It has also been observed that there is a positive correlation between persons with hypercholesteremia. Slorniany, et al, Arch. Oral. Biol. 27(10), 803-808 (1982) and Murty, et al, RCS Med. Sci. 10(5), 359 (1982). The paucity of studies correlating serum and saliva cholesterol may be due to the fact that the available methods for assaying cholesterol and thus correlating serum and saliva have been too insensitive. The enzymic and chromatographic methods of detecting cholesterol rely on high levels not available in saliva. Thus, these methods require large amounts of saliva and studies on lipids have generally been done on pools. Measurement of cholesterol in saliva is further complicated because saliva contains high amounts of peroxidase, an enzyme component of some cholesterol assays.
It is therefore an object of the present invention to provide a non-invasive, non-instrumental, accurate, simple and cost-effective means for determination of a marker for CAD, HDL, LDL, and/or the ratio of LDL:HDL.
SUMMARY OF THE INVENTION
A method and kit has been developed to detect the levels of apolipoproteins A-1 and B in saliva, which is correlated with the levels of HDL and LDL in serum, respectively. In unstimulated saliva, the ratio of Apo A to Apo B is correlated with the ratio of HDL to LDL in serum. In stimulated saliva the levels of Apo B normalized to albumin correlate with both serum Apo B and serum LDL. The high degree of correlation in combination with a simple, quick test that can be performed at the site of collection provides a cost effective, patient friendly means to monitor an individual's risk of heart disease. In the preferred embodiment, saliva production is stimulated by means such as breath mint or tart solution (such as lemon) and the effect of dilution controlled by reference to albumin. In the most preferred embodiment, the assay is an immunoassay performed using the Serex laminated strip format as described in U.S. Pat. Nos. 5,710,009, 5,500,375, and 5,451,504. These strips are advantageous since they serve as the collection and assay device, greatly simplifying handling, as the sample is applied directly to the strip test and processed as an integral part of the analytical procedure. This method requires less than 200 microliters, which should be available in the average person's mouth at any time. Additional saliva production can be obtained, however, using breath mints or a tart juice such as lemon juice. The assay of saliva at POC will eliminates the need for preservatives to store the sample and entirely avoids the problem with contamination by oral flora, since the assay can be completed within 10 minutes of saliva collection.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of the absorbance of saliva samples assayed by ELISA for the presence of HDL, using serum and Apo A1 at different dilutions (1×1:10, 1:100) as controls.
FIG. 2A is a graph of the absorbance of saliva samples assayed by ELISA for the presence of LDL, using serum and Apo B as different dilutions (1×, 1:10, and 1:100) as controls.
FIG. 2B is a graph of Apo B (mg/dl) relative to Apo A1 (mg/dl) in lemon stimulated saliva. FIG. 2C is a graph of Apo B (mg/dl) relative to Apo a1 per mg of albumin in lemon stimulated saliva.
FIG. 3 a is a graph of color density in a strip immunoassay for LDL for LDL in serum at dilutions of 1:100, 1:75, 1:25 and 1:10. FIG. 3 b is a graph of color density in a strip immunoassay for HDL for HDL in serum at dilutions of 1:1,200, 1:600, 1:100, and 1:10.
FIG. 4 a is a graph of the correlation of the rato of Apo B to Apo A in serum. FIG. 4 b is a graph of the correlation of the ratio of Apo B in serum measure by the ELISA described herein compared to the Roche commercially available Cobas Mira assay. FIG. 4 c is a graph of the correlation of the ratio of Apo B to Apo A in lemon stimulated saliva
DETAILED DESCRIPTION OF THE INVENTION
It has now been demonstrated that ApoA and ApoB are both present in saliva, but that these proteins are not detectable by electrophoresis or immunoassay except in very fresh samples, presumably due to degradation of the lipoproteins by saliva enzymes or bacteria or both. This explains why other studies have not observed these proteins; since they detected cholesterol by enzymic methods, and in the time required for this the proteins were degraded.
I. Reagents for Detection of Apolipoproteins
Antibodies are known in the literature and available from commercial sources and from the ATCC.
Antibodies to Apo B
Antibodies to Pan B
D 6 MAb is an antibody with equal binding and high affinity for all Apo B-containing lipoproteins in human plasma, as described by Koren, E. et al., Biochim. Biophys. Acta , 876:91-100 (1986); Koren, E. et al., Biochim. Biophys. Acta , 876:101-107 (1986), specifically including Apo B-48 and Apo B-100. D 6 binds to an epitope localized at the amino terminal half of Apo B and recognizes both B-48 and B-100.
Antibodies to Apo B-100
Conventional ways of producing Monoclonal antibodies to Apo B-100 include immunization of mice with LDL. This approach is convenient because it is relatively simple to isolate LDL. However, Monoclonal antibodies produced using LDL as an immunogen tend to be sensitive to conformational changes of Apo B-100 caused by variations in the lipid composition of LDL particles. For example, Apo B-100 epitopes are less reactive with a number of anti-Apo B Monoclonal antibodies due to the presence of various amounts of triglycerides (Keidar, S. et al., Metabolism , 39: 281-288 (1990); Galeano, N. F. et al., J. Biol, Chem ., 269:511-519 (1994); Harduin, P. et al., Arterioscl. Thromb , 13: 529-535 (1993)).
PCT PCT/US95/08331 “Antibodies to Lipoproteins and Apolipoproteins and Methods of Use Thereof ” by Oklahoma Medical Research Foundation describes antibodies that provide selective recognition of LDL and high and invariable reactivity with LDL particles, irrespective of possible variations in their lipid composition and/or conformation, that is, an antibody which recognizes a stable, conformation-independent epitope which is uninfluenced by the lipid content and which is equally expressed in all LDL particles, but inaccessible in VLDL and chylomicrons. HB 3 cB 3 binds to the epitope near the T2 carboxy terminal region of B-100, exclusively, and does not recognize B-48. The epitope recognized by HB 3 cB 3 may be conformationally changed or masked by lipids and/or other apolipoproteins present in VLDL. Chylomicrons are not recognized by HB 3 cB 3 because they lack Apo B-100. The HB 3 cB 3 antibody and LDL-binding fragments derived therefrom, can be used as an LDL-specific binding molecule in all of the compositions and methods described herein because of its specificity for LDL and lack of cross-reactivity with other lipoproteins.
Two other LDL specific Monoclonal antibodies are described by Milne, R. et al., J. Biol Chem ., 264:19754-19760 (1989); and WO 93/18067 by La Belle, et al. and La Belle, M. et al., Clin. Chim. Acta , 191:153-160 (1990) (8A2.1 and 4B5.6).
Antibodies to Apo A-I
Two antibodies to Apo A-I are also described in PCT PCT/US95/08331 by OMRF which both bind to HDL with a high affinity and show negligible reactivity with any other lipoprotein density class. The two anti-Apo A-I Monoclonal antibodies, AIbD 5 and AIbE 2 , bind to sterically distant epitopes since they do not compete with each other in their binding to either delipidized and purified Apo A-I or intact HDL particles. Both Monoclonal antibodies to Apo A-I bind with high affinity to delipidized Apo A-I and to HDL and show negligible or no binding to LDL, VLDL, chylomicrons and Apos A-II, C-III and E
Antibodies to Apo A-II
A monoclonal antibody to Apo A-II which binds with high affinity to HDL and is capable of removing all the HDL particles containing Apo A-II (LP-A-I:A-II particles) from plasma or serum, leaving the HDL particles without Apo A-II (LP-A-I particles) intact, CdB 5 , is described by Koren, E. et al., Arteriosclerosis , 6:521a (1986); Alaupovic, P. et al., J. Lpid Res ., 32:9-19 (1991).
Antibodies to Apo C-III
An MAb to Apo C-III, XbA 3 , which is useful in quantification of VLDL particles is described by Koren, E. et al., Atherosclerosis , 95:157-170 (1992).
Antibodies to Apo E
Two Monoclonal antibodies to Apo E are described by Koren, E. et al., Atherosclerosis , 95:157-170 (1992). One of them, EfB 1 , binds preferably to Apo E associated with VLDL which are precipitated by heparin whereas the other (EfD 3 ) binds predominantly to Apo E in HDL which are not precipitated by heparin treatment of a sample.
II. Sample Preparation
In a preferred embodiment, saliva is collected, filtered through cotton or a similar pore size filter to remove mucopolysaccharides, and kept chilled to 4° C. until assayed. Preferably the sample is assayed within three hours of collection. Preservatives and protease or other enzyme inhibitors can be added to the sample.
III. Simultaneous Sample Collection, Preparation and Assay
In an alternative embodiment, an integrated collection and assay device can be used. As described in PCT PCT/US98/16256 “Integrated Collection and Assay Device for Saliva and Blood ” by Serex, Inc., this device can include a fluid collector, a processing and metering pad and/or filter, and one or more assay strips. The fluid collector can be adapted for collection of saliva or blood. The assay strips can be any type presently used. Nitrocellulose is a preferred material. Preferably, the assay strips are laminated dipsticks such as described in U.S. Pat. No. 5,500,375.
In a preferred embodiment, this device includes holder having a stem portion and a funnel portion. In one embodiment, the holder can be a double sheet of plastic that is laminated together at the stem portion. For example, the holder can be made of polyethylene or another clear, flexible plastic. The funnel portion is sealed on the edges to form lateral seals that extend down the stem portion. Thus, an open top collection “funnel” is formed in the funnel portion, which is in fluid communication with the stem portion. At the neck of the device, or the juncture of the funnel portion and stem portion, is the processing and metering pad. The pad is preferably an absorbent pad or sponge which serves to filter oral debris and mucopolysaccharides from the sample. It can be formed of any suitable material, preferably of a fibrous nature, most preferably a material such as a cellulose or cellulose derivative. In some embodiments, the material may be charged or contain substances which effect separations or passage through the filter. For example, the pad may also contain buffers and reagents such as dissociating or mucolytic agents and surfactants which may be required. The pad further serves to meter the amount of sample which is transferred to the assay strip. This is accomplished by selection of the size, shape, porosity and composition of the pad, which can be adjusted as necessary to optimize separation and metering of sample volume.
The device includes one or more assay strips. These may be of the same or different materials, providing for measurement of multiple analytes in the sample. The assay strip extends from the pad into the stem portion. The assay strip includes a carrier which supports a membrane which is in liquid communication with the pad. The assay strip can be any chromatographic assay strip but is preferably designed as described in U.S. Pat. Nos. 5,500,375 and 5,710,009. In the most preferred embodiment, the membrane is a nitrocellulose strip which includes a sample application region adjacent to the processing or metering pad. The membrane further includes a mobilization zone having immobilized thereupon mobilizable labelled reagent, for example. The membrane also includes one or more trap zones. Three contain various reagents for capturing unreacted analyte or labelled analyte, for example, depending upon the design of the assay. In this preferred embodiment, the membrane further includes one or more detection zones which may be the same as one or more of the trap zones. The section of the holder overlying the detection zones is preferably clear so that the results of the assay can be read.
IV. Other Immunoassays
The apolipoproteins in the saliva can be measured using any of a number of different assays, including ELISA and automated immunoturbidimetric assays, as well as dipsticks made using conventional technology.
Elisa
In ELISA, sample is placed in separate wells in microtiter plates and allowed to adsorb to the wall of the wells. The wells are then treated with a blocking agent, such as bovine serum albumin or nonfat milk proteins, to cover areas in the wells not bound by antigen. Antibody is then added in an appropriate buffer to the well, in one or more concentrations and the microtiter plate incubated under conditions adequate to allow the antibody to bind the antigen adsorbed on the wall of each well. The presence of antibody bound to antigen (i.e., Apo A1, Apo B, etc.) in a well can then be detected using a standard enzyme-conjugated anti-antibody which will bind antibody that has bound to apolipoprotein in the well. Wells in which antibody is bound to antigen are then identified by adding a chromogenic substrate for the enzyme conjugated to the anti-antibody and color production detected by an optical device such as an ELISA plate reader.
Other detection systems can also be used, for example, a biotin-streptavidin system. In this system, one of the antibodies (either the antibody immunoreactive with the apolipoprotein or the antibody immunoreactive with the specific antibody) is biotinylated. The nonbiotinylated antibody are incubated with wells coated with the apolipoprotein or lipoprotein antigen. Quantity of biotinylated antibody bound to the coated antigen is determined using a streptavidin-peroxidase conjugate and a chromogenic substrate.
Antibodies can alternatively be labeled with any of a number of fluorescent compounds such as fluorescein isothiocyanate, europium, lucifer yellow, rhodamine B isothiocyanate (Wood, P. In: Principles and Practice of Immunoasay , Stockton Press, New York, pages 365-392 (1991)) for use in immunoassays. In conjunction with the known techniques for separation of antibody-antigen complexes, these fluorophores can be used to quantify apolipoprotein. The same applies to chemiluminescent immunoassay in which case antibody or apolipoprotein can be labeled with isoluminol or acridinium esters (Krodel, E. et al., In: Bioluminescence and Chemiluminescence: Current Status . John Wiley and Sons Inc. New York, pp 107-110 (1991); Weeks, I. et al., Clin. Chem . 29:1480-1483 (1983)). Radioimmunoassay (Kashyap, M. L. et al., J. Clin. Invest , 60:171-180 (1977)) is another technique in which antibody can be used after labeling with a radioactive isotope such as 125 I. Some of these immunoassays can be easily automated by the use of appropriate instruments such as the IMx™ (Abbott, Irving, Tex.) for a fluorescent immunoassay and Ciba Coming ACS 180™ (Ciba Corning, Medfield, Mass.) for a chemiluminescent immunoassay.
Immunoprecipitation
Immunoprecipitation is another means of identifying small amounts of protein in a complex mixture by its interaction with antibody. The amount of antigen present can be determined by changes in turbidity of a solution using optical detection means such as a spectrophotometer, or the precipitate isolated and measured by detection of label on the antibody, typically using ELISA, measurement of a fluorescent label or measurement of a radiolabel. In those cases where the antibody does not precipitate antigen, precipitation may be enhanced through the use of a second anti-antibody or a second antibody immunoreactive with the same antigen.
For example, in an immunoturbidimetric assay for LDL, one preferably would use a single monoclonal antibody capable of precipitating exclusivly LDL. Single Monoclonal antibodies generally do not precipitate the antigens they are immunoreactive with. Accordingly, two or more Monoclonal antibodies immunoreactive with the same antigen can be used to precipitate the antigen. For quantitation of LDL, one would use two monoclonal antibodies which are specific for LDL. Useful antibodies include HB3cB3 combined with another antibody such as WbA53aC1-A6, described by Koren, et al. Biochemistry 26, 2734-2740 (1987). This results in immunoprecipitation of LDL without affecting other plasma lipoproteins such as VLDL and HDL.
In addition, the above-described sandwich method can be used to detect any blood protein of interest in a particular sample, provided, as described above, that either two distinct Monoclonal antibodies are available which do not interfere with each other's binding to the particular protein, or one MAb and a polyclonal antibody are available for the particular protein and the MAb is allowed to bind to the particular protein before the polyclonal antibody.
As noted above, anti-LDL Monoclonal antibodies, such as HB 3 cB 3 , are useful for quantification of LDL-cholesterol in antibody-antigen precipitation techniques and enzyme-linked immunosorbent assays (ELISA). For example, in a precipitation method the anti-LDL MAb is added to human serum or plasma and allowed to bind to LDL. The immune complex of LDL bound to anti-LDL MAb is then precipitated by mixing in an excess amount of protein A or an anti-mouse IgG polyclonal antibody. Precipitation of the complexes is enhanced by centrifuging the mixture and then discarding the supernatant. The precipitate containing LDL is then washed and dissolved in 8 M urea in PBS or treated with detergents such as Triton X-100 and cholic acid (Sigma, St. Louis, Mo.). This is followed by determination of LDL-cholesterol using an enzymatic assay for cholesterol (Sigma, St. Louis, Mo.).
Antibodies can be bound to a solid phase material for use in assays described herein. Various types of adsorptive materials, such as nitrocellulose, Immobilon™, polyvinyldiene difluoride (all from BioRad, Hercules, Calif.) can be used as a solid phase material to bind the anti-lipoprotein antibodies. Other solid phase materials, including resins and well-plates or other materials made of polystyrene, polypropylene or other synthetic polymeric materials can also be used. In the preferred embodiment for assaying lipoprotein concentrations, pieces or strips of these materials are coated with one or more antibodies, or functional fragments thereof, directed against specific epitopes of HDL, LDL, other lipoproteins, or apolipoproteins for use in patient samples. Such strips are referred to herein as “dipsticks”. The dipsticks may also be attached to one end of a longer strip of a solid support material, such as plastic, which can serve as a handle for dipping a dipstick into a solution or sample. The plastic handle can also serve as a tether so that multiple dipsticks can be attached to a common support. Such a multi-strip design may be particularly useful in a set-up for testing multiple lipoproteins and/or apolipoproteins simultaneously.
Although various sizes of dipsticks are possible, typically, pieces of the solid phase material that are coated with antibody have the general dimensions of 0.5 cm×0.5 cm and can be attached to the longer solid support strips having general dimensions of 0.5 cm×5 cm. Such dimensions permit an accurate determination of lipoprotein or apolipoprotein levels in as little as 100 μl of sample.
The present invention will be further understood by reference to the following non-limiting examples.
EXAMPLE 1
Demonstration of the Presence of Apolipoproteins in Saliva
A. Polyacrylamide gel electrophoresis
Sample preparation
Fresh saliva samples were collected into test tubes and analyzed within 30 minutes or were kept overnight at 4C with 0.1% sodium azide. Serum samples were used as molecular weight markers; these were kept frozen and were thawed before analysis. Lipoproteins, HDL and LDL and apolipoproteins, ApoAI and ApoB from human plasma were from Calbiochem, La Jolla, Calif. Before electrophoresis all samples were treated with 2.5% sodium dodecyl sulfate (SDS) and incubated for 5 minutes in boiling water bath. In another variation of above treatment, the incubation mixture contained also 1% dithiothreitol (DTT). Bromophenol blue indicator was added to samples prior to electrophoresis.
EIectrophoresis
Electrophoresis was performed with Phast System (Pharnacia Biotech, Piscataway, N.J.) using manufacturers' protocols and materials. The polyacrylamnide gel at a pH 4-15 gradient and buffer system consisted of 0.2 M Tris buffer, pH 8.1 with 0.55% SDS. Pretreated samples were applied to gels and gels were subjected to automated separation according to the protocol provided by Pharnacia. After completion of electrophoresis, gels were stained with Coomassie Blue R-350 and then destained and analyzed.
Results
Results from electrophoresis of unreduced samples were as follows: The HDL sample and ApoAI sample migrated as single bands. Relative mobility (Rf), measured with reference to bromophenol blue marker was 0.94 for each one. Rf for LDL sample was 0.24 and for ApoB sample was 0.25. The serum sample showed three bands at the region relative to HDL (Rf were 0.97; 0.94; and 0.88) and one band at the region relative to LDL (Rf0.24). Saliva samples showed two bands at the region relative to HDL (Rf were 0.94 and 0.91) and one band at the region relative to LDL (Rf=0.24-in one case Rf=0.22).
Electrophoresis for DTT reduced samples showed HDL and ApoAI as single bands with Rf=0.85 for each. LDL appeared as two bands (Rf0.26 and 0.22) and ApoB was a single band (Rf=0.26). Serum sample showed two bands at the region relative to HDL (Rf0.82 and 0.79) and no sharp bank in LDL area. Saliva samples showed a single band at the region relative to HDL (Rf=0.82 for each saliva sample) and no sharp band at the region relative to LDL.
Protein bands were only visible on gels when freshly collected saliva samples were analyzed.
B. Western Blotting.
Protein Blotting
Protein blotting was done essentially according to the Phast System™ Development Technique File 220: Nitrocellulose (supplied with the Phast System unit) was prewetted with 1×PBS. Upon completion of electrophoresis the nitrocellulose was placed on top of the gradient gel and the temperature was increased to 70° C. and diffusion-mediated transfer proceeded for 20-30 minutes.
The nitrocellulose was incubated with shaking for 1 hour at RT followed by washing for 5 minutes in wash buffer (WB, 1×PBS, 0.05% TWEEN®20). The blot was then incubated with shaking for 30-60 minutes with a 1:1000 dilution of mouse anti-apolipoprotein B (monoclonal W a B 2 bD 6 , immunoreactive with ApoB independent of lipid content, obtained from Dr. Eugen Koren, Oklahoma Medical Research Foundation, Oklahoma City, Okla.) in 10 mg/ml BSA, 1×PBS. After a 5 minute wash in WB the gel was incubated for 30-60 minutes at room temperature (RT) with shaking with a 1:500,000 dilution of horseradish peroxidase (HRP) goat anti-mouse conjugate (Jackson InmunoResearch; West Grove, Pa.) and subsequently washed 6 times. The blot was submerged in chemiluminescent development reagent SUPERSIGNAL BLAST™(Pierce; Rockford, Ill.) for five minutes, placed in a transparent laminate, exposed to BIOMAX™ MR-2 film (Kodak; Rochester, N.Y. for 10 seconds and developed with KODAK™ developer and fixer as per manufacturer's instructions.
Results
Monoclonal anti-apolipoprotein B stained material of very high molecular weight was observed for both purified Apolipoprotein B and purified LDL. Each of these sample showed a faint band at the approximately 60 kd site. In saliva the predominant staining was seen at approximately 60 kd mw. When Apolipoprotein B was added to the saliva sample and incubated for 1 hour at room temperature prior to electrophoresis, a decrease in the amount of the high molecular weight band and a distinct increase in the immunoreactive material at approximately 60 kd mw was observed, indicating that Apo B is degraded by the saliva enzymes.
Serum samples generated three bands that reacted with anti-Apo B, a double band at very high molecular weight which was also seen in purified LDL, and an approximately 60 kd and possibly 45 kd mw fraction. Purified LDL showed only a very high molecular weight band. Apo A1 was present in saliva in the 30 kd serum form. Apo B immunoreactive with antibody was present in an approximately 60 kd form: When LDL or ApoB was added to saliva and incubated the same approximately 60 kd immunoreactive form was generated, indicating that the degradation is by saliva enzymes.
The levels of ApoA1 and ApoB measured in saliva by Western blot corresponded to about 1/50 th of the amount seen in serum.
EXAMPLE 2
Correlation of ApoA:ApoB Saliva Levels with ApoA:ApoB Serum Levels.
Sample Collection
Saliva: Stimulated and unstimulated saliva was collected and analyzed. Saliva flow was stimulated by asking the individual to suck either a lemon or a super mint. Stimulated saliva was collected by stimulating the same individual five minutes after collection of unstimulated saliva. Saliva samples were immediately filtered through a serum separator and then chilled in an ice water bath. Saliva samples were assayed within three hours of collection.
Stimulated saliva provided superior correlation. The super mint gave superior results and was more acceptable to saliva donors.
Serum: Serum was collected from 12 fasting subjects, immediately frozen and was thawed immediately before testing.
Analysis of Serum Lipids
Serum samples were analyzed for serum lipids on the Roche Cobas Mira Automated Chemistry Analyzer (software version 8735; Roche Diagnostic System, Nutley, N.J.). Roche Apo A-1 and Apo B reagents and apolipoprotein standards were used to set up the calibration curve for determination of Apo A-1 and B in both serum and saliva samples. Roche cholesterol reagent and calibrator serum were used to determine the level of total cholesterol. Roche Unimate HDL direct HDL-Cholesterol calibrator and HDL direct calibrator were used to determine the level of HDL cholesterol. Roche triglycerides reagent and calibrator were used to determine the level of VLDL cholesterol, which is one-fifth of triglycerides. LDL cholesterol was determined as the difference of the determined sum of the VLDL and HDL cholesterol from total cholesterol.
For each of the assays, assay accuracy was monitored by comparison of experimental values to the published values for Liquichek and Lyphochek control levels I and II (Bio-Rad; Hercules, Calif.) and for Cardiolipid and Apolipoprotein control levels I and II (Sigma Diagnostics; St. Louis, Mo.). Assay precision was estimated by determining average %CV of the same samples on successive days using Roche Reagents and additionally assayed for ApoA1 and ApoB by Elisa Immunoassay of Lipoproteins. The correlation of the Roche serum assay with the Elisa was used to demonstrate correlation of the assays.
ELISA for Apo A-1 and B in Saliva:
Microtiter plates were coated overnight at RT and 100 microliters per well of Apo A-1 or B from Intracell, Issaquah, WA added. Wells were blocked with 1% BSA/PBS for 2 hrs at RT. 10 microliters of saliva sample was incubated for 15 minutes at RT with 90 microliters of either rabbit polyclonal anti ApoA-1 (antibody provided by E. Koren, San Francisco) at 1:30,000 dilution or a 1:25,000 dilution of goat polyclonal anti ApoB (also provided by E. Koren, OMRF). After a thirty minute incubation RT, plates were washed twice with 0.1% BSA/PBS. 100 microliters of HRP goat anti rabbit (ApoA-1 determination) or HRP rabbit anti-goat (ApoB determination) (Jackson InmuunoResearch was added with shaking at RT for 30 minutes). This was followed by two washes with BSA/PBS and followed by the addition of 150 microliters of 3, 3′, 5, 5′ tetramethyl-benzidine (TMB) for 15 minutes with shaking. The colorimeteric reaction was stopped with 2 N sulfuric acid and plates were read on a Titertek Plate Reader at 450 nm to determine final absorbance. Absorbance readings were converted to mg/dL of ApoA-1 and B by reference to a calibration curve for ApoA-1 and B constructed from different dilutions of a serum sample pool. ApoA-1 and B values for the undiluted sample pool were determined from the Roche autoanalyzer assay.
Elisa for Albumin
Microtiter plates were coated overnight at RT with 100 microliters per well of human serum albumin (Sigma A1151, St. Louis, Mo.) at 2 microgram/ml. Wells were blocked with 1% BSA/PBS for 2 hrs at RT. 10 microliters of saliva at 1:10 and 10 microliters at 1:100 was preincubated for 15 minute at RT with 90 microliters of goat anti-human albumin A1:100K and then transferred to the plate. After a thirty minutes incubation at RT, plates were washed twice with 0.1% BSA/PBS. 100 microliters of HRP rabbit anti-goat (Jackson ImmunoResearch) was added with shaking at RT for 30 minutes. This was followed by two washes with BSA/PBS and followed by the addition of 150 ul of 3, 3′5, 5′ tetramethyl-benzidine (TMB) for 15 minutes with shaking. The colorimeteric reaction was stopped with 2N suliric acid and plates were read on a Titertek Plate Reader at 450 nm to determine final absorbance. Absorbance readings were converted to mg/dL of albumin by reference to a calibration curve constructed from different dilutions of a Sigma Human serum albumin.
Results
Lipoproteins in serum and saliva samples competed with lipoproteins coated on plates for anti-apolipoprotein antibody binding, as shown by FIG. 1 . With increasing amount of lipoprotein in the sample, less antibody bound to the plate and decrease in signal was observed. Seven saliva samples exhibited different levels of measured apolipoproteins. The level of Apo A1 measured by ELISA in saliva samples was less than 10% of the expected serum level of Apo A1. The level of ApoB measured by ELISA in saliva samples was less than 1% of the serum level of Apo B.
The correlation between the values measured in serum samples using the commercially available Roche assay and the ELISA for Apo A and Apo B is shown in Table 1. The correlation between the values measured in serum samples for Apo A1 and Apo B by the Roche assay and serum LDL and HDL measured by the ELISA is shown in Table 2.
The correlation between Saliva Apo B/A1 and Serum Apo B/A1, measured by ELISA is shown in Table 3. In stimulated saliva samples, albumin is secreted in the same manner as the Apo B. As a result, albumin can be used to correct for dilution of the saliva sample. Apo B levels in saliva and Apo B levels normalized for dilution by reference to albumin correlate highly with serum Apo B and LDL levels.
The correlation coefficient for the Apo A:Apo B ratio obtained with stimulated saliva is not as high as the correlation coefficient in unstimulated salivastimulated saliva's when expressed in a Apo A/Apo B ratio did not correlate as well as unstimulated saliva. Apo A lipoprotein levels correlate highly r=0.95 and 0.92 with Apo B levels whether expressed as mg/dL or normalized to saliva albumin FIGS. 1 a and b . In contrast the serum ApoA:B levels for these same samples had r=less than 0.04. Thus it appears that during stimulated and (unstimulated) saliva flow Apo B secretion increases in relation to the amount of ApoA-1 and is on the order of three to four times as much Apo B as Apo A, as shown in FIGS. 2B and 2C in contrast to the serum Apo B/Apo A ratio, which ranges from 0.36 to 1.4. Thus, there is much higher Apo B:Apo A ratio than observed in serum. This could reflect the selectively higher secretion of Apo B in saliva or may be an artifact reflecting that the partially fragmented Apo B is more immunoreactive than the intact B protein.
TABLE 1
Correlation (r) of the Roche Serum Assays with the Serum
ELISA for Apo A and Apo B.
ELISA
ELISA
ELISA
Roche Values
Apo A1
Apo B
Apo B/A1
ApoA1
0.81
ApoB
0.94
ApoB/A1
0.93
TABLE 2
Correlation (r) of Roche Serum Apo A1 and Apo B with
Serum LDL and HDL Measured by ELISA.
LDL
HDL
LDL/HDL
ApoA1
0.95
ApoB1
0.98
ApoB/A1
0.99
TABLE 3
Correlation (r) of Saliva ApoB/A1 with Serum ApoB/A1
Measured by ELISA.
Serum
Serum
Serum
Saliva
ApoB/A1
ApoB
LDL
ApoB/A1
0.75
ApoB/Albumin
.88
.82
EXAMPLE 3
Detection of Saliva Levels of ApoB and ApoA-1 in Competitive Format Immunochromatographic Strips.
Preparation of Immunochromatographic Strips
5 micron Nitrocellulose membrane (Millipore, Burlington, Mass.) was coated with human HDL or LDL from Calbiochem, La Jolla, Calif. at a concentration of 2 mg/ml in an amount of 3 microliters/3 mm wide strip using a Camag Linomat IV (CAMAG, Switzerland). Gold particles were coated with anti-ApoA1 with the monoclonal Lpa1HB4 (American Type Culture Collection, Rockville, Md.), or with anti-ApoB with WaB2bD6 (Dr. Koren, OMRF).
Preparation of Samples
To assay, serum samples were diluted 1:2000, 1:600, 1:100, 1:75, 1:25 and 1:10 50 into PBS. 50 microliter of sample was pipetted into a test tube containing 5 microliters of gold conjugate and 5 microliter of 5% BSA (Sigma, St. Louis, Mich.). The sample was vortexed and a strip was inserted in the tube. When the fluid had migrated to the end of the strip, the strip was removed from the tube, allowed to dry and the intensity of the band was measured using a Graytag D19C/D196 remission Densitometer (Greytag, Switzerland).
Results
FIG. 3 a and FIG. 3 b shows that color intensity was strongly inhibited by a 1:2000 dilution of serum and 1:100 dilution of Apo B. There was a good dose dependent inhibition of binding. Since saliva has an average of 1:50 th of the amount of Apo A1 and at least that amount of ApoB, the results demonstrate that the assay of Apo A1 and Apo B in saliva proteins is amenable to quantitative immunochromatographic detection and could be adapted to the Serex reland format described in U.S. Pat. Nos. 5,451,504, 5,500,375, and 5,710,00.
Modifications and variations of the methods and materials described herein will be obvious to those skilled in the art and are intended to come within the scope of the appended claims. | 4y
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TECHNICAL FIELD OF THE INVENTION
The present invention relates to a motor vehicle propeller shaft assembly and a constant velocity joint (CVJ) cap of such an assembly.
BACKGROUND OF THE INVENTION
For safety reasons, propeller shaft assemblies for motor vehicles which are oriented longitudinally with constant velocity joints are typically designed with a shock absorption capability during telescopically collapse of the shaft assembly in the event of a frontal impact. These assemblies also need proper sealing against lubricant leakage on the one hand and a venting system on the other hand. All these requirements make the construction of a propeller shaft assembly complex.
SUMMARY OF THE INVENTION
The present invention simplifies the propeller shaft assembly by providing a cap inserted into or abutting the outer race of a constant velocity joint (CVJ) that enables both proper sealing and venting without interfering with the energy absorption capability of the assembly.
The grease retention and vent cap of this invention may enable a collapse of the propeller shaft assembly in various ways. In a first example, the grease retention and vent cap has a rim pressed into or adjacent the outer race of the CVJ which stays rigid during a vehicle crash. If the propeller shaft is fabricated with a beaded weld which projects into the inside diameter of the shaft, this rim may be retained or broken by the weld bead during a crash. Internal CVJ components abut a central portion of the cap and cause this central portion to break away from the cap rim and pass through the tubular propeller shaft ahead of the internal joint components, allowing the propeller shaft assembly to collapse telescopically.
Alternatively, the entire rim of the cap can disintegrate into pieces small enough to enter the tubular propeller shaft.
For applications for a propeller shaft which does not have an inwardly protruding weld bead, the entire cap may be pushed into the tubular propeller shaft without breaking. The cap has an arrangement of vent ducts leading from the internal components of the CVJ to a radial annular groove surrounding the entire circumference of the cap. From there, a connection to the atmosphere is established by radial bores in the outer race of the CVJ in the axial area of the annular groove at any angular position on the tubular shaft. The invention thus encompasses both a venting system incorporated into the cap and a crash feature for a propeller shaft assembly, eliminating the need for two separate systems for such features.
Grease is retained inside the outer race of the CVJ in the propeller shaft assembly by providing a vent hole for communication with the interior components of the CVJ in the axial center of the cap, thereby ensuring that the vent hole is never at the bottom of the tubular shaft, regardless of the orientation of the cap. The rim thus forms a seal along the entire circumference of the cap.
In this configuration, the cap will act as a venting system, provides grease retention for the CVJ, and allows for crash optimization.
Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which the present invention relates from the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a side view of a first illustrative example of a cap in accordance with this invention;
FIG. 2 depicts the cap of FIG. 1 in a first perspective view showing one of two major surfaces of the cap;
FIG. 3 depicts the cap of FIG. 1 in a second perspective view showing the other one of the two major surfaces of the cap;
FIG. 4 is a longitudinal cross-sectional view of a propeller shaft assembly according to this invention showing the components thereof during normal vehicle operation; and
FIG. 5 is a longitudinal cross-sectional view of a propeller shaft assembly according to this invention showing the components thereof following a vehicle crash.
FIG. 6 depicts a first perspective view of a grease retention and vent cap according to a second exemplary embodiment of the invention.
FIG. 7 depicts a second perspective view of the grease retention and vent cap of FIG. 6 .
FIG. 8 depicts a cross-sectional view of the venting system in the grease retention and vent cap of FIG. 6 .
FIG. 9 depicts a side view on the grease retention and vent cap of FIG. 6
FIG. 10 depicts the grease retention and vent cap of FIG. 6 within a propeller shaft system during normal vehicle operation.
FIG. 11 depicts the grease retention and vent cap of FIG. 6 within a propeller shaft system during a vehicle crash.
FIG. 12 depicts the grease retention and vent cap of FIG. 6 within a first propeller shaft system after a vehicle crash.
FIG. 13 depicts the grease retention and vent cap of FIG. 6 within a second propeller shaft system after a vehicle crash.
DETAILED DESCRIPTION OF THE INVENTION
The figures of the drawings are provided for purely illustrative purposes and are not intended to limit the scope of the invention.
Referring to FIGS. 1 through 3 , a first exemplary embodiment of a grease retention and vent cap 1 has a rim 2 dimensioned to be placed and retained in an outer race 9 of a CVJ. As shown, CVJ has a counter-bored region for receiving cap 1 . Other embodiments (not shown) can provide an inside diameter surface for retaining cap 1 adjacent to the CVJ. Retaining the rim 2 in the outer race 9 may be accomplished by a slight radial annular indent placed on a corresponding annular protrusion in the outer race 9 .
Axially adjacent to the rim 2 is an axial area forming a hollow chamber 3 that extends radially across the entire width of the cap 1 . The hollow chamber 3 is open at both radial ends and terminates in an annular groove 4 that extends around the entire circumference of the cap 1 . An axial vent hole 5 is located centrally in cap wall 18 that bounds the hollow chamber 3 at an axial end opposite the rim 2 . The vent hole 5 establishes fluid communication of the hollow space 3 to the outside of the cap 1 .
Referring now to FIG. 4 , the cap 1 is pressed into a recessed inside diameter portion of the outer race 9 of a propeller shaft CVJ and retained at its outer diameter by rim 2 . The cap 1 separates internal components of a CVJ, such as a stub shaft 12 , an inner race, a cage and balls (known as the internal joint components and referred to by reference number 8 ) from a tubular shaft portion 11 of the propeller shaft. A dust boot 13 seals the gap between the stub shaft 12 and the outer race 9 to prevent contamination. Air is allowed to pass from the internal components 8 of the CVJ to the cap hollow chamber 3 through the vent hole 5 , which is centrally located in the cap 1 and extends axially through a face of the cap 1 into the hollow chamber 3 . This allows atmospheric pressure venting which prevents the development of pressure differentials between the area of the joint internals 8 and atmosphere, which can lead to the introduction of contaminants which can degrade the service life of the CVJ.
The vent hole 5 is located on a major face of the cap wall 18 and oriented to face the internal CVJ components 8 . Air is then allowed to pass from the hollow air chamber 3 of the cap 1 through the radially open ends of the hollow chamber 3 into the radial annular groove 4 that runs 360 degrees around the outer periphery of the cap 1 . The air then passes through bores 17 drilled into the outer race 9 of the CVJ to the atmosphere.
The hollow air chamber 3 in the cap 1 has a cavity volume which ensures that the propeller shaft CVJ does not allow water ingress during an event in which the CVJ is hot and then cooled quickly, for example by water submersion during operation of the associated motor vehicle. In such a situation, the rapid quenching can cause water to be sucked into the cap 1 . By providing sufficient volume in the internal hollow chamber 3 of the cap 1 , the sucked-in water will be retained in the hollow chamber 3 and will not reach the internal joint components 8 through vent hole 5 . The exact volume of the hollow chamber 3 depends on anticipated temperature differences and on physical properties of the propeller shaft assembly, such as enclosed air volume. The central location of vent hole 5 ensures that the vent hole 5 is never at the bottom of the hollow chamber, regardless of the angular orientation of the cap 1 inside the propeller shaft assembly. Therefore, any water accumulated at the bottom of the hollow chamber 3 cannot flow into the area of the internal joint components 8 .
The tubular shaft 11 of the propeller shaft assembly is connected to the outer race 9 via a weld 10 . The weld 10 as shown, has a bead which extends both radially outwardly, and also inwardly from the inside diameter of shaft 11 , which is typical in a friction welding process. To not interfere with axial movement of a cap, machining of the bead of weld 10 would be required. In order to still allow for a telescopic collapse during a frontal impact without interior machining of the weld 10 , the cap 1 is configured to withstand axial displacement of the internal joint components 8 in direction 14 only to a limited extent. Upon a vehicle crash exceeding such displacement, the rim 2 of the cap 1 are retained inside the CVJ outer race 9 . A central portion 6 of the cap 1 shears away, separating from the rim 2 , and allows the internal joint components 8 to escape from the outer race 9 into the tubular shaft 11 .
The cap 1 is made of a material, for instance a suitable plastic material, that is tunable to collapse at a certain energy produced by the vehicle during a crash. The exact energy and resulting force to trigger a separation of the central portion 6 from the rim 2 can be empirically determined and depends on several factors that may include vehicle weight and spatial dimensions inside the vehicle.
FIG. 4 depicts the cap 1 used within a propeller shaft system during normal vehicle operation. The cap 1 is pressed inside the outer race 9 . The internal joint components 8 are retained and sealed by the cap 1 . Grease is retained within the outer race 9 by the cap 1 . The air vent bores 17 in the outer race 9 allow venting from the internal joint components 8 through the axial vent hole 5 , via the hollow chamber 3 and the bores 17 to the atmosphere.
FIG. 5 depicts the cap 1 used within a propeller shaft system during a vehicle crash. During the impact, forces acting on the vehicle transmission shift the stub shaft 12 , producing displacement in the direction shown by the arrow 14 . The internal joint components 8 impact the cap 1 , forcing the cap toward the tubular shaft 11 until the rim 2 , acting as a low force retention feature, contacts the interior bead of the weld 10 . The rim 2 remains in contact with the weld 10 , while the impact causes the central portion 6 of the cap 1 to shear and break away. The central portion 6 exits the outer race 9 ahead of the internal joint components 8 and enters the tubular shaft 11 , giving way for the internal joint components 8 to follow.
The internal joint components 8 are small enough to pass from the outer race 9 through the tubular propeller shaft 11 following a backward shift of an engine or transmission during a vehicle collision, to absorb the energy created by the vehicle collision, thereby enabling the telescopic effect described earlier.
The cap 1 may be used in a propeller shaft which uses either a friction weld, gas metal arc weld or magnetic arc weld to join the CVJ outer race 9 to the tubular propeller shaft 11 . With the use of a friction weld 10 , during a collision, the cap 1 contacts the internal bead of the weld 10 and the central portion 6 of the cap 1 is sheared away from the rim portion 2 as described above.
With the use of either a gas metal arc weld or magnetic arc weld forming a smooth surface at the inner tube diameter, the cap 1 may be made with a diameter small enough such that it is able to pass through the weld portion and into the tubular propeller shaft 11 . Accordingly, absent an interior weld bead, the grease retention and vent cap 1 remains intact during the collision. In the drawings, the cap 1 of FIG. 4 would simply move to the right as a whole, ahead of the internal CVJ components, without shearing of the cap.
Referring now to FIGS. 6 through 9 showing an alternative embodiment of cap 101 , axes x, y, and z of a virtual coordinate system are indicated in the drawings to illustrate the respective perspectives of the individual drawing figures. In a second exemplary embodiment of the present invention, a grease retention and vent cap 101 has a rim 102 dimensioned to be placed and retained in an outer race 109 of a CVJ. Retaining the rim 102 in the outer race 109 may be accomplished by a slight radial annular indent or expansion matched with a corresponding annular shape in the outer race 109 .
Axially adjacent to the rim 102 is an axial area forming a plurality of hollow channels 103 that extend parallel across the entire radial width of the cap 101 . The hollow channels 103 are separated by parallel walls 107 arranged in such a way that the radial center of the cap 101 is not obstructed by a wall 107 . The hollow channels 103 are open at both radial ends. A radial annular groove 104 in end portions of the walls 107 extends around the entire circumference of the cap 101 . An axial vent hole 105 is located centrally in a radially extending wall 118 that bounds the hollow channels 103 at an axial end opposite the rim 102 . The vent hole 105 establishes an axial communication of that one of the hollow channels 103 that extends across the central location to the axial outside of the cap 101 .
FIG. 6 shows optional reinforcing webs 115 supporting the rim 102 , the thickness as well as radial and axial dimensions of these webs 115 can be dimensioned to meet specifications regarding a threshold force along the arrow 114 (shown in subsequent figures) required to separate the rim 102 from the central portion 106 of the cap 101 or to disintegrate the rim as explained in more detail in connection with FIGS. 10 through 12 .
Referring now to FIG. 10 , the cap 101 is pressed into the outer race 109 of a propeller shaft CVJ and retained at its outer diameter at rim 102 . The cap 101 separates a stub shaft 112 , an inner race, a cage and balls (known as the internal joint components and collectively identified by reference number 108 ) from a tubular portion 111 of the propeller shaft. The stub shaft 112 and the outer race 109 are sealed via a dust boot 113 to prevent contamination. Air is allowed to pass from the internal components 108 of the CVJ to the central one of the hollow channels 103 through the vent hole 105 which is centrally located in the cap 101 and extends axially through a face of the cap 101 into the hollow channel 103 .
The vent hole 105 is located on a major face of the cap 101 oriented to face the internal CVJ components 108 . Air is then allowed to pass from the central hollow channel 103 of the cap 101 through the radially open ends of the hollow channel 103 into the radial annular groove 104 that runs 360 degrees around the outer periphery of the cap 101 . The air then passes through bores 117 drilled into the outer race 109 of the CVJ to the atmosphere.
The hollow air channels 103 in the cap 101 have a cavity volume which ensures that the propeller shaft CVJ does not allow water ingress during an event in which the CVJ is hot and then cooled quickly, for example by water submersion. In such a situation, the rapid quenching can cause water to be sucked into the cap 101 . By providing sufficient volume in the internal hollow channels 103 of the cap 101 , the sucked-in water will be retained in the hollow channels 103 and will not reach the internal joint components 108 through vent hole 105 . The exact volume of the hollow channels 103 depends on anticipated temperature differences and on physical properties of the propeller shaft assembly, such as enclosed air volume.
The central location of vent hole 105 ensures that the vent hole 105 is never at the bottom of the hollow channels 103 , regardless of the angular orientation of the cap 101 inside the propeller shaft assembly. Therefore, water accumulated at the bottom of the hollow channels 103 , even in the central hollow channel 103 , cannot flow into the area of the internal joint components 8 .
The tubular shaft 111 of the propeller shaft assembly is connected to the outer race 109 via a weld 110 . The weld 110 of the type shown has an interior bead that would require machining to remove. In order to still allow for a telescopic collapse during a frontal impact without interior machining of the weld 110 , the cap 101 is configured to withstand axial forces from the internal joint components 108 in direction 114 only to a limited extent. Upon a vehicle crash exceeding such limited force, the rim 102 of the cap 101 is retained inside the CVJ outer race 109 . The central portion 106 of the cap 101 gives way, separates from the rim 102 , and allows the internal joint components 108 to escape from the outer race 109 into the tubular propeller shaft 111 . The rim 102 is configured to break into pieces at the time of separation from the central portion 106 . The pieces of the rim 102 are small enough to disperse into the tubular propeller shaft 111 without impeding the telescopic movement of the internal joint components 108 into the tubular propeller shaft 111 .
The cap 101 is made of a material, for instance a suitable plastic material, that is tunable to collapse at a certain energy produced by the vehicle during a crash. The exact energy and resulting force to trigger a separation of the central portion 106 from the rim 102 or to break the rim 102 can be empirically determined and depends on several factors that may include vehicle weight and spatial dimensions inside the vehicle. The dimensions of the webs 115 can be utilized for fine-tuning the cap properties to given demands, for instance by model simulations or by experimentation.
The cap 101 may be used in a CVJ outer race 109 that is joined to a tubular propeller shaft 111 by welding. When the joining method is friction welding, during a collision the grease retention and vent cap 101 contacts the weld 110 and collapses as illustrated in FIGS. 11 and 12 . Upon a frontal impact, the walls 107 may collapse when the cap 101 first abuts the interior bead of the weld 110 as illustrated in FIG. 11 . This collapse leaves the webbed axial surface of the cap 101 intact. Once the rim 102 reaches the weld, it may either be retained as shown in the embodiment of FIGS. 1 through 5 , or it may break into pieces that may disperse inside the tubular propeller shaft 111 as illustrated in FIG. 12 . In FIG. 12 , the stub shaft 112 has been pushed so far into the tubular shaft 111 that the dust boot 113 is torn. The rim 102 of the cap 101 is destroyed and broken into many small pieces dispersed in the tubular shaft 111 . The pieces are small enough not to impede the movement of the internal joint components 108 .
If the CVJ and tubular propeller shaft 111 are fabricated by a process other than friction welding, such as a magnetic arc welding or gas metal arc welding, no interior bead is created. In this approach, the cap 101 may be small enough to pass through the connection between the CVJ and the tubular propeller 111 shaft into the tubular propeller shaft 111 during a collision, without breaking the cap as shown in FIG. 13 .
The caps 1 and 101 are dimensioned to be sufficiently robust to withstand general handling and operation during normal use over the entire lifetime of a propeller shaft.
The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled. | 4y
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to vehicle brake actuating arrangements and, more particularly, to a vehicle brake control whereby the hand-brake lever and the foot-brake pedal can be independently operated without interference with each other.
2. Description of the Prior Art
Vehicles have had both safety hand brakes and foot brakes for many years. These current braking systems have linkages or cables which run from the foot pedal or hand lever all the way to the brake. Such systems require a considerable number of additional parts to convey the actuating force to the brake. In addition, the linkages or cables being strung out over considerable distances are subject to abuse and wear and can become disabled due to interference with extraneous parts or due to failure of parts of said linkages or cables.
In some systems, an individual brake actuator is actuated by more than one source, such as a hand lever and a foot pedal, but in such systems actuation of the brake actuator by the hand lever prevents actuation by the foot pedal and vice versa. In another system, actuation of the foot pedal will actuate part or all of the hand-lever linkage which can cause problems with the hand-lever linkage.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming one or more of the problems set forth above.
According to the present invention, a vehicle brake actuator is provided whereby the vehicle brakes are actuated either by a foot-operated pedal or by a hand-operated handle, without interference from each other. A central brake actuator is provided for all wheels or tracks of the vehicle that are to be braked. A dual lever arrangement is provided whereby actuation of the foot pedal and associated linkage will actuate the dual lever and the brake without moving, or in any way activating, the hand-brake linkage. The dual lever arrangement also provides for actuation of the hand-brake handle and linkage whereby the dual lever is actuated to set the brake without moving, or in any way activating, the foot-brake linkage.
Actuation or failure of the hand-brake handle and linkage will in no way affect the actuation of the foot-brake pedal and linkage and, conversely, actuation or failure of the foot-brake pedal and linkage will in no way affect the actuation of the hand-brake handle and linkage. It is also possible to set both the hand brake and foot brake without one interfering with the other and when both the hand brake and foot brake are set, release of one will not release the vehicle brake until the other is also released.
BRIEF DESCRIPTION OF THE DRAWINGS
The details of construction and operation of the invention are more fully described with reference to the accompanying drawings which form a part hereof and in which like reference numerals refer to like parts throughout.
In the drawings:
FIG. 1 is a partial elevational view of a vehicle having both a hand-brake handle and a foot-brake pedal for actuating the vehicle brakes;
FIG. 2 is an elevational view of the improved dual linkage and lever arrangement for actuating the vehicle brakes;
FIG. 3 is an elevational view similar to FIG. 2 only showing the hand-brake lever in the brake set position;
FIG. 4 is a cross-sectional view taken along the line 4--4 of FIG. 2; and
FIG. 5 is a perspective view, partially exploded, of the improved dual lever actuating arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and in particular to FIG. 1 thereof, a vehicle 10 is illustrated which, in the form shown, is a track-type tractor. An operator's station 12 is located on the vehicle 10 such that an operator, when seated in the seat of the compartment, has access, by the use of his hands and feet, to the various handles 14, knobs 16, and pedals 18, and the like, for driving and steering the vehicle 10 and actuating various equipment on the vehicle. One hand-operated handle 14 is a hand brake and, as shown in FIG. 1, projects horizontally across the access area to and from the operator's compartment 12. A foot brake actuator lever 18 projects downwardly and rearwardly from the inside of the fire wall 20 of the vehicle 10 with a foot-engaging pedal portion 24 projecting toward the operator's station 12. A foot rest 26 is located close to the foot pedal 24 upon which the operator can rest his foot when it is not needed for other purposes, such as actuating the pedal 24 of the foot brake 18. The handle 14 of the hand brake extends horizontally substantially parallel to the floor or deck 28 of the operator's compartment 12 and obstructs access to and from the operator's compartment when the brake associated with the hand lever is in the "off" or "inoperative" position. An operator, to leave the operator's compartment 12, must maneuver over or around the horizontal handle 14 which is intended to remind him to set the hand brake on the vehicle. The hand brake is put in the "on" position by pivoting the handle 14 clockwise, as viewed in FIG. 1, downward and rearward from its horizontal position in a manner to be described more in detail hereinafter.
Referring to FIGS. 2 and 3, in particular, as they relate to FIG. 1, the handle 14 is pivotally mounted at 30 to the frame 32 of the vehicle 10. A connecting link 34 has one end portion 35 pivotally mounted at 36 to the handle 14 at an intermediate location between the hand grip portion 38 of the handle 14 and said pivot 30. The other end portion 40 of the connecting link 34 is pivotally mounted at 42 to one leg 43 of the bell crank link 44, which bell crank link 44, in turn, is pivotally mounted at 46 to a bracket 48 mounted on the frame 32. A second connecting link 50 is connected at one end portion 52 by means of a pivot 54 to a second leg 55 of the bell crank link 44 and is connected at its other end portion 56 by means of pivot 58 to one leg 59 of a lever 60. The lever 60 is pivotally mounted on a shaft 62 for a purpose to be described more in detail hereinafter. Comparing FIGS. 2 and 3, it can be seen that when the handle 14 is in the horizontal position of FIG. 2, the connection through the link 34, bell crank 44 and link 50 to the lever 60, positions the leg 59 of said lever 60 in a raised position relative to the horizontal. In FIG. 3, the handle 14 has been rotated about the pivot 30 in a clockwise direction which has pivoted the bell crank 44 in a counterclockwise direction through the link 34 and has pivoted the lever 60 counterclockwise through the link 50 so that in FIG. 3, the leg 59 of the lever 60 is in a lowered position relative to the raised position of FIG. 2.
Positioned to the left of the foot rest 26 is the foot-brake actuator lever 18 which supports the foot pedal 24 at the lower end thereof. The foot-brake actuator lever 18 is pivotally mounted about a pivot 74 which is supported by a bifurcated bracket 76 mounted on the fire wall 20 of the vehicle 10. The foot-brake actuator lever 18 has a transversely extending leg 80 integrally formed at the pivot end thereof and projects rearwardly through the fire wall 20 from the pivot 74 so that pivotal movement of the foot-brake actuator lever 18 about the pivot 74 will, likewise, move the leg 80 an equal amount. A connecting link 82 is pivotally mounted at pivot 84 to the outer end portion of the leg 80 with the opposite end portion of said link 82 being pivotally mounted at pivot 86 to the outer end portion of one leg 88 of a bell crank 90. The bell crank 90 is pivotally mounted at pivot 92 to a bracket 94 secured to the fire wall 20. The bell crank 90 has a second leg 96 pivotally connected at 98 to a connecting link 100. The opposite end portion of the connecting link 100 is pivotally mounted by means of pivot 102 to the lower end of a lever 104 which is rotatably mounted on said shaft 62. Thus, it can be seen that pressure applied to the pedal 24 of the foot-brake actuator lever 18 will pivot the lever 18 counterclockwise to raise the leg 80 and connecting link 82 thereby pivoting the bell crank 90 in a counterclockwise direction about the pivot 92. The counterclockwise movement of the bell crank 90 will move the link 100 to the right, as viewed in FIG. 2, which will pivot the lever 104 about the axis of the shaft 62 in a counterclockwise direction.
Referring to FIGS. 4 and 5, in combination with the structure described with respect to FIG. 2, it will be noted that a sealed housing 106 is bolted to the undersurface of the deck 28 and has a downwardly and angularly disposed sleeve 108 formed thereon. A plate 110 seals the opening at the end of the sleeve 108 with a rod 112 extending into the housing 106 through a sleeve guide bearing 114. The rod 112 is connected through a connector 116 to a pivot pin 118 extending between the bifurcated end 120 of a lever 122. The lever 122 is splined at 124 to the shaft 62 which shaft is rotatably mounted in bearings 126 in the side walls 128 of the housing 106. The shaft 62 projects laterally from the housing 106 and has a T-shaped lever 130 splined at 131 to the exposed end portion 133 of said shaft 62. The T-shaped lever 130 has a head portion 132 projecting axially in opposite directions from the shaft 135 of the "T" so as to provide independent overhanging contact pads 134, 136 on the outer end portions thereof. Since the T-shaped lever 130 is splined to the shaft 62 in the same manner as the lever 122 is splined to said shaft 62, rotational movement of the T-shaped lever 130 about the axis of the shaft 62 will rotate the lever 122 a like amount.
The lever 104 is rotatably mounted on the shaft 62 by a bearing 141 so that the lever 104 is free to rotate relative to the shaft 62. Lever 104 has a pair of radially and oppositely directed legs 142, 144 with the leg 142 having a contact pad 146 aligned with and adapted to selectively contact the contact pad 134 on the T-shaped lever 130. The leg 144 of the lever 104 has a bifurcated end portion 148 through which a pin 150 passes to engage with and secure the end portion of the link 100 to the lever 104. The lever 60, which has previously been described as being rotatably mounted on the outer end portion of the shaft 62, is rotatably supported by a bearing 64 and is secured against axial displacement from the shaft 62 by means of a snap ring 161. The lever 60 has one short leg 162 which extends radially outward from the body of the lever 60 and has a contact pad 164 aligned with and adapted to selectively contact the contact pad 136 of the T-shaped lever 130. The lever 60 has the elongate leg 59 extending radially outward from the body of said lever 60 along an axis angularly disposed from the axis of the leg 162. The outer end portion of the leg 59 is pivotally secured by pivot 58 to the one end portion 56 of the connecting link 50. From the above, it will be noted that the levers 104 and 60 are free to rotate independent of each other and independent of the shaft 62, the lever 104 being actuated by movement of the connecting link 100, bell crank 90, link 82 and foot-brake actuator lever 18, and the lever 60 being actuated by movement of the connecting link 50, bell crank 44, link 34, and hand brake 14.
It should be noted that the handle 14, when in the position of FIG. 2, positions the lever 60 so that the short leg 162 extends substantially straight upward with respect to the shaft 62. When the handle 14 is pivoted in a counterclockwise direction to the position of FIG. 3, the links 34 and 50, through the bell crank 44, will pivot the lever 60 in a counterclockwise direction so that the short leg 162 will pivot in a counterclockwise direction, as viewed in FIGS. 2 and 3, so that the contact pad 164 will engage with the contact and 136 on the T-shaped lever 130 which will rotate the lever 130, shaft 62 and lever 122 in a counterclockwise direction, once again as viewed in FIGS. 2 and 3. The counterclockwise movement of the end portion 120 of the lever 122 will move the rod 112 to the right, as viewed in FIG. 2, to the position of FIG. 3 which will set the brakes of the vehicle. It should be noted that the lever 104 is in no way affected by the movement of the levers 60 and 130 as that the position of the foot pedal 24 is not altered.
In normal operation, the hand-brake handle 14 will be in the horizontal position of FIG. 2 such that the lever 60 will have the leg 162 in the vertical position, out of contact with the lever 130. As the vehicle is operated, it becomes necessary to brake the vehicle by the operator depressing the pedal 24 which will pivot the foot-brake actuator lever 18 about the pivot 74 which will raise the link 82, pivot the bell crank 90 in a counterclockwise direction, and shift the link 100 to the right, as viewed in FIG. 2, which, in turn, will pivot the link 104 in a counterclockwise direction, as viewed in FIG. 2, whereupon the leg 142 of the lever 104 will be pivoted in a counterclockwise direction with the pad 146 contacting the contact pad 134 of the link 130. This will rotate the link 130, shaft 62 and lever 122 in a counterclockwise direction which will shift the rod 112 and set the brake. It should be noted that actuation of the foot brake will in no way affect the position of the hand brake so that the link or lever 60 connected to the hand brake 14 will remain in position with the contact pad 164 out of contact with the contact pad 136 of the lever 130.
It should be noted that in the event the foot brake is set, as just described, the operator can pivot the handle 14 of the hand brake from the horizontal position of FIG. 2 to the set position of FIG. 3 which will pivot the lever 60 so as to bring the contact pad 164 in contact with the contact pad 136 of the lever 130. Since the brake is already set, this will in no way change the position of the rod 112. However, in the event the operator removes his foot from the pedal 24 of the foot-brake actuator lever 18, the connecting link 82, bell crank 90, and link 100 will be free to shift in a clockwise direction, as viewed in FIG. 2, so as to remove the contact pad 146 from contact with the contact pad 134 of the lever 130. However, the brakes will remain set due to the set position of the hand brake. The operator at that point can release the hand brake by grasping the handle 14 and rotating the handle 14 in a counterclockwise direction, as viewed in FIG. 3, to the horizontal position of FIG. 2, whereupon the lever 60 will be rotated in a clockwise direction which will permit the lever 130 to rotate in a clockwise direction thereby shifting the rod 112 and releasing the brake.
In summary, a dual brake actuating mechanism has been described wherein a hand brake can be set without in any way affecting the operation or position of the foot brake and foot-brake lever. Likewise, the foot brake can be set without in any way affecting the position of the hand-brake lever and hand-brake handle. In other words, one or the other of the brake actuating mechanisms can be operated without affecting the other's position or operation. Both brakes can be set at the same time and the release of one will not automatically release the other, therefore, it requires a positive action to release either or both of the brakes, which brakes are independently operative. | 4y
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FIELD OF THE INVENTION
The present invention relates generally to tooling used to manufacture lightweight fan blades used in gas turbine engines.
BACKGROUND OF THE INVENTION
Gas turbines include, but are not limited to, gas turbine power generation equipment and gas turbine aircraft engines. A gas turbine includes a core engine having a high pressure compressor to compress the air flow entering the core engine, a combustor in which a mixture of fuel and the compressed air is burned to generate a propulsive gas flow, and a high pressure turbine which is rotated by the propulsive gas flow and which is connected by a larger diameter shaft to drive the high pressure compressor. A typical front fan gas turbine aircraft engine adds a low pressure turbine (located aft of the high pressure turbine) which is connected by a smaller diameter coaxial shaft to drive a front fan (located forward of the high pressure compressor) and to drive an optional low pressure compressor (located between the front fan and the high pressure compressor). The low pressure compressor sometimes is called a booster compressor or simply a booster.
The fan and the high and low pressure compressors and turbines have airfoils each including an airfoil portion attached to a shank portion. Rotor blades are those airfoils which are attached to a rotating gas turbine rotor disc. Stator vanes are stationary airfoils which are attached to a non-rotating gas turbine stator casing. Typically, there are alternating circumferential rows of radially-outwardly extending rotor blades and radially-inwardly extending stator vanes. When present, a first and/or last row of stator vanes (also called inlet and outlet guide vanes) may have their radially-inward ends also attached to a non-rotating gas turbine stator casing. Counter-rotating “stator” vanes are also known.
Conventional airfoil designs used in the compressor section at the engine typically have airfoil portions that are made entirely of metal, such as titanium, or are made entirely of a composite. A “composite” is defined to be a material having any (metal or non-metal) fiber filament embedded in any (metal or non-metal) matrix binder, but the term “composite” does not include a metal fiber embedded in a metal matrix. The term “metal” includes alloys such as titanium Alloy 6-2-4-2. An example of a composite is a material having graphite filaments embedded in an epoxy resin.
The all-metal blades, including costly wide-chord hollow blades, are heavier in weight which results in lower fuel performance and require sturdier blade attachments, while the lighter all-composite blades are more susceptible to damage from bird ingestion events. Known hybrid blades include a composite blade having an airfoil shape which is covered by a surface cladding (with only the blade tip and the leading and trailing edge portions of the surface cladding comprising a metal) for erosion and foreign object impacts. The fan blades typically are the largest (and therefore the heaviest) blades in a gas turbine aircraft engine, and the front fan blades are usually the first to be impacted by foreign objects such as birds.
Recent improvements have resulted in lighter-weight gas turbine blades, and especially a gas turbine aircraft engine fan blade that is comprised of a combination of metal and lightweight materials. These blades have been made lighter by removing metal from the pressure side of the blade. In order to retain the aerodynamic characteristics of the blade, the removed metal is replaced by the lightweight material. Restoring the aerodynamic characteristics to the blade by adding the lightweight material to replace the removed metal involves the use of specialized tooling. However, the specialized tooling that includes a special caul sheet currently used in the process of adding lightweight material to the pressure side of the fan blade in order to restore aerodynamic characteristics requires that an effective seal be formed against the blade pressure side by the caul sheet. The caul sheet currently used in the process of adding the lightweight material relies on an O-ring to form the seal with the pressure side of the blade. However, the O-ring can cause the caul sheet to stand off from the pressure side of the blade. The result is that there is a lack of good contact between the caul sheet and the pressure surface, and a step is formed in the molded surface of the lightweight material that can rise above the pressure surface up to the diameter of the O-ring. This step is undesirable, as it adversely affects the aerodynamics of the pressure side of the blade. It is time consuming to and very difficult to remove this step from the lightweight material, as the material is also very tough. What is needed is better method using improved tooling for adding lightweight material to a blade.
SUMMARY OF THE INVENTION
A flexible tool is formed to fit over the pressure or concave side of a metallic airfoil that includes a lightweight material component for a gas turbine engine during fabrication of the airfoil. Typically the airfoil is a metallic fan blade. The metallic fan blade includes pockets or cavities that have been machined into the blade in order to reduce the weight of the blade. The tool is a flexible body manufactured from sheets of composite material and includes an integral elastomeric seal.
The flexible tool is formed by laying up thin sheets of composite material that includes fiber over a metallic master tool. As used herein, composite material is material formed from sheets of plastic resin matrix material having a fiber reinforcement, in which the fiber reinforcement may be unidirectional or bidirectional (woven). This material is sometimes referred to as prepreg. The metallic master tool has a profile that matches the profile of the pressure side of the fan blade, but includes a plurality of slots that are located at positions that correspond to locations along the perimeter of the fan blade, that is, positions just beyond the leading edge, trailing edge or tip end. As used herein, matching the profile of the pressure side of the fan blade means that the metallic tool has a surface that substantially corresponds to the contours, dimensions and curvatures as the pressure side of a corresponding metallic fan blade that is manufactured without cavities. The slot positions correspond to preselected positions, which allow the flexible caul sheet and seal to be correctly assembled to the blade. The slot depth may vary, but need only be sufficiently deep to allow the layers of composite material to be laid into them, thus forming lugs that positively locate the flexible caul sheet when it is placed on to the concave (pressure) side of the blade.
The elastomeric material is partially cured and is placed along the tool within an area inside the outline of the blade, which is permanently marked on the tool, such as by scribing the tool surface. Thus, the elastomeric material is placed on the tool inside of markings that correspond to the perimeter of the blade. The sheets of composite material are laid up to achieve a predetermined thickness over the elastomeric material, over the tool surface in the region outlining the blade and into the slots on the tooling surface. The predetermined thickness provides a predetermined stiffness so that the flexible tool will not deform when lightweight a material is injected under pressure into the pockets of the blade beneath the tool. The tool also includes at least one injection port corresponding to a pocket or cavity so that the lightweight material can be injected through the tool into the blade pockets. Additional ports, each corresponding to a pocket, may be added as required. A surround frame for added local stiffness is assembled from sheets of composite material and is separated from the flexible tool using a TEFLON® (polytetrafluoroethylene—PTFE) film. The surround frame extends around the perimeter of the blade outline on the tooling surface so that it overlies the partially cured elastomer and the sheets of composite material.
The metallic master tool with the partially cured elastomer, the laid up composite sheets and the surround frame secured thereto is then placed in an elevated temperature atmosphere under pressure to cure the composite sheets and the elastomer to form the flexible tool. After curing, the surround frame is removed from the flexible tool, which in turn is removed from the metallic master tool. The flexible tool, which now includes an integral seal extending around its perimeter formed as the partially cured elastomer cures with the composite sheet, has a profile that matches the profile of the pressure side of the blade and can now be used to facilitate the injection of lightweight material into pockets of a fan blade by positioning the flexible tool over the fan blade and securing it into position. The integral seal is concave at room temperature to facilitate assembly of the tool to the blade, but expands on heating to form an effective seal against the blade.
An advantage of the present invention is that the problem of standoff is eliminated. Standoff, which is caused by use of an O-ring, results in poor contact between the tool and the blade, and results in a step when a flowable, curable, lightweight material is injected into the blade pockets.
Another advantage of the present invention is that a plurality of identical flexible tools can be manufactured from the metallic master tool that has an indefinite life.
Another advantage of the present invention is that the tool is more easily located on the blade, as the integral seal is concave at room temperature and the problems associated with positioning a tool having a movable O-ring that extends away from the tool surface are eliminated.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a cross section of a prior art caul sheet with an O-ring seal positioned over a fan blade having pockets, before being clamped in place;
FIG. 2 depicts a partial cross-section of a prior art caul sheet with an O-ring seal;
FIG. 3 is a partial cross-section of a caul sheet with an integral seal of the present invention;
FIG. 4 is a perspective view of a metallic tool used to manufacture a caul with an integral seal;
FIG. 5 is a cross section of the metallic tool of FIG. 4 with elastomeric material applied to tool surface, along lines 5 — 5 ;
FIG. 6 is a cross section of the metallic tool of FIG. 5 after lay-up of the sheets of the composite material over elastomeric material onto the tool surface and into the slots;
FIG. 7 is a cross section of the sheets of composite material arranged over the tool of FIG. 5 with separator film and surround frame in place;
FIG. 8 is a cross section of the cured caul sheet in place on the tool of FIG. 7 prior to cooling and after removal of the separator film and surround frame;
FIG. 9 is a cross section of the caul sheet at room temperature;
FIG. 10 is a cross section of a caul sheet assembled to a fan blade at room temperature;
FIG. 11 is a cross section of a caul sheet assembled to a fan blade at an elevated temperature after lightweight material has been injected into the blade pockets;
FIG. 12 is a cross section of a finished caul sheet at room temperature; and
FIG. 13 is a cross section across a lug of a finished caul sheet at an elevated temperature.
Whenever possible, the same reference numbers will be used throughout the Figures to refer to the same parts.
DETAILED DESCRIPTION OF THE INVENTION
Lightweight fan blades have been made by placing a caul sheet with an O-ring over a fan blade after the pockets have been formed in the blade. FIG. 1 depicts such a caul sheet 10 positioned over such a fan blade 12 having pockets 14 . O-ring 16 fits within a slot 18 formed in the face 20 of caul sheet 10 that contacts the pressure side 22 of fan blade 12 . Injector ports 24 extend through caul sheet 10 to provide access to fan blade pockets 14 . Slot 18 is dimensioned so that it fits over a perimeter 26 on the pressure side 22 of fan blade 12 extending around pockets 14 and inboard a preselected dimension from the blade edge 28 . FIG. 2 depicts an enlarged partial cross section of FIG. 1 showing caul sheet 10 with O-ring 16 . As can be seen, O-ring 16 must be compressed into slot 18 . Because O-ring 16 is a separate piece, it has a tendency to roll when placed in contact with the pressure side 22 of blade 12 , making it difficult to position. Furthermore, O-ring 16 must be properly compressed by clamps (not shown) completely around perimeter 26 so that O-ring 18 is flat against pressure side 22 and substantially fills and extends across slot 18 . If it is not flat against the pressure side 22 , that is, if it stands off from the surface of the blade, and/or if it does not extend completely across slot 18 , then a leak path exists outside the contour of the pockets that injected material will flow into. This material creates a step at the surface of the material filling the pocket that has adverse effects on the aerodynamics of the pressure side 22 of the blade 12 . The step can be as large as the radius of O-ring 16 . This extra material cannot be removed readily without risking damage to the blade.
A partial cross section of the caul sheet 110 of the present invention is depicted in FIG. 3 . This caul sheet is comprised of composite material and includes an elastomeric seal 116 . The elastomeric seal 116 is manufactured so that it is integral with caul sheet 110 . At room temperature, elastomeric seal 116 has a concave contour 118 that is substantially below the contour of the surface 120 of caul sheet 110 that will contact a fan blade when assembled thereto. A smooth, convex contour 121 rises along caul sheet 110 opposite elastomeric seal 116 at room temperature.
Referring now to FIG. 4, a perspective view of a tool 250 used in manufacturing caul sheet 116 is depicted. Tool 250 is a replica of a solid fan blade surface without pockets 14 , similar to blade 12 depicted in FIG. 1 . Except as noted, it has the same profiles and contours of the pressure side of such a blade. Tool 250 , however, is slightly wider and slightly longer than a blade. A scribe line 252 is placed along surface 254 of tool 250 . Scribe line 252 indicates the edge of a fan blade of a preselected design. Portions of tool surface 254 extend beyond scribe line 252 . Tip portion 255 of tool 250 extends beyond the portion of scribe line 257 indicative of the tip of a fan blade, while leading edge portion 258 and trailing edge portion 259 extend beyond the leading edge portion of the scribe line 260 and trailing edge portion of scribe line 261 . Tool 250 is slightly larger than an actual fan blade of the preselected design. Tool 250 includes slots 256 at three positions in a preferred embodiment that are located in the leading edge portion 258 and the tip portion 256 of the tool outside of scribe line 252 . Depending on the blade design, tool 250 may include more slots 256 and the slots may be located at various positions, including along the trailing edge if desired. However, at least two slots 256 are required.
Referring now to FIG. 5 which is a cross section of FIG. 4 along lines 5 — 5 , a continuous strip of partially cured elastomeric material 266 of preselected crosssection is laid on surface 254 of tool 250 inside of the perimeter of scribe line 252 . After elastomeric material 266 is placed onto tool 250 , a plurality of sheets of composite material 270 are placed over tool 250 in contact with surface 254 and over elastomeric material 266 as shown in FIG. 6 . The elastomeric material is preferably cut precisely to fit over the scribe line 252 with protrusions to fit into each of slots 256 . However, the sheets of composite when placed on surface 254 may extend beyond scribe line 252 and may be trimmed to the required size in a subsequent operation. Sheets of composite material 270 are laid into slots 256 , one of which is shown in FIGS. 5-8. The composite sheets 270 in slots 256 , when cured, form integral projections extending substantially perpendicular to the finished flexible tool or lugs that provide a positive location mechanism for caul sheet 110 when it is fitted to a blade. Tool 250 may be made of any material that can withstand elevated temperatures as will be explained. In a preferred embodiment, the material of choice is a metal capable of withstanding elevated temperatures, and the preferred metals are aluminum and its alloys.
Partially cured elastomeric material 266 , when fully cured, must be capable of being reheated a plurality of times without affecting the properties of the elastomeric material, and when cured, must be capable of forming a seal against the blade surface at elevated temperature and must be compatible with composite material. The composite material 270 used to form the caul body must be capable of being layed up on a tool used to form the caul body and be cured to form a composite body, and must be compatible with elastomeric material 266 .
The cured composite body in the form of a caul sheet must be flexible enough to accommodate the permissible variations in geometry from blade-to-blade when clamped in position, yet must be sufficiently stiff that when lightweight filler material is injected into fan blade pockets 14 , there is no deformation in the surface of the caul sheet. For elastomeric material 266 to be compatible with composite material 270 , there must be bonding as the materials are cured. While any elastomeric material 266 that has these properties may be used, urethane rubbers and fluorosilicone rubbers are acceptable. In the preferred embodiments, fluorocarbon rubbers such as Viton® available from E. I. Du Pont de Nemours are used. Composite material sheets that are acceptable include a matrix of epoxy reinforced by fibers. The sheets may include unidirectional fibers or woven fibers. The fibers that can be used include silicon carbide fiber, kevlar fiber, alumina or sapphire fiber, and graphite fiber. In a preferred embodiment, the sheets of composite material 270 are a carbon fiber/epoxy.
The sheets of composite material 270 are laid up to a thickness of between about 0.090-0.150 inches (0.228-0.381 cm). Each sheet or ply of composite material has a thickness of about 0.005-0.025 inches (0.013-0.064 cm). In a preferred embodiment, the thickness of the caul sheet is about ⅛ inch, about 0.120-0.130 inches (0.305-0.330 cm). As previously noted, the sheets may include woven fiber or unidirectional fiber. When sheets including unidirectional fiber are used, the sheets are placed on the tool in a quasi-tropic arrangement, that is, after the first sheet is applied, referred to as the reference sheet, at 0°, a second sheet is placed so that the fibers have an orientation of +45° to the fibers in the reference sheet, the next sheet is placed so that the fibers have an orientation of 90° to the fibers in the reference sheet, the next sheet is placed so that the fibers have an orientation of −45° to the fibers in the reference sheet, and the final sheet is placed so that the fibers are parallel to the fibers of the reference sheet. The pattern of alternating orientations is continued until the desired thickness is achieved. This quasi-tropic arrangement provides greater strength to the cured composite. While the sheet orientation pattern of 0°, 45°, 90°, (−45°) has been described, other orientation patterns may be used as desired.
After the composite sheets are laid up, as previously discussed they can be trimmed to an appropriate size. In the regions in which injector ports are located, small sheets (not shown) of composite material are cut to size and added to form the stiffening ribs and pads for the injector line adaptor at the injection ports. These additional sheets may be added in any other areas where additional strength or stability is required.
Referring back to FIG. 4, the edges of the sheets of composite material are cut so that they extend into slots 256 to form the positive location lugs for the caul sheet on the blade. The layup of composite sheets is then covered with a thin film of separator material 272 as shown in FIG. 7 . The separator material may be any material that the composite matrix will not adhere to during the curing process and serves as a barrier between the composite materials and the curing bags used during the curing process, as will be explained. TEFLON® film (polytetrafluoroethylene—PTFE) has been found to be an excellent separator material.
After the separator material 272 is placed over the layup, a surround frame 274 is placed over the film. The surround frame extends around the periphery of tool 250 . The purpose of the surround frame is to secure the partially cured elastomeric material in position as the sheets of composite material 270 and the elastomeric material 266 are fully cured together, and to add stiffness.
After the sheets of composite material 270 are trimmed to size, the assembly of FIG. 7 is then placed in an autoclave and cured. The assembly is bagged using a nylon bag (not shown) placed over the TEFLON® (polytetrafluoroethylene—PTFE) film 272 . Both the nylon bag and TEFLON® (polytetrafluoroethylene—PTFE) extend around the slots 256 to the side of the tool opposite surface 264 to secure the layup in place. The sheets of composite material 270 and the elastomeric material 266 are cured in an autoclave at suitable temperatures and pressures to form caul sheet 110 . For VITON® and carbon fiber reinforced epoxy, used in the preferred embodiment of the present invention, the material is cured in an autoclave at a temperature of about 350° F. (177° C.) at a pressure of about 50 psi for about 2 hours. Different material combinations may require different temperatures, pressures and/or times to cure properly. The curing process not only causes crosslinking of the matrix material of the composite and the partially cured elastomeric material 266 , but also cross-linking occurs between the matrix material and elastomeric material 266 , forming a strong bond between the elastomeric material 266 which, on curing, forms seal 116 and the matrix material so that the seal is an integral part of the caul sheet 110 . FIG. 8 depicts the cured caul sheet 110 assembled to tool 250 while still hot. As cooling occurs, elastomeric material 266 contracts, causing a gap between a portion of the elastomeric material and tooling 250 . Two different cross-sections of cured caul sheet 110 are depicted in FIGS. 12 and 13 to illustrate the effect of elevated temperatures on the integral seal 116 . FIG. 12 illustrates a first cross section of caul sheet 110 at room temperature. At this temperature, the cross-linking between the matrix material of the composite 270 and the elastomeric material 266 restrains the elastomeric material, and concave contour 118 results as the seal contracts. Also shown is a node 280 that extends completely around the surface of caul sheet 110 formed opposite seal 116 . The amount that the elastomeric material 266 projects above surface 254 of tool 250 during fabrication of caul sheet 110 determines the contour and height of node 280 , with more material and a higher projection resulting in a node with a more severe contour and a higher height. FIG. 13 illustrates a second cross section of caul sheet 110 at an elevated temperature. At this temperature, about 300-350° F. (149°-177° C.), the cross-linking between the matrix material of the composite 270 and the elastomeric material 266 still restrains the elastomeric material, but convex contour 282 results as the seal expands. The cross sections of FIGS. 12 and 13 also illustrate one of lugs 290 formed by curing of the composite sheets that were placed slots 256 . Each lug 290 fits over an edge of fan blade 12 along the blade perimeter, and the lugs are somewhat flexible to account for small manufacturing variations among the blades of a particular design.
An enlarged view of caul sheet 110 and seal 116 is shown in partial cross-section in FIG. 9 at room temperature. On cooling the material of integral elastomeric seal contracts, but as a result of the strong bonding with the matrix material, it is restrained from contracting along its sides, so that concave contour forms.
In use, caul sheet 110 is assembled to fan blade 12 having pockets 14 , as shown in FIG. 10 by placing each of lugs 290 around the edge of the blade along a perimeter. This placement basically aligns blade 12 with the caul sheet 110 . Prior to filling pockets 14 with lightweight material 302 in the form of a lightweight, flowable, curable liquid, the assembly is heated to a temperature in the range of 220-250° F. (104-121° C.) to expand seal 116 against pressure side 22 of blade, as shown in FIG. 11 .
To facilitate and assure fit-up during addition and curing of lightweight material 302 , after caul sheet 110 is aligned on blade 12 , a plurality of clamping blocks 296 are assembled onto caul sheet 110 to facilitate the use of clamps 298 to secure caul sheet 110 to blade 12 while lightweight material 302 , shown in FIG. 11, is injected into pockets 14 after elastomeric seal 116 has been expanded into contact against pressure side 22 of the blade. In the preferred embodiment, each of clamping blocks 298 have a contoured surface 304 corresponding to the contour of node 280 . Clamping blocks, however, are not required to completely cover node 280 around the perimeter of the airfoil, but are present in a plurality of discrete locations around the assembly. Although the caul sheet 110 may be heated before assembling to blade 12 , in a preferred embodiment the caul sheet is assembled and clamped to the blade, and the clamped assembly is heated. This assures the proper expansion of seal 116 against pressure side 22 .
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | 4y
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CROSS-REFERENCE TO RELATED APPLICATION(S)
This application relates to U.S. patent application Ser. No. 13/176,842, filed Jul. 6, 2011, entitled “Pipeline Power Gating,” naming inventors Daniel W. Bailey et al., which application is incorporated herein by reference in its entirety.
BACKGROUND
1. Field of the Invention
This invention relates to power savings in integrated circuits and more particularly to reducing leakage current during runtime.
2. Description of the Related Art
Power consumption in integrated circuits can be attributed to both actively switching circuits and to idle circuits. Even when circuits are idle, leakage current from the transistors results in undesirable power consumption. Previous solutions to saving power have identified large architectural features that have been idle for a period of time and have implemented power savings in such circuits by reducing the voltage being supplied and/or the frequency of clock signals being supplied to the unused circuitry. For example, in a multi-core processor, one or more of the cores may be placed in a lower power consumption state by reducing the supplied frequency and/or voltage while maintaining active other functional blocks, such as input/output blocks. However, particularly in battery driven devices, such as mobile devices, laptops, and tablets, finding additional ways to save power is desirable to extend battery life, reduce heat generation, and ease cooling requirements. Even in desktop or server systems, reducing power consumption leads to reduced heat generation, cost savings by reducing electricity use, and reduced cooling requirements. Power saving considerations continue to be an important aspect of integrated circuit and system design.
SUMMARY OF EMBODIMENTS OF THE INVENTION
Additional power savings can be achieved by focusing on small-grained features of the integrated circuit. One embodiment provides a method of reducing leakage current that includes waking a first plurality of gates coupled between first source storage elements and second destination storage elements, to allow current flow in the first plurality of gates, the waking in response to assertion of any of one or more first source clock enable signals associated with the first source storage element. The method includes waking a second plurality of gates, coupled between second source storage elements and second destination storage elements plurality, to allow current flow in the second plurality of gates, in response to assertion of any of one or more second source clock enable signals associated with the second source storage elements. The method further includes waking a third plurality of gates, in response to assertion of any of the one or more first source clock enable signals and waking the third plurality of gates in response to the assertion of the any of the one or more second source clock enable signals. The third plurality of gates are slept to reduce leakage current in the third plurality of gates in response to, at least in part, all of the one or more first and second source clock enable signals being deasserted.
In another embodiment, an apparatus includes a plurality of first power-gated gates coupled between first source storage elements and first destination storage elements. A plurality of second power-gated gates are coupled between second source storage elements and second destination storage elements. A plurality of third power-gated gates are coupled between at least one of the first or second source storage elements and the first and second power-gated gates. At least one power gate is coupled in series between a power supply node and the third power-gated gates, the power gate to reduce current flow through the third power-gated gates in response to a power gate control signal indicating a sleep state and to allow current flow through the power-gated gates in response to the power gate control signal indicating a wake state. Control logic for the at least one power gate is configured to cause the power gate control signal to indicate the wake state based on first and second control signals associated with the first and second power gated gates that respectively cause the first and second power-gated gates to enter sleep and wake states.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood, and its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
FIG. 1 shows a high level diagram of an integrated circuit suitable for using embodiments of the invention.
FIG. 2 illustrates a high level diagram of power-gating logic gates according to an embodiment of the invention
FIG. 3 illustrates a timing diagram associated with the embodiment of FIG. 2 .
FIG. 4A illustrates an exemplary power-gating approach.
FIG. 4B illustrates an exemplary power-gating approach utilizing additional power gates.
FIG. 4C illustrates a high level diagram of an exemplary power-gating power approach in which timing constraints are eased by eliminating gates from being power gated.
FIG. 5 illustrates a configuration in which gates in Group A and gates in Group B are power gated and gates in Group AB are not power gated.
FIG. 6 illustrates a configuration in which logical coverage is increased over the configuration of FIG. 5 .
FIG. 7 illustrates another configuration for multiple groups providing improved logical coverage as compared to the configuration of FIG. 5 and improved power savings compared to the configuration of FIG. 6 .
FIG. 8 illustrates additional details of Group AB found in one embodiment.
The use of the same or similar reference symbols in different drawings indicates similar or identical items.
DETAILED DESCRIPTION
Power gating groups of gates achieves additional power savings during run-time operation by reducing the leakage current of transistors in the gates. In one embodiment a power gate is formed by a transistor (or many transistors in parallel) that are in series between the power-gated gates and their power supplies, e.g., VDD and/or GND. The power gate(s) are then selectively controlled to disconnect the gates from VDD and/or ground so the leakage current can be reduced when the gates are not being used.
Referring to FIG. 1 , a high-level block diagram illustrates an integrated circuit 101 such as a microprocessor, which includes multiple macro architectural features 102 such as processing cores, whose power can be controlled by placing them in power states that provide varying levels of performance, from a sleep state to a fully powered state. In addition, one or more of the macro architectural features have groups of gates 103 that can be controlled to reduce power consumption during the full (or a reduced) operational state during run time.
FIG. 2 illustrates an exemplary embodiment of how the groups of gates can be controlled during run time to decrease power consumption. Referring to FIG. 2 , nFET power gate 201 is in series between the power-gated gates 203 and GND. The power-gated gates 203 correspond to the group of gates 103 shown in FIG. 1 . The gates that are power gated are typically AND, OR, NOR, NAND, and similar logic gates and are represented in FIG. 2 as power-gated gates 203 . When the gates 203 are idle, the power gate 201 can be turned off, reducing the voltage across the gates and thereby reducing the leakage current from the gates. In addition, or instead of using the nFET 201 , a pFET 202 can be used in series with VDD, and switched off to reduce the voltage across the gates, thereby reducing the leakage current.
A significant issue with run-time power gating is having adequate time to transition the gates from sleeping to fully powered, i.e., having enough time to wake. That is, when power gate 201 is turned on, the power-gated gates take time to fully charge to their fully powered state in response to power gate 201 (and/or 202 ) turning on. One approach is to include sufficient timing margin in the design, e.g., a guard band in the timing design, to ensure the gates are fully powered. However, such a timing penalty is generally unacceptable in high-performance integrated circuits such as microprocessors.
Control logic 205 monitors the clock gate enables 221 and 223 of the source flip-flops 207 to determine when to wake, and when to sleep the power-gated gates. The number of clock gate enables shown is illustrative and other numbers of enables may be utilized based on design requirements. Note that the AND gate 208 may also be considered part of control logic 205 and helps control the clocking of the destination flip-flops as described further herein. Note that while flip-flops are shown in FIG. 2 , any source and destination storage elements, such as latches, may be used instead of, or in addition to, the flip-flops shown in FIG. 2 .
FIG. 2 illustrates the basic operation and construction of an exemplary embodiment. A chosen set of destination flip-flops 209 determines the set of gates 203 that can be power gated. That is, a gate can be power gated if all of its output paths terminate exclusively at one or more of the destination flip-flops 209 . Gates with output paths that go to places other than destination flip-flops are not power gated. For example, the inverter 215 has an output path 217 that goes somewhere other than destination flip-flops 209 , e.g., to a different flip-flop, latch, or output port. Accordingly, inverter 215 is not included as part of the power-gated gates 203 . In an exemplary embodiment the control logic 205 is a state machine that controls the power gate, monitors the clock gate enables and determines when to wake the power-gated gates, and when the power-gated gates can sleep.
Consider an initial state of sleep. In the initial sleep state shown in FIG. 2 , destination flip-flops 209 are blocked from clocking and the power-gated gates 203 are sleeping. The term sleeping refers to the power gate 201 (or 202 ) being turned off to reduce leakage current in the power-gated gates 203 . In the sleeping state the state machine in the control logic 205 is in a first state in which the WAKE signal is deasserted. FIG. 3 illustrates a timing diagram associated with the circuits shown in FIG. 2 . The term “wake” refers to the power gate 201 (and/or 202 ) being turned on to allow current to flow in the power-gated gates 203 .
Referring to FIG. 3 , assume a clock signal CLK 301 on clock signal line 224 . Latches 226 and 228 are used to supply the enable signals ENA 1 221 and ENA 2 223 for the clock signals for source flip-flops 207 . The enable signals are ANDed with the clock signals in AND gates 230 and 232 . Gates 203 wake in response to assertion of any of the source flip-flop clock gate enables 221 or 223 (shown at 302 ) after the delay through OR gates 225 , 227 , and 229 . The state machine flip-flop 231 asserts its output on the rising edge of the next cycle at 304 , thus changing to a second state. The assertion of the output of the flip-flop 231 results, after a delay, in the assertion of the DEST_ENA_ 3 signal at the output of the AND gate 208 at 306 . The destination flip-flops 209 are then clocked after the delay through latch 210 and AND gate 212 . The enable (ENA 3 ) for the destination flip-flops is assumed to be asserted at that time. Using the state machine, there is at least a one-cycle delay between assertion of the source enables at 302 and the assertion of the destination enable at 306 , allowing the power-gated gates time to fully charge before the destination flip-flop clocks are unblocked and clocked.
The power-gated gates 203 are held awake by the control logic 205 until the destination flip-flops are clocked. Once destination flip-flops are clocked after DEST_ENA_ 3 236 is asserted at 306 and the source enables 221 and 223 are deasserted, the output of the state machine flip-flop deasserts at 308 at the rising clock edge, returning to the first state, causing the power-gated gates to sleep by deassertion of the WAKE signal at 310 . Any further clocks for the destination flip-flops 209 are blocked by AND gate 208 until source flip-flops are clocked again. The destination flip-flops will not change, of course, if the source flip-flops do not change. The blocking function allows a full clock period before destination flip-flop inputs are consumed.
An embodiment may have multiple destination enables. If so, there is a need to wait until all destination clock enable signals have asserted before putting the power-gated gates to sleep. Since conceivably the destination enables can arrive at different times, the signals can be stored in flip-flops and then reset when all bits have been asserted at least once and supplied to the logic to cause sleep through the flip-flop 231 . In an embodiment, bits could be encoded to save on the number of flip-flops.
FIG. 4A illustrates an embodiment in which the power-gated gates 403 between source flip-flop 402 and destination flip-flop 404 are coupled to a single power gate 405 . In FIG. 4B multiple power gates 407 and 409 are used. If there are a large number of power-gated gates, the distribution of WAKE to the power gates may take several stages of buffers. FIG. 4B shows how timing requirements can be relaxed by partitioning gates into critical timing gates (attached to WAKE 1 ) and non-critical timing gates (attached to WAKE 2 ). Thus, power gate 407 receives WAKE 1 and power gate 409 receives WAKE 2 . Gates temporally closest to the source flip-flops are most critical. In the embodiment shown in FIG. 4B , the power gate for the critical gates receive WAKE 1 using no buffers (or fewer buffers) as compared to WAKE 2 . For ease of illustration, WAKE 2 is shown being generated with one buffer and WAKE 1 with no buffers. Other number of buffers may be required depending on the particular implementation and the number of power gates driven by each of the wake signals.
Timing requirements are aggressive, but can be relaxed. The OR of the enables of the source flip-flops supplies the state machine flip-flop 231 . The clock for the flip-flop 231 can be delayed, however, since it initiates the sleeping function, not the waking.
A second timing constraint is that the gates should be fully powered by the time they are used, or timing can suffer. They should be wakened by the time the source flip-flops outputs can transition. This timing constraint can be relaxed by not power gating stages of gates immediately following the source flip-flops. Referring to FIG. 4C , gates 411 and 415 are not power gated and not included with power-gated gates 417 to provide additional timing margin for the control signal WAKE to wake the power-gated logic gates. Both of these timing relaxation techniques shown in FIGS. 4B and 4C reduce the leakage savings. As shown in FIG. 4C , the setup requirement can be relaxed by trading off coverage of how many gates are subject to power gating.
The active power gating approach described herein is applicable to microprocessor design, but is widely applicable to circuit design generally. Because the techniques herein can be generally applied to digital circuitry, the active power gating described herein can achieve high coverage, which in turn means more power savings. Timing impact is modest. The timing impact results from a term being ANDed in AND gate 208 in the clock enable path, and there is additional load for the one or more source enable signals from the OR tree. As clock gating efficiency improves over current approaches, the active power gating herein will automatically improve in terms of its impact on leakage savings.
Power gating described herein may lead to higher use of LowVT (LVT) gates, or even UltraLowVT (ULVT) gates, within power-gated domains because leakage power is selectively and transiently reduced. Active-mode power gating puts leakage power on par with dynamic power when making performance-power tradeoffs.
An additional benefit of the approach described in FIG. 2 is that dynamic power is likely to be reduced, too, because of the clock blocking function by AND gate 208 on the clock for the destination flip-flops. That is, if the destination clocks are blocked by the control logic 205 , additional power savings occurs.
As has been described above, pipeline Power Gating (PPG) reduces leakage of inactive circuits during run time. In certain embodiments, it is possible to increase the logical coverage of PPG while preserving the original power savings so that leakage savings is increased.
Referring to FIG. 5 , consider the illustrated configuration in which gates in Group A supplying destination flip-flops 501 and gates in Group B supplying destination flip-flops 503 are power gated. Gates in Group AB are not power gated because they terminate in more than one set of destinations, both Group A destination flip-flops and Group B destination flip-flops. Group AB gates must be awake anytime either Group A or Group B destination flops are clocked.
Another important concern is that power-gated domain outputs must not drive fully powered gates without isolation gates. The consequence would be crossover current and possible compromise of reliability. An isolation gate is a gate that is configured to selectively ignore an input, and requires a full-rail signal to control it. For Group A and Group B gates, the isolation gates are the destination flops, and the isolation controls are the clocks. Adding isolation gates to the outputs of Group AB gates would impact timing if generally applied.
As shown in FIG. 6 , logical coverage can be increased by combining the multiple sets of destination flip-flops into a single set of destination flops. As shown in FIG. 6 , groups of gates A and B are subsumed into a larger Group AB. The circuit shown in FIG. 6 increases the logical coverage, but the main problem with this approach is that static and dynamic power savings may actually be reduced. Group A gates are now likely to be slept less often than in the original configuration since they are awakened by any of the Group A and Group B source enables. Similarly, dynamic power is likely to increase because Group A destination flops are clocked when either ENA 3 _A or ENA 3 _B is asserted, instead of just ENA 3 _A. The same static and dynamic disadvantages apply to Group B gates.
In addition, there are two other problems with the approach shown in FIG. 6 . First, it is unclear which group of gates should be combined when there are more than two sets of destinations. Consider if there are also Group C, AC, BC, and ABC gates. If all groups are subsumed into a Group ABC, then the power savings problem described above is worse. If Group AB is formed, then Groups AC, BC, and ABC are not included in the logical coverage (without duplication of logic). The second problem is that the register transfer language (RTL) description must be rewritten to restructure the logic as groups are combined.
FIG. 7 shows an exemplary approach for combining power-gated groups that provides improved logical coverage and power savings. Unlike the circuit in FIG. 6 , in FIG. 7 Group A and Group B gates are power gated as often as they are in the original configuration in FIG. 5 . Also, Group A and Group B destination flip-flops are clocked as often as they are in the original configuration. Therefore, in FIG. 7 , Group AB gates add to the leakage savings. In this approach, anytime either Group A or Group B gates are awake, Group AB gates are also woken. The function of the AND gate 701 driving the Group A power gate is to ensure Group AB gates are awake before Group A gates are woken, i.e., the AND is for power deracing. The same principle applies to the AND gate 703 driving the Group B power gate.
The approach described by FIG. 7 provides another advantage in that the formation of any groups does not prevent the formation of other groups. If there are also Group C, AC, BC, and ABC gates, they can all be power gated separately using similar logic.
Note that the preferred approach reduces timing margin by adding an AND gate delay in the power gate enable path. Also, the register transfer language (RTL) description of the circuit has to be updated as combined groups are added. But the approach of FIG. 7 increases the logical coverage and leakage savings from Pipeline Power Gating without decreasing the dynamic power savings, and the approach is scalable for all combinations of groups.
FIG. 8 illustrates an embodiment in which flip-flops 502 and 504 supply AND gate 801 in Group AB. Other logic gates are typically included in Group AB but FIG. 8 only shows AND gate 801 for ease of illustration. As can be seen in FIGS. 5-8 , source storage element 502 is a source element for both Group A and Group B through the combinational logic in Group AB. Similarly, source storage element 504 is a source element for both Group A and Group B supplied through combinational logic in Group AB. Thus, source storage elements such as flip-flops 502 and 504 may serve as source storage elements for different groups of destination storage elements 809 and 811 . Thus, assertion of either of the clock enable signals ENA 1 _B or ENA 1 _A wakes both Group A and Group B (and Group AB). The power savings can be seen in that Group A can remain power gated when ENA 2 _B is asserted and Group B can remain power gated when ENA 2 _A is asserted. Group AB is wakened whenever any of the enables for Group A or Group B are asserted. Thus, Group AB can be slept when both Group A and Group B are slept, saving power as compared to FIG. 5 . In addition, Group A can be slept when Group AB and B are awake and Group B can be slept when Group A and AB are awake, thus providing power savings as compared to FIG. 5 or 6 .
While circuits and physical structures have been generally presumed in describing embodiments of the invention, it is well recognized that in modern semiconductor design and fabrication, physical structures and circuits may be embodied in computer-readable descriptive form suitable for use in subsequent design, simulation, test or fabrication stages. Structures and functionality presented as discrete components in the exemplary configurations may be implemented as a combined structure or component. Various embodiments of the invention are contemplated to include circuits, systems of circuits, related methods, and computer-readable medium having encodings thereon (e.g., HDL, Verilog, GDSII data) of such circuits, systems, and methods, as described herein. Computer-readable medium includes tangible computer readable medium e.g., a disk, tape, or other magnetic, optical, or electronic storage medium. In addition to computer-readable medium having encodings thereon of circuits, systems, and methods, the computer-readable media may store instructions as well as data that can be used to implement the invention. Structures described herein may be implemented using software executing on a processor, firmware executing on hardware, or by a combination of software, firmware, and hardware.
The description of the invention set forth herein is illustrative, and is not intended to limit the scope of the invention as set forth in the following claims. Other variations and modifications of the embodiments disclosed herein may be made based on the description set forth herein, without departing from the scope and spirit of the invention as set forth in the following claims. | 4y
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This invention was made with Government support under Subcontract No. ZL-7-06031-3 awarded by the Department of Energy. The Government has certain rights in this invention.
FIELD OF THE INVENTION
The present invention relates to low cost photovoltaic devices and, more particularly, relates to improvements in polycrystalline photovoltaic cells and methods of manufacturing such cells which enable the n-type layer of the photovoltaic junction to be highly transmissive of low wavelength energy, therefore increasing the efficiency of the photovoltaic device.
BACKGROUND OF THE INVENTION
Photovoltaic cells capable of converting sunlight directly to electrical energy have been commonly used for decades. Most present-day photovoltaic devices employ single cells, which are satisfactory for low energy consumption devices, but inherently have a high cost/output watt ratio. Polycrystalline photovoltaic cells can be manufactured at a much lower cost than single crystal cells, but have generally reduced efficiencies. Nevertheless, a great deal of research has been and is continuing with respect to the development of higher efficiency polycrystalline photovoltaic products which utilize thin layers of particular chemical compositives to form the n-type material and the p-type material of the photovoltaic junction. Much of this technology has detracted from the advantages of low cost in favor of increased efficiency. While high efficiency is obviously desired, low material and manufacturing costs are critical if photovoltaic technology is to have increased practical significance. Low cost polycrystalline cells can currently provide relatively low cost electrical power at remote locations, such as telecommunication stations, agricultural water pumping sites, remote villages and portable housing facilities. Improvements in such technology may well result in future photovoltaic power plants which compete with conventional hydrocarbon consuming plants. The present invention is directed to such polycrystalline photovoltaic technology and, most importantly, is directed to improvements in photovoltaic technology which will result in increased efficiency but do not significantly increase the material or manufacturing costs of the photovoltaic cells.
A low cost photovoltaic cell with a p-type Cu x S layer and an n-type CdS layer disclosed in U.S. Pat. Nos. 3,902,920 and 4,086,101. Such a cell may be formed on a glass substrate according to the techniques disclosed in U.S. Pat. No. 3,959,565. Improved CdS film for such a cell is the subject of U.S. Pat. No. 4,095,006, and residual chlorides in a CdS layer are disclosed in U.S. Pat. No. 4,178,395. The n-type and/or the p-type polycrystalline layers of the photovoltaic cell may be regrown as disclosed in U.S. Pat. No. 4,362,896. Improved equipment for forming such a low cost cell is disclosed in U.S. Pat. Nos. 4,224,355, 4,239,809, 4,338,078 and 4,414,252. Instead of utilizing a spray pyrolysis technique, the n-type polycrystalline layer or the p-type polycrystalline layer may be formed according to a technique which utilizes compression preceding regrowth, as disclosed in U.S. Pat. No. 4,735,909. After the various polycrystalline layers have been formed on a substrate, individual cells may be formed and interconnected in a series arrangement according to U.S. Pat. Nos. 4,243,432 and 4,313,022. Various cell or panel encapsulation techniques have been devised, and a low cost yet reliable panel encapsulation technique is disclosed in U.S. Pat. No. 5,022,930. The series connected cells on a glass substrate form a photovoltaic panel, and various photovoltaic panels may be assembled in a module according to the techniques of U.S. Pat. No. 4,233,085.
Various materials have been suggested for forming the junction layers of the polycrystalline photovoltaic cell. A great deal of research has been expended with respect to polycrystalline silicon photovoltaic cells, in part because early tests resulted in reasonably high efficiency for these cells. Copper indium diselenide polycrystalline cells have been developed, and show some promise of improved efficiencies. Cadmium telluride cells, and particularly such cells wherein the cadmium telluride is the p-type material, nevertheless are generally considered to offer the lowest cost production potential. It must be recognized, of course, that the commercial cost of a photovoltaic cell does not only consist of the material and manufacturing cost of active junction layers which convert sunlight into electrical energy, since the material and manufacturing costs of the substrate, the appropriate electrode configuration of the cells and for interconnecting the cells, and the encapsulation mechanism must all be considered in analyzing the overall cost of the photovoltaic product. The ideal solution to one problem, i.e., high efficiency and low cost junction formation, must also be compatible with the technology used to achieve a desired overall photovoltaic product at the desired cost/output ratio.
Cadmium telluride photovoltaic cells offer an advantage of relatively low costs. Moreover, cadmium telluride cells may be manufactured with low-cost deposition equipment for applying the CdTe film layer, as described in the previously-referenced patents, and this cell does not require extremely close quality control to obtain reasonable efficiency. Various materials have been proposed for the n-type layer for forming the photovoltaic junction with the cadmium telluride layer. Cadmium sulfide has been considered a suitable n-type material for such a cell, and particularly for a low cost cadmium telluride cell, since it also has a relatively low manufacturing cost and may be deposited at atmospheric pressure utilizing low-cost deposition equipment. U.S. Pat. No. 4,568,792 discloses various types of cadmium telluride cells, and notes that CdS is an advantageous n-type material because of its wide band gap. Various materials have been suggested for "doping" the p-type cadmium telluride layer, while the n-type layer may be oppositely doped. U.S. Pat. No. 4,705,911 discloses a CdS/CdTe solar cell, wherein an oxygen-releasing agent is provided to minimize reduction of the p-type characteristics of the cadmium telluride.
In spite of its low-cost per watt of useful power output, CdS/CdTe cells have not been widely accepted because of continuing relatively poor efficiency. One long-recognized reason for such poor efficiency relates to the construction of the cells and the optical band gap of the CdS layer. To produce electrical energy, light must reach the junction of the cell, i.e., the CdS/CdTe interface. The CdTe layer generally serves as the light absorber, and in a typical structure the CdS serves as a heterojunction partner and an optically transmissive layer. This design may result in a "backwall" cell, wherein light passes through a CdS layer which is deposited on the CdTe layer, which was previously deposited on an opaque substrate. Alternatively, an "inverted backwall" design may be used, wherein light first passes through a highly-transmissive substrate (glass) then through the CdS layer which was deposited over the substrate, to reach the junction formed when the CdTe layer is deposited on the CdS layer. A "front wall" cell may be formed utilizing a CdS/CdTe design, wherein the CdTe layer is deposited over a CdS layer, which was previously deposited on an opaque substrate, or an inverted front wall" cell formed by depositing the CdTe layer on a glass substrate, with the CdS layer then applied on the CdTe layer. While the backwall or inverted backwall design of a CdS/CdTe cell is preferred, a significant quantity of energy is lost in the CdS layer, since cadmium sulfide does not pass optical energy with a wavelength shorter than approximately 520 nm unless the film is very thin. The CdS layer must be continuous to provide the desired junction and, most importantly, to prevent shorts to the electrode layer. To utilize the desired low-cost deposition equipment, the CdS layer has necessarily been of a thickness such that very little of the optical energy with wavelengths less than 520 nm reached the junction and produced useful energy. U.S. Pat. No. 4,251,286 discloses utilizing a zinc sulfide blocking layer to prevent electrical shorts, but this technique is expensive and introduces additional complexities which are believed to have a significant adverse affect on the life of the cell. U.S. Pat. No. 4,598,306 also discloses the use of a barrier layer for preventing electrical shorts between the active photovoltaic layers and an electrode. The barrier layer operates as a series resistor to limit current flow through the otherwise short circuit current path. U.S. Pat. No. 4,544,797 discloses another technique for preventing short circuits by passivating areas of a first conductive electrical contact which are not covered by the adjoining n-type or p-type material. This passivating step may be performed by immersing the device in ammonium sulfide to convert a silver metallic layer at the location of pinholes to an n-conductive Ag 2 S material. This procedure is similarly costly and again introduces additional chemicals into the cell formation process which are not desired. An article entitled "Properties of the Screen-Printed and Sintered CdTe Film Formed on a CdS Sintered Film" in Technical Digest of the International PVSEC, Vol. B-III (1987), p. 5 suggests that screen-printed CdS/CdTe cells may have improved longer wavelength sensitivity due to the formation of mixed CdS x Te 1-x crystals during sintering of the CdTe.
The disadvantages of the prior art are overcome by the present invention, and an improved photovoltaic cell and method of forming a photovoltaic cell are hereinafter disclosed. A photovoltaic panel comprising a plurality of cells formed according to the techniques of the present invention has the desirable benefit of low material and manufacturing costs, yet produces a considerable increase in photovoltaic conversion efficiency compared to prior art devices which have not included this technology, thereby resulting in a photovoltaic panel having relatively low overall cost per watt of useful power output.
SUMMARY OF THE INVENTION
A high efficiency CdS/CdTe photovoltaic cell may be formed according to the present invention. A continuously relatively thick CdS layer is initially formed on a substrate, but its thickness is reduced during regrowth of the active photovoltaic layers. At the regrowth temperature, CdS diffuses or migrates into either the space between the formed large CdTe crystals or into the crystals themselves, resulting in a continuous CdS layer, yet a CdS layer having a reduced effective thickness. The effective thickness of the resulting CdS layer may be in the range of approximately 100 Å to approximately 500 Å, so that a high percentage of optical energy less than 520 nm passes through the CdS layer to the junction, thereby increasing efficiency.
Special precautions are taken to ensure that the CdTe layer does not provide a significant shunting path to the conductive layer adjoining the CdS layer, while at the same time ensuring that the conductive layer is highly transmissive of light. This conductive layer preferably comprises one highly-conductive layer of tin oxide (approximately 10 20 carriers per cm 3 ), and another substantially lower conductivity layer adjoining the CdS layer. This second lower conductivity tin oxide layer has its carrier concentration adjusted so that when in contact with CdTe (where there are flaws in the CdS layer), a voltage and current are produced and shunting is avoided. The highly conductive tin oxide layer provides the desired low resistance path for the transmission of electrical energy within and between cells. A high degree of continuity of the low conductivity tin oxide layer is essential if there are a significant number of flaws in the CdS layer, and the desired uniformity of this tin oxide layer may be obtained by spraying a low molarity tin oxide solution for a long enough time so that a large number of droplets provide uniform statistical coverage of the high conductivity tin oxide layer. The conductivity of tin oxide may be easily varied in the range of at least six orders of magnitude.
According to one embodiment of the present invention, a high efficiency CdS/CdTe backwall photovoltaic panel is formed by first spraying a high conductivity tin oxide layer on a glass substrate utilizing spray pyrolysis to obtain a layer with a specific conductivity in the range of from 1000 to 5000 mho/cm. The low conductivity second tin oxide layer is then applied by the same technique using a low molarity solution suitably doped to obtain a desired carrier concentration in the resulting film. In an exemplary case, a conductivity of approximately 0.10 mho/cm with a carrier concentration of 4×10 17 carriers/cm 3 is used, with a CdTe layer having a carrier concentration of 5×10 15 carriers/cm 3 to produce a satisfactory photovoltaic cell. In this case, cadmium was used as the tin oxide dopant, but zinc or other metals may be used. It should be pointed out that the carrier concentration, while related to conductivity, is not a direct function of it but is related in part to the dopant used and resulting mobility. Conductivity measurements are expressed in this application because carrier concentration is difficult to measure. The CdS layer may then be applied by spray pyrolysis (or other suitable technique) to an initial thickness in the range of from 2,000 to 12,000 Å, and a substantially thick CdTe layer applied by an atmospheric temperature spraying and compression technique (or similar method). The panel is then heat treated and the active photovoltaic layers regrown at approximately 540° C. to form large CdTe crystals, while the CdS diffuses or migrates between or into these crystals and forms a layer having an effective thickness in the range of approximately 1/20th of its initial thickness. The panel is then divided into cells and the cells series interconnected, and the completed panel encapsulated. The active areas of a photovoltaic panel have a comparatively high efficiency up to 18% over a long cell life, in large part due to the increased efficiency attributable to the effectively thin CdS layer. The quantum efficiency of the cell in the spectral band at wavelengths shorter than 520 nm may surprisingly be approximately 90%. The tin oxide layer, with an appropriate carrier concentration, in combination with a suitable p-type material layer, will produce voltage and current when exposed to sunlight where there are flaws in the CdS layer.
It is an object of the present invention to provide a substantially high efficiency polycrystalline photovoltaic cell, wherein the n-type material layer of the photovoltaic junction is made highly transmissive to short wavelength energy by reducing the effective thickness of the n-type material layer by diffusing or interdiffusing into or with the p-type layer a substantial portion of this layer.
It is a further object of the present invention to reduce the effective thickness of the n-type material layer in a photovoltaic cell to approximately 1/20th of its applied effective thickness, thereby forming a substantially continuous, reduced thickness layer for increased short wavelength light transmissivity.
A major object of this invention is to provide a polycrystalline cell with a relatively thin yet continuous n-type material layer, and with a relatively low conductivity and doped layer adjacent the n-type material layer, and a high conductivity conductor layer adjacent to the low conductivity layer and formed from substantially the same base material as the low conductivity layer, such that any flaws in the n-type material layer do not allow a short between the p-type material layer and the low conductivity layer, but rather actually produce energy in the area of any flaws in the n-type layer by the proper adjustment of the relative carrier density of the low conductivity layer and the p-type material layer.
It is a feature of the present invention to provide a high efficiency CdS/CdTe photovoltaic cell, wherein the effective thickness of the applied CdS layer is significantly reduced by diffusion or migration into the CdTe layer, thereby reducing the effective thickness of the CdS layer to allow a high percentage of short wavelength light to reach the CdS/CdTe junction.
It is a further feature of this invention to utilize low cost techniques to apply a uniform and continuous CdS layer, and to substantially reduce the thickness of the applied layer to obtain a desired relatively thin CdS layer.
Yet another feature of the present invention is to regrow the CdS/CdTe photovoltaic layers at a temperature in excess of approximately 400° C., such that relatively large CdTe crystals are obtained while a significant portion of the CdS layer migrates or diffuses between or into the CdTe crystals to substantially reduce the effective thickness of the CdS layer.
Still another feature of this invention is to provide a CdS/CdTe photovoltaic cell with a tin oxide conductive layer comprising a relatively low conductivity tin oxide layer adjoining the CdS layer, and a high conductivity tin oxide layer adjoining the low conductivity layer.
It is still another feature of the invention that the carrier density of the high resistivity tin oxide layer is adjusted to be compatible with the CdTe layer to form an energy producing junction in areas where the CdS layer contains flaws.
It is a significant feature of the present invention that the material and equipment costs of applying the required layers of the photovoltaic cell are substantially reduced compared to prior art manufacturing techniques, resulting in high efficiency photovoltaic devices.
It is an advantage of the present invention that the techniques for effectively reducing the desired effective thickness of the CdS layer and for minimizing or avoiding shunts and/or dead areas between the CdTe layer and the conductive layer adjoining the CdS layer may be used for various photovoltaic cell arrangements.
It is a further advantage of the present invention that various techniques may be used for applying the layers of the photovoltaic cell according to the present invention, thereby rendering the present invention suitable to spray pyrolysis, dip coating, gas deposition, and similar processes for applying relatively thin polycrystalline layers.
These and further objects, features, and advantages of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view, partially in cross-section, of one embodiment of a photovoltaic panel formed according to the present invention which is not encapsulated.
FIG. 2 is a cross-sectional view of a panel depicting various layers applied over a glass substrate according to the present invention prior to regrowth of the active photovoltaic layers.
FIG. 3 is a cross-sectional view of the panel as shown in FIG. 2 subsequent to regrowth and prior to dividing and series interconnection.
FIG. 4 is a cross-sectional view of an alternate embodiment photovoltaic panel subsequent to regrowth and prior to dividing and series interconnection.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 generally depicts a photovoltaic panel 10 including a plurality of photovoltaic cells 12 according to the present invention. The panel consists of relatively thin chemical layers 18 formed on a common vitreous substrate 14. Glass is a preferred substrate due to its relatively low cost and its ideal flat surface for applying thin layers, and for subsequently heating those layers due to the low thermal expansion of the substrate. It should be understood that each of these applied layers, which are particularly shown in FIG. 3, are relatively thin to reduce material costs, and together will typically be less than 20 microns, so that the panel as shown in FIG. 1 visually appears to be little more than a rectangular sheet of glass with a thin painted coating. Also, it should be understood that the panel as shown in FIG. 1 may be complete in the sense that it is capable of producing electrical energy directly from sunlight. To maintain any form of reasonable efficiency, however, the panel needs to be encapsulated to prevent water vapor-related degradation of the cells.
FIG. 1 depicts a backwall cell configuration, i.e., sunlight passes first through the glass substrate and then to the junction formed by the active photovoltaic layers. The panel as shown in FIG. 1 is thus turned over during typical outdoor use, so that the glass substrate 14 is above the layers 18. Nevertheless, the panel is formed with the glass as the base or substrate, and accordingly, the terms "top" or "upper" when referring to the layers discussed subsequently should be understood with respect to the substrate being beneath these layers. The techniques of the present invention are also applicable to manufacturing front wall photovoltaic cells, wherein sunlight is absorbed by the junction formed by a cadmium telluride adsorber layer on top of the CdS window layer, so that light rays do not pass through the CdS layer.
The photovoltaic panel shown in FIG. 1 may be formed by successively applying thin, continuous layers of chemicals on a glass substrate. Individual cells are formed by making a series of elongate parallel cuts 20 through at least some of these layers to divide the panel into an elongate strips of cells according to the disclosure of U.S. Pat. No. 4,243,432. A layer or layers applied over the active photovoltaic layers also preferably provide the series interconnection of these cells to form the desired output voltage, and series interconnection strips 16 for accomplishing this purpose are generally depicted in FIG. 1. A suitable series interconnection configuration for electrically connecting cells is discussed subsequently. A suitable panel according to the present invention may thus be approximately 60 cm by 60 cm, and is capable of producing an output of approximately 50 watts with an incident isolation of approximately 1000 watts per square meter. For many commercial purposes, the desired electrical output is obtained by housing a plurality of panels in a module similar to the arrangement disclosed in U.S. Pat. No. 4,233,085.
FIG. 2 depicts in cross-section a panel prior to regrowth (crystallization) of the active photovoltaic layers. It should be understood that the thickness of each of the applied layers as shown in FIGS. 2 and 3 is approximately to scale with respect to the other depicted layers, but not with respect to the glass substrate 14. During the first step of constructing the photovoltaic panel, a bottom electrode may be formed on the substrate, with the electrode itself consisting of a bottom continuous electrode layer 24 having a high conductivity, and a top electrode layer 26 having a comparatively low conductivity. Each of these layers may be formed from a tin oxide solution utilizing spray pyrolysis techniques disclosed in the previously-cited prior art. The desired conductivity of these layers may be varied and, within reasonable limits, easily controlled by adjusting the amount of zinc or cadmium which is added to the tin oxide spray solution. Since the panel particularly described herein is of a backwall configuration, light must pass both through the glass substrate and the layers 24, 26 before reaching the junction formed by the active photovoltaic layers. High transmissivity of these tin oxide layers can nevertheless be maintained while changing the conductivity of these layers by a factor of approximately six orders of magnitude.
The bottom tin oxide layer 24 serves the primary purpose of passing electrical energy through the cell and interconnecting the cell in a series arrangement, and thus should have a high conductivity. Preferably the layer 24 has a conductivity of more than 1000 mho/cm, and most preferably more than 2200 mho/cm. Using prior art techniques, a highly conductive yet highly transmissive tin oxide layer has been generated having a specific conductivity of 3700 mho/cm, so that obtaining a tin oxide layer with a specific conductivity of approximately 2200 mho/cm is feasible on a commercial basis. For reasons explained subsequently, the top tin oxide layer 26 must have low conductivity, should be thin, and also must have a high degree continuity (few pinholes or flaws in layer 26 are permissible). High continuity of this layer may be obtained utilizing a low molarity tin oxide spray solution for the spray pyrolysis process. The specific conductivity of the upper tin oxide layer preferably is in the range from approximately 1.25×10 -3 to 100 mho/cm. The thickness of the lower tin oxide layer is not particularly critical, but is preferably in the range 0.4 to 1.0 microns. The thickness of the upper tin oxide layer may be from approximately 0.1 to approximately 1.0 microns and, as previously noted, is doped with a suitable metal such as cadmium or zinc to produce low carrier concentration.
Once the tin oxide layers have been formed, a relatively continuous layer 28 of CdS may be applied utilizing spray pyrolysis. The thickness of the deposited CdS layer may be in the range of from approximately 2,000 Å to 12,000 Å (0.2 to 1.2 microns), and this layer also has a high degree of continuity (few pinholes). A fairly thick CdTe layer 30 may then be applied on the CdS layer, with the thickness of layer 30 being substantially greater than that of the CdS layer 28. The CdTe layer may be economically formed using the atmospheric temperature spray and compression technique disclosed in U.S. Pat. No. 4,375,909. It should be understood that various techniques may be used for applying any of the layers 24, 26, 28 and 30, including spray pyrolysis, dip coating, or gas deposition. The preferred deposition technique has low cost deposition equipment and thus low manufacturing costs, and will result in continuous, thin, and thus relatively inexpensive layers.
As shown in FIG. 2, the layers 28, 30 as applied have relatively small crystals (not shown), which is undesirable for high photovoltaic efficiency. To increase the conversion efficiency, these layers are regrown at a temperature in excess of 400° C., and preferably from approximately 520° C. to approximately 550° C., to form substantially large crystals as shown in FIG. 3. Individual lower crystals 36A, 36B, 36C, and 36D in the regrown CdTe layer have dimensions approximating 2 microns, while the total thickness of the regrown layer 44 is typically approximately 6 microns. The smaller CdTe crystals are generally toward the upper portion of layer 44. Alternatively, the CdTe crystals could have a thickness approximating that of the layer itself, which is likely an achievable goal. Regrowth occurs at a temperature and during a time interval sufficient to cause substantial interdiffusion between the CdS and the CdTe layers and the CdS is also believed to migrate into the CdTe layer, and particularly in the interstices between the large diameter CdTe crystals. The term effective thickness, as used herein, is intended to mean its apparent thickness as defined by its transmissivity of short wavelength sunlight, i.e., wavelengths below 520 nm. As an example, using an absorptivity coefficient of CdS of 10 5 /cm, a CdS layer having an actual uniform thickness of 3,500 Å may pass less than approximately 3% of sunlight having a wavelength less than 520 nm, while a CdS layer having an actual thickness of approximately 200 Å may pass more than 92% of this low wavelength energy. The photovoltaic cell formed according to the techniques of the present invention has an efficiency with respect to such short wavelength energy which would be equivalent to a device having a very thin CdS layer, and accordingly it is convenient to discuss the effective thickness of the CdS layer. As exemplified in FIG. 3, it is believed that the actual thickness of portion 32 of the CdS layer between the bottom of a CdTe crystal and the top of the low conductivity tin oxide layer 26 is substantially minimized, and it is also believed that the CdS tends to diffuse away from the tin oxide layer and partially enters the cadmium telluride crystals, occupies a portion of the voids between CdTe crystals, and deposits on CdTe grain surfaces. This diffusion or migration of the CdS is generally in the lower portion of the CdTe layer, and some voids 48 generally will still exist between CdTe crystals, with diffused CdS "surrounding" these voids and adjoining the CdTe grain boundaries. The effective thickness of the CdS layer and the tin oxide layer is substantially reduced by the interdiffusion of CdTe and CdS and the "transfer" of CdS onto CdTe grains. FIG. 3 thus represents the presumed flow of CdS material during regrowth, with some of the CdS material migrating upward to deposit on CdTe crystal surfaces or form irregular upwardly extending walls 34 of CdS material between CdTe crystals, while some of the CdS material may form a relatively thin, generally planar layer 32 between the bottom of individual CdTe crystals and the top of the layer 26. During regrowth, some of the CdS material also may diffuse into the CdTe crystals and some CdTe may likewise diffuse into the CdS material. This diffusion and/or interdiffusion also may result in the desired substantial reduction in the effective thickness of the CdS layer.
The significant reduction of the effective thickness of the CdS layer during the regrowth of the active photovoltaic layers can be exemplified by noting that the CdS layer 28 in FIG. 2 prior to regrowth has an effective thickness of from 2,000 to 10,000 Å, while the effective thickness of the CdS layer 32 after regrowth as shown in FIG. 3 is preferably in the range of from approximately 100 to approximately 500 Å. Accordingly, the effective thickness of the CdS layer has been reduced during regrowth so that its thickness subsequent to regrowth is approximately 1/20th or less of its thickness prior to regrowth. This substantial reduction in effective thickness of the CdS layer is thus a primary reason for the substantial increase in photovoltaic efficiency, since the thin CdS layer is able to pass short wavelength light (less than 520 nm) to the junction, while the comparatively thick CdS layer absorbed and wasted that short wavelength energy as heat.
In the middle of the blue response region of photovoltaic devices, e.g., 450 nm, cells using relatively thick CdS layers (with absorptivities of 10 5 /cm) have less than 3% quantum efficiency at that wavelength. Cells according to the present invention, however, have a quantum efficiency at the same wavelength of from 60 up to 80% at that wavelength. While an extremely thin CdS layer is desired to pass this low wavelength energy, the average effective thickness of the CdS layer must be sufficient to minimize the number of pinholes or flaws in this layer, and must also be sufficient to form a reasonable junction with the CdTe crystals. According to the present invention, the effective thickness of the CdS layer may be uniformly reduced to less than 500 Å by diffusing a great deal of the material from this layer into the CdTe layer 44 during regrowth, and at least some of this material migrates to enter the gaps between the CdTe crystals.
If the CdS is deposited by spray pyrolysis, the quantum efficiency of the regrown cell decreases slightly with an increase in as-deposited CdS effective thickness greater than 2,000 Å. In one experimental program, an as-deposited CdS layer effective thickness from 5,000 to 6,000 Å nevertheless results in quantum efficiency in excess of 70% at 450 nm on a finished device. While the effective thickness of the CdS layer subsequent to regrowth may thus be reduced to approximately 1/20th of its as-applied thickness, a slightly greater or slightly less effective thickness reduction may occur. In any event, however, the effective thickness of the CdS layer will be significantly reduced during regrowth, and preferably will be reduced to an effective thickness less than approximately 10% of its as-applied thickness, and most preferably will be reduced to approximately 500 Å or less. The addition of cadmium chloride as a flux in the CdTe layer during regrowth may be important for large diameter crystal formation. It is also noted that generation of hot halogen-containing gases during regrowth is important for acceleration of the interdiffusion of the CdS and CdTe.
Due in large part to the substantially reduced effective thickness of the CdS layer, it is possible that some pinholes or other flaws in the applied CdS layer may occur. If a conventional conductor layer adjoins the CdS layer, a pinhole in the CdS layer will result in a short between the CdTe layer and the conductor layer, thereby destroying the energy producing effect of the cell. According to the present invention, such shorting is avoided by applying two dissimilar tin oxide layers, with the layer adjoining the CdS layer being the relatively low conductivity layer. Due to the special nature of this layer, a pinhole in the CdS layer will not result in shorting of the cell, but rather, it will actually produce power due to the heterojunction formed between the cadmium telluride and the low conductivity tin oxide. Since this low conductivity (high resistivity) tin oxide layer is thin, preferably less than about 8000 Å, and since current passes in a direction normal or perpendicular to the plane of this layer, the low conductivity of this layer adds little series resistance to the overall panel. Current flow in the high conductivity tin oxide layer moves in a direction generally parallel to the plane of this layer, and high conductivity for the bottom tin oxide layer is essential to achieve high efficiency.
It has been determined that, by properly doping the top tin oxide layer with zinc or other suitable metal, the electron carrier density of this level may be adjusted to be compatible with the presumed electron carrier density of the p-type layer, in this case the CdTe layer. Adjusting the electron carrier density of the upper tin oxide layer by adding a suitable metal also affects the resistivity of this layer, and to a much lesser amount affects transmissivity. Accordingly, a reasonable tradeoff must be made between the desire to achieve the desired carrier density for this layer, at the same time ensuring that this layer has high transmissivity and the desired resistivity. Nevertheless, it is possible to obtain high transmissivity for this layer, achieve the desired specific conductivity in the range of from 1.25×10 -3 to 100 mho/cm, and simultaneously obtain an electron carrier density for this layer which preferably is adjusted to be within the range of approximately two to three orders of magnitude of the known or presumed hole carrier density for the CdTe layer. By making the carrier density of the top tin oxide layer compatible with the p-type layer (within at least two or three orders of magnitude), any reasonable flaws in the CdS layer would not result in short-circuiting of the cell for reasons previously noted, but rather an energy-producing junction is formed by the CdTe layer and the top tin oxide layer. If the adjusted electron carrier density of the top tin oxide layer is too low relative to the carrier density of the CdTe layer, the junction formed with the tin oxide layer is undesirably shallow within the CdTe crystals, thereby resulting in low open-circuit voltage for that small contact area between the CdTe and the high resistivity tin oxide layer. On the other hand, if the electron carrier density of the tin oxide layer is undesirably high relative to that of the CdS layer, the junction formed in the CdTe crystals is too deep, thereby resulting in low short circuit current and an unsatisfactory junction. Nevertheless, a reasonably efficient junction may be obtained between the CdTe layer and a tin oxide layer doped with a suitable metal. While it is preferred to form a cell according to the present invention so that a very thin CdS layer capable of passing low wavelength sunlight is obtained, flaws in such a CdS layer will not destroy the cell for the reasons noted above, and accordingly extreme quality control procedures for applying and for regrowing crystals in this layer are not required. Also, it should be understood that it is possible to entirely eliminate the CdS layer and form a suitable photovoltaic cell, so that the bottom tin oxide layer acts as a conductor, the top tin oxide layer acts as the n-type layer (heterojunction partner), and cadmium telluride or other suitable material acts as the p-type layer.
As a further explanation of the latter embodiment described above, it is recognized that the cost of producing photovoltaic modules has been a major limitation to large-scale terrestrial use of photovoltaics as an energy source. The low-cost production of photovoltaics is primarily a function of reducing the cost of materials used, reducing the cost of deposition equipment for applying the active film layers, the simplicity of design of the active layers and the module itself, and a lack of sensitivity to process variations as a function of the materials and the design utilized. Each additional material present in the photovoltaic device adds to the complexity and therefore the cost of the device. A number of materials can conceivably be matched to a given absorber layer (typically the p-type layer) by adjusting the relative ratio of electron or hole carrier concentration contained in each of the p-type and n-type layers. The function of practically adjusting the carrier density of the junction partner layer (typically the n-type layer) often includes complexities which add significantly to the cost of the deposition.
According to this invention, the method of adjusting the carrier concentration of a tin oxide layer is disclosed. The carrier concentration is related to the specific resistivity which may be adjusted by over seven orders of magnitude by changing the amount and type of dopant added to the tin oxide solution, which may be sprayed on top of the heated substrate (glass). The reliability of manufacturing according to this technique is simplified since the base material for each of the various tin oxide layers need not be significantly changed and the deposition technique need not change. The carrier concentration of the tin oxide layer may thus be matched to any of various p-type absorber layers, thus eliminating the requirement of a separate CdS layer, and thus reducing the cost of the photovoltaic modules.
FIG. 4 illustrates in cross-section a photovoltaic cell according to this latter invention. The glass substrate and conductive layers 24 and 26 are as previously described. Preferably substantially the same conductive material composition is used to form both layers 24 and 26, with the selected material forming a transparent, conducting layer with suitable characteristics, and preferably being from a group consisting of tin oxide, zinc oxide, indium tin oxide, and cadmium stannate. More particularly, this selected material for the layer 24 should be highly conductive, while at the same time this material can be doped to form a layer 26 which acts as a heterojunction partner and a window layer for the photovoltaic cell. For purposes of explanation, this discussion assumes that the material for the p-type layer will be cadmium telluride, although various compounds may be used to form the p-type layer, and exemplary alternatives are discussed below. Also, for purposes of explanation, the layer 26 may be doped with cadmium or zinc to reduce the conductivity of this layer and result in the desired n-type material, although lead, mercury, selenium, sulfur, sodium, cesium, mercury, boron, and chromium may be alternative doping materials.
The photovoltaic panel as shown in FIG. 4 thus comprises a substantially continuous conductive layer 24 of tin oxide for electrically interconnecting the plurality of cells, and a polycrystalline tin oxide layer 26 being applied on layer 24 and doped with a selected amount of a desired dopant. A polycrystalline p-type layer 46 is then formed on the layer 26 with the cadmium telluride crystals of layer 46 being of the form and size previously described. The top electrode layer 38 as shown in FIG. 3 is applied over the cadmium telluride layer, and may migrate down into the porous CdTe layer 46 with no significant adverse affect. A spacing between the lowermost migrated material of layer 38 and the uppermost migrated n-type material is preferred, as shown in FIG. 3, with this spacing being occupied by CdTe crystals and voids between the crystals. For the embodiment as shown in FIG. 4, the migrating material of layer 38 does not contact the tin oxide layer 26, and again voids occur between the CdTe crystals and between this migrating material and the tin oxide layer 26. Sunlight thus passes through the substrate 14 and the layer 24 to reach the junction formed by the n-type layer 26 and the p-type layer 46. Preferably both the layers 24 and 26 are deposited by the same process to reduce manufacturing costs and improve quality control, and spray pyrolysis is one suitable process for depositing both the conductive tin oxide layer 24 and the doped tin oxide layer 26.
According to the method of this invention, a photovoltaic panel including a plurality of photovoltaic cells may be formed on a common substrate by selecting a material for the conductive polycrystalline film layer 24, then depositing this selected material by spray pyrolysis or another technique on to the substrate to form a substantially continuous optically transmissive conductive layer for electrically interconnecting the plurality of photovoltaic cells. The p-type material for forming the photovoltaic heterojunction is selected, and the presumed carrier density or approximate carrier density of the p-type layer is known. Substantially the same material used to form the layer 24 may then be selectively doped to form the n-type layer, with the amount of dopant being a function of the presumed carrier density of the p-type photovoltaic layer. The high conductivity layer 24 may consist of tin oxide and a small amount of fluorine, which may be added to the tin oxide material for layer 24 to enhance conductivity. Although a different dopant is added to the tin oxide material for layer 26, the material for forming both layers 24 and 26 prior to adding the dopant is substantially the same, e.g., tin oxide. This doped material may then be deposited by spray pyrolysis on the conductive thin film layer 24 to form an n-type polycrystalline thin film layer for the photovoltaic cells, and finally the selected p-type material may be deposited on the n-type material to form a p-type photovoltaic layer and the junction with the n-type layer. Once a panel as shown in FIG. 4 is formed by this technique, the large photovoltaic cell may be divided to form a plurality of photovoltaic cells in the manner described in the prior art, and the divided photovoltaic cells then interconnected to form a photovoltaic panel.
Tin oxide is a preferred material for achieving the above purposes due to its high transparency and dopability to achieve a wide range of resistivity. Other materials may, however, be used. Zinc oxide is one alternative and, although its extinction coefficient is smaller than that for tin oxide, its specific resistivity is considerably higher. The large electron density of tin oxide, generally greater than about 10 20 /cm 3 , prevents its use as a junction material with every potential semi-conductor partner layer. Cadmium telluride may form the p-type layer for such a photovoltaic cell, since its carrier density can be approximately 10 16 /cm 3 . The cell formed from these layers can thus be expected to have a low open-circuit voltage and/or unsatisfactory short-circuit current. By doping the tin oxide layer, however, a junction may be produced with the cadmium telluride layer which results in a reasonable voltage, current, and fill factor. The uniform continuity of the low carrier concentration density tin oxide layer is necessary to avoid shorts, while at the same time this tin oxide layer must remain thin, and preferably less than about 8,000 Å, to prevent unnecessary optical absorption. These objectives can be achieved by applying this layer with spray pyrolysis utilizing a large number of low molarity droplets to consistently and completely cover the low resistance tin oxide layer and thereby prevent low resistance shunt paths.
It should also be understood that the p-material layer may be formed from materials other than CdTe. According to the above technique, an inexpensive copper indium diselenide cell may be formed with the n-type material being a doped tin oxide layer formed by spray pyrolysis. A similar cell may be formed utilizing copper sulfide, copper indium disulfide or copper indium diselenide as the p-type material. Other cells which may be formed according to this invention include cells having a p-type semi-conductor layer of either polycrystalline silicon, aluminum antiminide, gallium arsenide, or indium phosphide.
According to the method of the present invention, the effective thickness of the n-type material layer is reduced so that at least a substantial amount of sunlight, i.e., at least 25%, and preferably at least 50%, having a wavelength with an energy higher than the bandgap of the n-type material for this layer (short wavelength light) passes through this reduced effective thickness n-type layer to be absorbed by the photovoltaic heterojunction. Since the n-type layer must be physically thin, flaws or holes in this otherwise continuous layer can be expected. According to a preferred embodiment of this invention, the p-type layer forms a desired photovoltaic junction with this thin n-type layer, and also forms a photovoltaic junction with the conductive layer 26 where flaws occur in the n-type layer. This latter junction has a reasonably high efficiency due to the doping at this layer 26, so that its electron carrier density is within at least three orders of magnitude of the known or presumed carrier density of the p-type material. In order to prevent shorts in the cell, the specific conductivity of this layer 26 is also maintained within the range previously described.
Once a panel has been regrown in a manner which results in layers 24, 26, 32, and 36 as shown in FIG. 3, or 24, 26, and 46 as shown in FIG. 4, the panel may be divided and series interconnected according to prior art techniques. Using either a mechanical cutter or a laser, a thin strip of applied layers may be removed down to the glass substrate, and a portion of the thin elongate gap formed by this operation filled with a suitable insulating film to cut the electrical connection between the bottom electrode layers 24 of adjacent cells. A desired electrode strip may be formed on an edge portion of the bottom tin oxide layer. Either prior or subsequent to this operation, a top electrode layer 38 as shown in FIG. 3 may be deposited over the CdTe layer, with some of this layer 38 optionally filling the upper portion of gaps between the CdTe crystals. Accordingly, the top electrode layer 38 may include downwardly projecting walls 40 which preferably do not come into contact with the upwardly projecting walls 34 of the CdS layer. Various materials may be used for the layer 38, and it is presently preferred that the layer be formed by a graphite paste process, thereby achieving relatively low material and deposition cost. The series interconnection of the cells may then be formed by depositing a conductive electrode layer on top of layer 38, with the conductive electrode layer filling part of the gap formed by the cell division technique and forming a reliable electrical connection between the top electrode of one cell and the bottom electrode of an adjacent cell. The completed cell may then be encapsulated according to techniques described in patents previously noted. Any of the layers 24, 26 or 44, 46 may thus include a narrow elongate cut to divide the panel into individual cells and to series interconnect the cells. Each of these layers is nevertheless deposited as and remains a substantially continuous layer, thereby resulting in comparatively low manufacturing costs.
While tin oxide is a preferred material for each of the high conductivity and low conductivity layers of a cell according to the present invention due to its high transmissivity and ability to easily adjust its carrier concentration, other materials may be used to form this bottom electrode. A zinc oxide layer may form this conductor layer, and is particularly well suited for forming the low conductivity layer. The material used to dope the conductor and adjust its carrier density and resistivity should not substantially affect the high transmissivity of this layer, and zinc, indium, gallium, and aluminum are a suitable doping metal for this purpose. Other dopants may also be used. While the tin oxide layers may be formed according to spray pyrolysis techniques, the invention is not limited to using spray pyrolysis to form the conductor layers. Also, it should be understood that while the bottom conductor layer as described herein consists of the bottom high conductivity tin oxide layer and a substantially increased resistivity top tin oxide layer, the conductivity of the conductor layer may change gradually from the bottom to the top of the conductor layer, so that two distinct layers are not formed but rather a gradual change in conductivity of the tin oxide layer occurs as one moves up through the thickness of the layer. The prospect of gradually changing the conductivity of this layer is not difficult to obtain when panels are formed on a mass production basis, since the glass substrate may be moved over a series of spray nozzles each having an increasing or decreasing amount of added metal as a dopant.
As previously noted, high continuity of the tin oxide layer adjoining the CdS layer is essential, and this high continuity can be obtained by reducing the molarity of the tin oxide solution which form this upper layer, and increasing the deposition time and thus the number of droplets reaching the substrate. While no precise molarity for forming this uppermost tin oxide layer is critical, the molarity of the solution forming the uppermost tin oxide layer typically will be less than 0.5 moles/liter, and frequently in the range of about 0.2 moles/liter or less. While the techniques of the present invention are particularly well-suited for forming a high efficiency CdS/CdTe photovoltaic cell, it should be understood that the concepts of the present invention are not limited to use of these chemical layers for either the p-type or the n-type material. In particular, it should be understood that substantially increased efficiency of a photovoltaic device is formed according to the present invention by obtaining an n-type material layer which has a substantially reduced effective thickness compared to its as-deposited thickness, and that this n-type layer is obtained by simultaneously heating the p-type material and the n-type material layer to substantially increase the size of the crystals in each of these layers while simultaneously diffusing and interdiffusing the n-type and the p-type layers.
A complete understanding of the mechanical and chemical functions occurring during the substantial reduction in the effective thickness of the CdS layer (or other n-type layer highly transmissive of sunlight) is not yet fully understood. This reduction in effective thickness is primarily believed to be due to diffusion, interdiffusion, and/or migration of CdS material into the CdTe (or other p-type material) layer, with CdS material entering the voids between the regrown CdTe crystals and depositing on the available CdTe surfaces. The term "diffusion" as used herein with respect to the action occurring during the reduction in the effective thickness of the n-type layer should be understood to encompass conventional diffusion, as well as interdiffusion and migration into the p-type layer. Also, those skilled in the art will appreciate that while diffusion of the n-type layer into the p-type layer will reduce the effective thickness of the n-type layer, as explained above, this action can also be similarly described as diffusion of the p-type layer into the n-type layer. The key is the desired effective reduction in the thickness of the n-type layer which occurs during heating, not the specific mechanical and/or chemical function which causes this reduction. Another benefit of this CdS "diffusion" action is that the n-type material tends to cover a substantially higher portion of the CdTe grain surfaces than would occur during a planar interface of two layers. Also, it should be understood that the benefit of passing short wavelength light to the junction will occur regardless of the selected n-type material, and that the earlier reference to passing light less than 52 nm is based on the bandgap of CdS, which is approximately 520 nm. The bandgap of various materials suitable for forming the n-type layer is well known, and energy bandgaps for various materials can be easily calculated from minimum room temperature energy gap values published in available handbooks, such as CRC HANDBOOK OF CHEMISTRY & PHYSICS, 58th Edition. The present invention thus envisions the significant reduction in the effective thickness of the n-type material layer by "diffusion" into the p-type layer, such that a majority of sunlight energy having a wavelength with an energy higher than the bandgap of the selected n-type material passes through the reduced thickness n-type layer to react with the photovoltaic junction.
While the invention has thus been described in terms of specific embodiments which are set forth in detail, it should be understood that this discussion and the drawings which form a part of this disclosure should not be understood as limiting this invention. Various alternative embodiments and operating techniques will become apparent to those skilled in the art in view of this disclosure. The invention should thus be understood to include various embodiments not described herein, and the invention is limited only by reasonable construction of the claims attached hereto in view of this disclosure. | 4y
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FIELD
[0001] This invention relates to a method of curing a curable composition using a source of electroluminescent light.
BACKGROUND
[0002] A desirable property for an adhesive composition may be described as “cure-on-demand”. Adhesives that can be cured-on-demand characteristically have an extended (or indefinite) open time and can be rapidly cured at a desired time by the user.
[0003] Adhesive bonding two or more objects together has two objectives: a long open time (time before the adhesive cures) for applying the adhesive so that substrates are brought into reasonable alignment; and rapid curing of the adhesive once alignment has been completed. These interests are neatly summed up in the phrase “Cure on Demand” (COD), so often heard in the adhesive industry.
[0004] Cure on demand has been addressed in a variety of ways depending on the method used to effect curing. These methods include exposure to air or moisture, exposure to vaporous chemicals such as volatile amines, or exposure of the adhesive to heat or radiation or combinations thereof.
[0005] One type of cure-on-demand adhesive is ultraviolet (UV) light curable adhesives. These adhesives typically comprise a curable monomeric or oligomeric material (e.g., an acrylate or methacrylate) along with a UV sensitive initiator. Exposure of the uncured composition to UV light initiates cure of the adhesive on demand. Although UV curable adhesive are desirable, the adhesive to be cured must be positioned so that it can be conveniently exposed to the source of UV light in a direct “line of sight” relationship. Therefore, cure between opaque substrates cannot easily be achieved.
SUMMARY OF THE INVENTION
[0006] The invention provides a method of curing a curable composition using an electroluminescent light source. The method comprises the steps of: (a) providing a curable composition; (b) providing an electroluminescent light source having a light emitting region; and (c) curing the curable composition by exposing the curable composition to light emitted from the light emitting region of the electroluminescent light source.
[0007] The inventive method takes advantage of curable composition formulations that cure in the presence of visible light and do not require UV light to cure. It enables one to bond objects in circumstances in which conventional light sources cannot illuminate the photocurable material because the adhesive can not conveniently be exposed to light, e.g., because the object to be bonded is opaque. It also enables curing extended and/or hidden bond lines in locations not accessible to typical curing lamps.
[0008] Long electroluminescent lamps used in the inventive method can emit a uniform intensity of light along the complete length of a bond line, including bond lines that follow a tortuous path. Examples of such applications include, but are not limited to glass bonding on windshields, panel bonding on automobile bodies and boats or hull bonding in boat construction.
BRIEF DESCRIPTION OF THE DRAWING
[0009] FIG. 1 is a cross sectional view of one example of the invention, showing the curable composition and electroluminescent positioned between two substrates as they would be for the operation of the inventive method.
DETAILED DESCRIPTION
[0010] According to the present invention, substrates are bonded together using a photocurable resin in the presence of an electroluminescent light, for example in the form of a light fiber. An exemplary process is illustrated in FIG. 1 wherein photocurable resin composition 12 is applied to the first major surface 14 of substrate 16 . An electroluminescent light fiber 18 is embedded into the photocurable resin composition 12 . A second major surface 20 of a second substrate 22 is brought into contact with the photocurable resin composition 12 . Voltage is applied to electroluminscent light fiber 18 by means of a power supply not shown, resulting in light emission at a suitable wavelength and of sufficient lux to cure resin composition 12 , thereby bonding substrates 16 and 22 .
[0011] For purposes of this description, the term “electroluminescent light” means an article that generates light from electrical energy applied to a light emitting material embedded, encased or contained within a polymeric or glass material. The term electroluminscent light does not include lighting devices that include a vacuum container such as conventional lighting tubes or bulbs. Electroluminescent (EL) light sources are known in the art and include point light sources such a light-emitting diodes (LED) and electroluminescent light-emitting screens which are used as back lighting for control panel displays. EL light sources also include organic light emitting devices powered by direct current such as described in U.S. Pat. No. 6,611,096.
[0012] A known construction of an electroluminescent light includes a transparent flexible substrate material having a transparent electrically conductive layer on it, which serves as a first electrode. A layer comprising a mass or multiplicity of special phosphors, referred to as electroluminophors (which emit light when excited by a capacitively coupled AC electric field) dispersed in a dielectric binder, is applied to the conductive layer. Another conductive layer is applied to the phosphor layer, forming a second electrode. Further detail on the functioning of EL lamps based on inorganic phosphors is in U.S. Pat. No. 5,349,269 (Kimball). Such inorganic phosphor EL lamps are essentially capacitors that glow in the presence of a strong electric field and a very low current because of the phosphor powder (electroluminophors). Alternating current can be supplied to an EL lamp by means of inverters, also described in U.S. Pat. No. 5,349,269.
[0013] A particularly suitable electroluminescent light source is described in U.S. Pat. No. 5,485,355 (Voskoboinik et al.). This source is a flexible, EL light source in the form of a cable. The cable EL light source comprises at least two electrodes mutually disposed in such a way as to create between them an electric field when an AC voltage is applied to them. At least one type of a powdered electroluminophor dispersed in a dielectric binder is disposed in such a proximity to electrodes as to be effectively excited by the electric field created and emit light of a specific color. The electrodes and electroluminophor can be encased in a transparent polymer sheath. EL sources of the type described above are available, for example, from ELAM Industries Inc. of Jerusalem Israel. Such an EL cable or wire can conform to an irregularly shaped article having a coating of a curable composition, in order to cure the composition, such as an adhesive or polymer (e.g., a glazing compound). Optionally, a second transparent polymeric sheath may encase EL fiber so that the fiber can slide out of the sheath, thereby facilitating removal of the EL fiber after the curing step.
[0014] “Actinic radiation” means photochemically active radiation and particle beams, including, but not limited to, accelerated particles, for example, electron beams; and electromagnetic radiation, for example, microwaves, infrared radiation, visible light, ultraviolet light, X-rays, and gamma-rays. “UV” or “ultraviolet” means actinic radiation having a spectral output between about 200 and about 400 nanometers (nm.). Wavelengths above 300 nm are considered actinic radiation for purposes of this application. More preferably, actinic radiation useful in the present invention includes wavelengths within the range 300 to 1200 run. Visible light (such as that emitted by an EL lamp) is generally in the range of 400-700 nm wavelength.
[0015] “Cure” means to initiate a chemical reaction in which molecules chemically combine to form linear and/or branched polymer or in which polymers are cross-linked. Curable compositions as defined in this invention are those that undergo conversion from a less viscous to an insoluble composition. In particular they include photocurable adhesive compositions that harden when their functional groups absorb light in the ultraviolet to the visible region. These groups could be in the form of monomers, oligomers, prepolymers or additives which yield electronically excited states that induce crosslinking directly or by energy transfer via formation of reactive intermediates such as free radicals, reactive cations or other means which subsequently initiate crosslinking of macromolecular chains.
[0016] The curable compositions useful in the present invention may be in the form of a liquid, gel, or solid and may be free-radically polymerizable and/or cationically-polymerizable. Such compositions comprise a photopolymerizable moiety and a visible- and/or near infrared-light photoinitiator therefor.
[0000] Free Radically Curable Compositions:
[0017] Free-radically polymerizable curable compositions comprise at least one free radically-polymerizable or cross-linkable molecule and a photoinitiation system that can be initiated by light having a wavelength in the range of about 300 nm to about 1200 nm.
[0018] Suitable free radically-polymerizable molecules contain at least one ethylenically-unsaturated double bond and may be monomeric or oligomeric. Such molecules include mono-, di- or poly-acrylates and methacrylates such as methyl acrylate, methyl methacrylate, ethyl acrylate, isopropyl methacrylate, n-hexyl acrylate, stearyl acrylate, allyl acrylate, glycerol diacrylate, glycerol triacrylate, ethyleneglycol diacrylate, diethyleneglycol diacrylate, triethyleneglycol dimethacrylate, 1,3-propanediol diacrylate, 1,3-propanediol dimethacrylate, trimethylolpropane triacrylate, 1,2,4-butanetriol trimethacrylate, 1,4-cyclohexanediol diacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, pentaerythritol tetramethacrylate, sorbitol hexacrylate, bis[1-(2-acryloxy)]-p-ethoxyphenyldimethylmethane, bis[1-(3-acryloxy-2-hydroxy)]-p-propoxyphenyldimethyl-methane, tris(hydroxyethylisocyanurate) trimethacrylate; the bis-acrylates and bis-methacrylates of polyethylene glycols of molecular weight 200-500, copolymerizable mixtures of acrylated monomers such as those of U.S. Pat. No. 4,652,274 (Boettcher et al.), incorporated herein by reference, and acrylated oligomers such as those of U.S. Pat. No. 4,642,126 (Zador et al.), incorporated herein by reference; unsaturated amides such as methylene bis-acrylamide, methylene bis-methacrylamide, 1,6-hexamethylene bis-acrylamide, diethylene triamine tris-acrylamide and beta-methacrylaminoethyl methacrylate; and vinyl compounds such as styrene, diallyl phthalate, divinyl succinate, divinyl adipate and divinylphthalate. Mixtures of two or more monomers can be used if desired.
[0019] A variety of visible or near-infra red photoinitiator systems may be used in the curable composition. For example, the monomer can be combined with a three-component (i.e., ternary) photoinitiator system. The first component in the photoinitiator system is the iodonium salt (i.e., a diaryliodonium salt). The iodonium salt is preferably soluble in the curable composition and is shelf-stable (i.e., does not spontaneously promote polymerization) when dissolved therein in the presence of the sensitizer and donor. Accordingly, selection of a particular iodonium salt may depend to some extent upon the particular curable material, sensitizer and donor. Examples of iodonium salts are described in U.S. Pat. Nos. 3,729,313 (Smith), 3,741,769 (Smith), 3,808,006 (Smith), 4,250,053 (Smith) and 4,394,403 (Smith), which are incorporated herein by reference. The iodonium salt may be a simple salt (e.g., containing an anion such as Cl − , Br − , I − or C 4 H 5 SO 3 − ) or a metal complex salt (e.g., containing SbF 5 OH − or AsF 6 − ). Mixtures of iodonium salts may also be used. Preferred iodonium salts include diphenyliodonium salts such as diphenyliodonium chloride, diphenyliodonium hexafluorophosphate and diphenyliodonium tetrafluoroborate.
[0020] The photoinitiator system also includes a sensitizer. Sensitizing compounds are for cationically-curable materials are known in the art. The sensitizer desirably is soluble in the monomer, and is capable of light absorption somewhere within the range of wavelengths of greater than 300 to 1200 nanometers, more preferably greater than 400 to 700 nanometers and most preferably greater than 400 to about 600 nanometers. The sensitizer may also be capable of sensitizing 2-methyl-4,6-bis(trichloromethyl)-s-triazine, using the test procedure described in U.S. Pat. No. 3,729,313. Preferably, in addition to passing this test, a sensitizer is also selected based in part upon shelf stability considerations. Accordingly, selection of a particular sensitizer may depend to some extent upon the particular monomer, oligomer or polymer, iodonium salt and donor chosen.
[0021] The initiator system also includes a donor. Examples of donors include amines (including aminoaldehydes and aminosilanes), amides (including phosphoramides), ethers (including thioethers), ureas (including thioureas), ferrocene, sulfinic acids and their salts, salts of ferrocyanide, ascorbic acid and its salts, dithiocarbamic acid and its salts, salts of xanthates, salts of ethylene diamine tetraacetic acid and salts of tetraphenylboronic acid. The donor may be unsubstituted or substituted with one or more non-interfering substituents. Particularly preferred donors contain an electron donor atom such as a nitrogen, oxygen, phosphorus, or sulfur atom, and an abstractable hydrogen atom bonded to a carbon or silicon atom in an alpha position relative to the electron donor atom. Examples of donors are reported in U.S. Pat. No. 5,545,676 (Palazzotto at el.), which is incorporated herein by reference.
[0022] Free-radical initiators useful in the invention also may include the class of acylphosphine oxides, as described in European Patent Application No. 173567 (Ying).
[0023] Free-radical initiators useful in the invention also may include the class of ionic dye-counterion complex initiators comprising a borate anion and a complementary cationic dye.
[0024] Cationic counterions can be cationic dyes, quaternary ammonium groups, transition metal coordination complexes, and the like. Cationic dyes useful as counterions can be cationic methine, polymethine, triarylmethine, indoline, thiazine, xanthene, oxazine or acridine dyes. More specifically, the dyes may be cationic cyanine, carbocyanine, hemicyanine, rhodamine, and azomethine dyes. Specific examples of useful cationic dyes include Methylene Blue, Safranine O, and Malachite Green. Quaternary ammonium groups useful as counterions can be trimethylcetylammonium, cetylpyridinium, and tetramethylammonium. Other organophilic cations can include pyridinium, phosphonium, and sulfonium. Photosensitive transition metal coordination complexes that may be used include complexes of cobalt, ruthenium, osmium, zinc, iron, and iridium with ligands such as pyridine, 2,2′-bipyridine, 4,4′-dimethyl-2,2′-bipyridine, 1,10-phenanthroline, 3,4,7,8-tetramethylphenanthroline, 2,4,6-tri(2-pyridyl-s-triazine) and related ligands.
[0025] Borate salt photoinitiators are described, for example, in U.S. Pat. Nos. 4,772,530 (Gottschalk et al.), 4,954,414 (Adair et al.), 4,874,450 (Shanklin et al.), 5,055,372 (Shanklin et al.), and 5,057,393 (Shanklin et al.), the disclosures of which are incorporated herein by reference.
[0026] In another embodiment, a photopolymerization reaction useful in the invention includes the visible radiation-activated addition reaction of a compound containing silicon-bonded hydrogen with a compound containing aliphatic unsaturation. The addition reaction typically can be referred to as hydrosilation. Hydrosilation by means of visible light has been described, e.g., in U.S. Pat. Nos. 4,916,169 (Boardman et al.) and 5,145,886 (Oxman et al.), both of which are incorporated herein by reference.
[0027] Examples of organic materials polymerizable by cationic polymerization and suitable for the hardenable compositions according to the invention are of the following types, which may be used by themselves or as mixtures of at least two components:
A. Ethylenically unsaturated compounds polymerizable by a cationic mechanism. These include:
1. Monoolefins and diolefins, for example isobutylene, butadiene, isoprene, styrene, α-methylstyrene, divinylbenzenes, N-vinylpyrrolidone, N-vinylcarbazole and acrolein. 2. Vinyl ethers, for example methyl vinyl ether, isobutyl vinyl ether, trimethylolpropane trivinyl ether and ethylene glycol divinyl ether; and cyclic vinyl ethers, for example 3,4-dihydro-2-formyl-2H-pyran (acrolein dimer) and the 3,4-dihydro-2H-pyran-2-carboxylic acid ester of 2-hydroxymethyl-3,4-dihydro-2H-pyran. 3. Vinyl esters, for example vinyl acetate and vinyl stearate.
B. Heterocyclic compounds polymerizable by cationic polymerization, for example ethylene oxide, propylene oxide, epichlorohydrin, glycidyl ethers of monohydric alcohols or phenols, for example n-butyl glycidyl ether, n-octyl glycidyl ether, phenyl glycidyl ether and cresyl glycidyl ether; glycidyl acrylate, glycidyl methacrylate, styrene oxide and cyclohexene oxide; oxetanes such as 3,3-dimethyloxetane and 3,3-di(chloromethyl)oxetane; tetrahydrofuran; dioxolanes, trioxane and 1,3,6-trioxacyclooctane; spiroorthocarbonates; lactones such as β-propiolactone, γ-valerolactone and ε-caprolactone; thiiranes such as ethylene sulfide and propylene sulfide; azetidines such as N-acylazetidines, for example N-benzoylazetidine, as well as the adducts of azetidine with diisocyanates, for example toluene-2,4-diisocyanate and toluene-2,6-diisocyanate and 4,4′-diaminodiphenylmethane diisocyanate; epoxy resins; and linear and branched polymers with glycidyl groups in the side-chains, for example homopolymers and copolymers of polyacrylate and polymethacrylate glycidyl esters.
[0033] Of particular importance among these above-mentioned polymerizable compounds are the epoxy resins and especially the diepoxides and polyepoxides and epoxy resin prepolymers of the type used to prepare crosslinked epoxy resins.
[0034] Epoxy compounds that can be cured or polymerized by the processes of this invention are those known to undergo cationic polymerization and include 1,2-, 1,3-, and 1,4-cyclic ethers (also designated as 1,2-, 1,3-, and 1,4-epoxides). The “Encyclopedia of Polymer Science and Technology”, 6, (1986), p. 322, provides a description of suitable epoxy resins. In particular, cyclic ethers that are useful include the cycloaliphatic epoxies such as cyclohexene oxide and the series of resins commercially available under the trade designation “ERL” from Dow Chemical Co., Midland, Mich., such as vinylcyclohexene oxide, vinylcyclohexene dioxide (trade designation “ERL 4206”), 3,4-epoxy-6-methylcyclohexylmethyl-3,4-epoxy-6-methyl-cyclohexene carboxylate (trade designation “ERL 4201”), bis(2,3-epoxycyclopentyl) ether (trade designation “ERL 0400”), 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexane carboxylate (trade designation “ERL 4221 ”), bis-(3,4-epoxycyclohexyl) adipate (trade designation “ERL 4289”), aliphatic epoxy modified from polypropylene glycol (trade designations “ERL 4050” and “ERL 4052”), dipentene dioxide (trade designation “ERL 4269”), and 2-(3,4-epoxycylclo-hexyl-5,5-spiro-3,4-epoxy) cyclohexene-meta-dioxane (trade designation “ERL 4234”); also included are the glycidyl ether type epoxy resins such as propylene oxide, epichlorohydrin, styrene oxide, glycidol, the series of epoxy resins commercially available under the trade designation “EPON” from Shell Chemical Co., Houston, Tex., including the diglycidyl either of bisphenol A and chain extended versions of this material such as those having the trade designation “EPON 828”, “EPON 1001”, “EPON 1004”, “EPON 1007”, “EPON 1009” and “EPON 2002” or their equivalent from other manufacturers; dicyclopentadiene dioxide; epoxidized vegetable oils such as epoxidized linseed and soybean oils commercially available under the trade designations “VIKOLOX” and “VIKOFLEX” from Elf Atochem North America, Inc., Philadelphia, Pa.; epoxidized liquid polymers having the trade designation “KRATON”, such as “L-207” commercially available from Shell Chemical Co.; epoxidized polybutadienes such as those having the trade designation “POLY BD” from Elf Atochem; 1,4-butanediol diglycidyl ether, polyglycidyl ether of phenolformaldehyde; epoxidized phenolic novolac resins such as those commercially available under the trade designations “DEN 431” and “DEN 438” from Dow Chemical Co.; epoxidized cresol novolac resins such as the one commercially available under the trade designation “ARALDITE ECN 1299” from Vantico, Inc. Brewster, N.Y.; resorcinol diglycidyl ether; epoxidized polystyrene/polybutadiene blends such as those commercially available under the trade designation “EPOFRIEND” such as “EPOFRIEND A1010” from Daicel USA Inc., Fort Lee, N.J.; the series of alkyl glycidyl ethers commercially available under the trade designation “HELOXY” from Shell Chemical Co., Houston, Tex., such as alkyl C 8 -C 10 glycidyl ether (trade designation “HELOXY MODIFIER 7”), alkyl C 12 -C 14 glycidyl ether (trade designation “HELOXY MODIFIER 8”), butyl glycidyl ether (trade designation “HELOXY MODIFIER 61”), cresyl glycidyl ether (trade designation “HELOXY MODIFIER 62”), p-tert-butylphenyl glycidyl ether (trade designation HELOXY MODIFIER 65”), polyfunctional glycidyl ethers such as diglycidyl ether of 1,4-butanediol (trade designation HELOXY MODIFIER 67”), diglycidyl ether of neopentyl glycol (trade designation “HELOXY MODIFIER 68”), diglycidyl ether of cyclohexanedimethanol (trade designation “HELOXY MODIFIER 107”), trimethylol ethane triglycidyl ether (trade designation “HELOXY MODIFIER 44”), trimethylol propane triglycidyl ether (trade designation “HELOXY MODIFIER 48”), polyglycidyl ether of an aliphatic polyol (trade designation “HELOXY MODIFIER 84”), polyglycol diepoxide (trade designation “HELOXY MODIFIER 32”); and bisphenol F epoxides.
[0035] The preferred epoxy resins include the “ERL” type of resins especially 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, bis-(3,4-epoxycyclohexyl) adipate and 2-(3,4-epoxycylclohexyl-5,5-spiro-3,4-epoxy) cyclohexene-meta-dioxane and the bisphenol A “EPON” type resins including 2,2-bis-(p-(2,3-epoxypropoxy)phenylpropane) and chain extended versions of this material. It is also within the scope of this invention to use a blend of more than one epoxy resin.
[0036] It is also within the scope of this invention to use one or more epoxy resins blended together. The different kinds of resins can be present in any proportion.
[0037] Optionally, monohydroxy- and polyhydroxy-alcohols may be added to the curable compositions of the invention, as chain-extenders for the epoxy resin. The hydroxyl-containing material used in the present invention can be any organic material having hydroxyl functionality of at least 1, and preferably at least 2.
[0038] Preferably the hydroxyl-containing material contains two or more primary or secondary aliphatic hydroxyl groups (i.e., the hydroxyl group is bonded directly to a non-aromatic carbon atom). The hydroxyl groups can be terminally situated, or they can be pendent from a polymer or copolymer. The molecular weight of the hydroxyl-containing organic material can vary from very low (e.g., 32) to very high (e.g., one million or more). Suitable hydroxyl-containing materials can have low molecular weights, i.e., from about 32 to 200, intermediate molecular weight, i.e., from about 200 to 10,000, or high molecular weight, i.e., above about 10,000. As used herein, all molecular weights are weight average molecular weights.
[0039] The hydroxyl-containing material can optionally contain other functionalities that do not substantially interfere with cationic cure at room temperature. Thus, the hydroxyl-containing materials can be nonaromatic in nature or can contain aromatic functionality. The hydroxyl-containing material can optionally contain heteroatoms in the backbone of the molecule, such as nitrogen, oxygen, sulfur, and the like, provided that the ultimate hydroxyl-containing material does not substantially interfere with cationic cure at room temperature. The hydroxyl-containing material can, for example, be selected from naturally occurring or synthetically prepared cellulosic materials. The hydroxyl-containing material is also substantially free of groups which may be thermally or photolytically unstable; that is, the material will not decompose or liberate volatile components at temperatures below about 100° C. or in the presence of actinic light which may be encountered during the desired curing conditions for the photocopolymerizable composition.
[0040] Useful hydroxyl-containing materials are described, for example, in U.S. Pat. No. 5,856,373 (Kaisaki et al.), which is incorporated herein by reference.
[0041] Any cationically-reactive vinyl ether may be used in the polymerizable compositions of the present invention. Examples of vinyl ethers that may be used include tri(ethyleneglycol) divinyl ether, commercially available under the trade designation “RAPI-CURE DVE-3”, from International Specialty Products, Wayne, N.J., di(ethyleneglycol) divinyl ether, di(ethyleneglycol) monovinyl ether, ethylene glycol monovinyl ether, triethyleneglycol methyl vinyl ether, tetraethyleneglycol divinyl ether, glycidyl vinyl ether, butanediol vinyl ether, butanediol divinyl ether, 1,4-cyclohexanedimethanol divinyl ether commercially available under the trade designation “RAPI-CURE CHVE” from International Specialty Products, 1,4-cyclohexanedimethanol monovinyl ether, 4-(1-propenyloxymethyl)-1,3-dioxolan-2-one, 2-chloroethyl vinyl ether, 2-ethylhexyl vinyl ether, methyl vinyl ether, ethyl vinyl ether, n-propyl vinyl ether, isopropyl vinyl ether, n-, iso- and t-butyl vinyl ethers, octadecyl vinyl ether, cyclohexyl vinyl ether, 4-hydroxybutyl vinyl ether, t-amyl vinyl ether, dodecyl vinyl ether, hexanediol di- and mono-vinyl ethers, trimethylolpropane trivinyl ether, commercially available under the trade designation “TMPTVE” from BASF Corp., Mount Olive, N.J., aminopropyl vinyl ether, poly(tetrahydrofuran) divinyl ether, divinyl ether resin commercially available under the trade designation “PLURIOL E200” from BASF Corp., ethylene glycol butyl vinyl ether, 2-diethylaminoethyl vinyl ether, dipropylene glycol divinyl ether, and the divinyl ether resins commercially available under the trade designation “VECTOMER” from Morflex Inc., Greensboro, N.C., such as a vinyl ether terminated aromatic urethane oligomer (trade designations “VECTOMER 2010” and “VECTOMER 2015”), a vinyl ether terminated aliphatic urethane oligomer (trade designation “VECTOMER 2020”), hydroxybutyl vinyl ether isophthalate (trade designation “VECTOMER 4010”), and cyclohexane dimethanol monovinyl ether glutarate (trade designation “VECTOMER 4020”), or their equivalent from other manufacturers. It is within the scope of this invention to use a blend of more than one vinyl ether resin.
[0042] It is also within the scope of this invention to use one or more epoxy resins blended with one or more vinyl ether resins. The different kinds of resins can be present in any proportion.
[0043] Bifunctional monomers may also be used and examples that are useful in this invention possess at least one cationically polymerizable functionality or a functionality that copolymerizes with cationically polymerizable monomers, e.g., functionalities that will allow an epoxy-alcohol copolymerization.
[0044] When two or more polymerizable compositions are present, they can be present in any proportion.
[0045] The broad class of cationic photoactive groups recognized in the catalyst and photoinitiator industries may be used in the practice of the present invention. Photoactive cationic nuclei, photoactive cationic moieties, and photoactive cationic organic compounds are art recognized classes of materials as exemplified by U.S. Pat. Nos. 4,250,311 (Crivello); 3,708,296 (Schlesinger); 4,069,055 (Crivello); 4,216,288 (Crivello); 5,084,586 (Farooq); 5,124,417 (Farooq); 4,985,340 (Palazzotto et al.), 5,089,536 (Palazzotto), and 5,856,373 (Kaisaki et al.), each of which is incorporated herein by reference.
[0046] The cationically-curable materials can be combined with a three-component or ternary photoinitiator system. Three-component initiator systems are described in U.S. Pat. Nos. 5,545,676 (Palazzotto et al.), 6,025,406 (Jacobs et al.) and 5,998,495 (Jacobs et al.), each of which is incorporated herein by reference. The first component in the photoinitiator system can be an iodonium salt, i.e., a diaryliodonium salt. The iodonium salt desirably is soluble in the monomer and preferably is shelf-stable, meaning it does not spontaneously promote polymerization when dissolved therein in the presence of the sensitizer and donor. Accordingly, selection of a particular iodonium salt may depend to some extent upon the particular monomer, sensitizer and donor chosen. Suitable iodonium salts are described in U.S. Pat. Nos. 3,729,313 (Smith), 3,741,769 (Smith), 3,808,006 (Smith), 4,250,053 (Crivello) and 4,394,403 (Smith), the iodonium salt disclosures of which are incorporated herein by reference. The iodonium salt can be a simple salt, containing an anion such as Cl − , Br − , I − or C 4 H 5 SO 3 − ; or a metal complex salt containing an antimonate, arsenate, phosphate or borate such as SbF 5 OH − or AsF 6 − . Mixtures of iodonium salts can be used if desired.
[0047] Examples of useful aromatic iodonium complex salt photoinitiators include: diphenyliodonium tetrafluoroborate; di(4-methylphenyl)iodonium tetrafluoroborate; phenyl-4-methylphenyliodonium tetrafluoroborate; di(4-heptylphenyl)iodonium tetrafluoroborate; di(3-nitrophenyl)iodonium hexafluorophosphate; di(4-chlorophenyl)iodonium hexafluorophosphate; di(naphthyl)iodonium tetrafluoroborate; di(4-trifluoromethylphenyl)iodonium tetrafluoroborate; diphenyliodonium hexafluorophosphate; di(4-methylphenyl)iodonium hexafluorophosphate; diphenyliodonium hexafluoroarsenate; di(4-phenoxyphenyl)iodonium tetrafluoroborate; phenyl-2-thienyliodonium hexafluorophosphate; 3,5-dimethylpyrazolyl-4-phenyliodonium hexafluorophosphate; diphenyliodonium hexafluoroantimonate; 2,2′-diphenyliodonium tetrafluoroborate; di(2,4-dichlorophenyl)iodonium hexafluorophosphate; di(4-bromophenyl)iodonium hexafluorophosphate; di(4-methoxyphenyl)iodonium hexafluorophosphate; di(3-carboxyphenyl)iodonium hexafluorophosphate; di(3-methoxycarbonylphenyl)iodonium hexafluorophosphate; di(3-methoxysulfonylphenyl)iodonium hexafluorophosphate; di(4-acetamidophenyl)iodonium hexafluorophosphate; di(2-benzothienyl)iodonium hexafluorophosphate; and diphenyliodonium hexafluoroantimonate (DPISbF 6 ).
[0048] Of the aromatic iodonium complex salts which are useful in the inventive method diaryliodonium hexafluorophosphate and diaryliodonium hexafluoroantimonate are among the preferred salts. These salts are preferred because, in general, they promote faster reaction, and are more soluble in inert organic solvents than are other aromatic iodonium salts of complex ions.
[0049] The second component in the photoinitiator system is the sensitizer. The sensitizer desirably is soluble in the monomer, and is capable of light absorption within the range of wavelengths of greater than 300 to 1200 nanometers, and is chosen so as not to interfere with the cationic curing process
[0050] Suitable sensitizers desirably include compounds in the following categories: ketones, coumarin dyes (e.g., ketocoumarins), xanthene dyes, acridine dyes, thiazole dyes, thiazine dyes, oxazine dyes, azine dyes, aminoketone dyes, porphyrins, aromatic polycyclic hydrocarbons, p-substituted aminostyryl ketone compounds, aminotriaryl methanes, merocyanines, squarylium dyes and pyridinium dyes. Ketones (e.g., monoketones or alpha-diketones), ketocoumarins, aminoarylketones and p-substituted aminostyryl ketone compounds are preferred sensitizers. For applications requiring high sensitivity it is preferred to employ a sensitizer containing a julolidinyl moiety. For applications requiring deep cure (e.g., cure of highly-filled composites), it is preferred to employ sensitizers having an extinction coefficient below about 1000, more preferably below about 100, at the desired wavelength of irradiation for photopolymerization. Alternatively, dyes that exhibit reduction in light absorption at the excitation wavelength upon irradiation can be used.
[0051] A preferred class of ketone sensitizers has the formula:
ACO(X) b B
in which X is CO or CR 1 R 2 , where R 1 and R 2 can be the same or different, and can be hydrogen, alkyl, alkaryl or aralkyl, b is zero or one, and A and B can be the same or different and can be substituted (having one or more non-interfering substituents) or unsubstituted aryl, alkyl, alkaryl, or aralkyl groups, or together A and B can form a cyclic structure which can be a substituted or unsubstituted cycloaliphatic, aromatic, heteroaromatic or fused aromatic ring.
[0052] Suitable ketones of the above formula include monoketones (b=0) such as 2,2-, 4,4- or 2,4-dihydroxybenzophenone, di-2-pyridyl ketone, di-2-furanyl ketone, di-2-thiophenyl ketone, benzoin, fluorenone, chalcone, Michler's ketone, 2-fluoro-9-fluorenone, 2-chlorothioxanthone, acetophenone, benzophenone, 1- or 2-acetonaphthone, 9-acetylanthracene, 2-, 3- or 9-acetylphenanthrene, 4-acetylbiphenyl, propiophenone, n-butyrophenone, valerophenone, 2-, 3- or 4-acetylpyridine, 3-acetylcoumarin and the like. Suitable diketones include aralkyldiketones such as anthraquinone, phenanthrenequinone, o-, m- and p-diacetylbenzene, 1,3-, 1,4-, 1,5-, 1,6-, 1,7- and 1,8-diacetylnaphthalene, 1,5-, 1,8- and 9,10-diacetylanthracene, and the like. Suitable alpha-diketones (b=1 and X=CO) include 2,3-butanedione, 2,3-pentanedione, 2,3-hexanedione, 3,4-hexanedione, 2,3-heptanedione, 3,4-heptanedione, 2,3-octanedione, 4,5-octanedione, benzil, 2,2′-3 3′- and 4,4′-dihydroxylbenzil, furil, di-3,3′-indolylethanedione, 2,3-bornanedione (camphorquinone), biacetyl, 1,2-cyclohexanedione, 1,2-naphthaquinone, acenaphthaquinone, and the like.
[0053] The third component of the initiator system is an electron donor. The electron donor compound(s) desirably meets the requirements set forth in U.S. Pat. Nos. 6,025,406 (Jacobs et al.) and 5,998,495 (Jacobs et al.), each of which is incorporated herein by reference, and are soluble in the polymerizable composition. The donor can also be selected in consideration of other factors, such as shelf stability and the nature of the polymerizable materials, iodonium salt and sensitizer chosen. A class of donor compounds that may be useful in the inventive systems may be selected from some of the donors described in U.S. Pat. No. 5,545,676 (Palazzotto et al.).
[0054] The donor is typically an alkyl aromatic polyether or an N-alkyl arylamino compound wherein the aryl group is substituted by one or more electron withdrawing groups. Examples of suitable electron withdrawing groups include carboxylic acid, carboxylic acid ester, ketone, aldehyde, sulfonic acid, sulfonate and nitrile groups.
[0055] A preferred group of N-alkyl arylamino donor compounds is described by the following structural formula:
wherein each R 3 , R 4 and R 5 can be the same or different, and can be H, C 1-18 alkyl that is optionally substituted by one or more halogen, —CN, —OH, —SH, C 1-18 alkoxy, C 1-18 alkylthio, C 3 - 18 cycloalkyl, aryl, COOH, COOC 1-18 alkyl, (C 1-18 alkyl) 0-1 —CO—C 1-18 alkyl, SO 3 R 6 , CN or an aryl group that is optionally substituted by one or more electron withdrawing groups, or the R 3 , R 4 or R 5 groups may be joined to form a ring; and Ar is aryl that is substituted by one or more electron withdrawing groups. Suitable electron withdrawing groups include —COOH, —COOR 6 , —SO 3 R 6 , —CN, —CO—C 1-18 alkyl and —C(O)H groups, wherein R 6 can be a C 1-18 straight-chain, branched, or cyclic alkyl group.
[0056] Preferred donor compounds include 4-dimethylaminobenzoic acid, ethyl 4-dimethylaminobenzoate, 3-dimethylaminobenzoic acid, 4-dimethylaminobenzoin, 4-dimethylaminobenzaldehyde, 4-dimethylaminobenzonitrile and 1,2,4-trimethoxybenzene.
[0057] The photoinitiator compounds are provided in an amount effective to initiate or enhance the rate of cure of the resin system. The amount of donor used can be very important particularly when the donor is an amine. Too much donor can be deleterious to cure properties. Preferably, the sensitizer is present in about 0.05-5 weight percent based on resin compounds of the overall composition. More preferably, the sensitizer is present at 0.10-1.0 weight percent. The iodonium initiator is preferably present at 0.05-10.0 weight percent, more preferably at 0.10-5.0 weight percent, and most preferably 0.50-3.0 weight percent. Likewise, the donor is preferably present at 0.01-5.0 weight percent, more preferably 0.05-1.0 weight percent, and most preferably 0.05-0.50 weight percent.
[0058] Photo-polymerizable compositions useful in the invention are prepared by admixing, under “safe light” conditions (conditions under which curing is not initiated), the components as described above. Suitable inert solvents may be employed if desired when effecting this mixture. Any solvent may be used which does not react appreciably with the components of the inventive compositions. Examples of suitable solvents include acetone, dichloromethane, and acetonitrile. A liquid material to be polymerized may be used as a solvent for another liquid or solid material to be polymerized. Solventless compositions can be prepared by dissolving an aromatic iodonium complex salt and sensitizer in an epoxy resin-polyol mixture with or without the use of mild heating to facilitate dissolution.
[0059] An alternative photoinitiator system for cationic polymerizations includes the use of organometallic complex cations essentially free of metal hydride or metal alkyl functionality selected from those described in U.S. Pat. No. 4,985,340 (Palazzotto et al.)
[0060] Compositions useful in the invention can contain a wide variety of adjuvants depending upon the desired end use. Suitable adjuvants include solvents, diluents, resins, binders, plasticizers, pigments, dyes, inorganic or organic reinforcing or extending fillers (at preferred amounts of about 10% to about 90% by weight, based on the total weight of the composition), thixotropic agents, indicators, inhibitors, stabilizers, UV absorbers, and the like. Suitable amounts and types of such adjuvants, and their manner of addition to a composition of the invention are within the skill of the art.
[0061] The invention will be further clarified by the following examples. Unless otherwise noted, all parts, percentages, and ratios reported in the examples are on a weight basis, and all reagents used in the examples were obtained, or are available commercially from suppliers such as the Sigma-Aldrich Chemical Company, Saint Louis, Missouri, or may be synthesized by conventional techniques.
[0062] The following abbreviations are used in the following Examples:
“CR1”: curable resin, bisphenol A diglycidyl ether dimethacrylate, commercially available from Polyscience, Inc., Warrington, Pa.; “CR2”: curable resin, triethyleneglycol dimethacrylate, commercially available under the trade designation “SR 205” from Sartomer, Inc., Exton, Pa.; “CR3”: curable resin, commercially available under the trade designation “CYRACURE UVR 6105”, from Dow Chemical Company, Midland, Mich.; “CR4”: curable resin, commercially available under the trade designation “POLY THF 250” from BASF Corp., Mount Olive, N.J.; “DYE1”: Tetraiodotetrachlorofluorescein disodium salt, commercially available under the trade designation “ROSE BENGAL” from Mallinckrodt Baker, Inc., Phillipsburg, N.J.; “DYE2”: tetrabromofluoroscein:disodium salt, commercially available under the trade designation “EOSIN Y” from J Mallinckrodt Baker, Inc.; “FS”: fumed silica filler, commercially available under the trade designation “AEROSIL-976” from Degussa AG, Dusseldorf, Germany; “SN1”: sensitizer, camphorquinone, commercially available from Sigma-Aldrich Company; “PI1”: photoinitiator, diphenyliodonium hexafluorophosphate, commercially available from Sigma-Aldrich Company; “ED1”: electron donor, ethyl 4-dimethylamino benzoate, commercially available from Sigma-Aldrich Company; “PI2”: photoinitiator, commercially available under the trade “RHODORSIL 2074” from Rhodia Inc., Rock Hill, S.C.;
EXAMPLE 1
[0075] A curable composition was prepared as follows. A base solution was made by mixing together using a spatula in a black plastic container: 50 parts by weight CR1 and 50 parts by weight CR2. To this mixture was added 0.25 parts by weight SN1, 0.5 parts by weight PI1, 0.75 parts by weight PI3, 0.05 parts by weight DYE1, and 5 parts by weight FS.
[0076] The composition was stored in a lightproof container and had a paste-like consistency.
[0077] A 1-inch (2.54 cm) by 4-inches (10.16 cm) piece of sheet steel, coated with electro-deposited epoxy primer, commercially available under the trade designation “ACT COLD ROLLED STEEL 04X12X032 B952 P60 DIW: UNPOLISHED E-COAT: ED5000” from ACT Laboratories, Inc., Hillsdale, Mich. was laid on a flat surface. With room lights off a portion of the curable composition was applied to the sheet steel using a spatula.
[0078] A 15 foot (4.5 meter) electroluminescent light fiber, 2.3 millimeters outside diameter, having a peak emission at approximately 500 nanometers, commercially available as ELF BLUE-GREEN from ELAM, INC., was placed in the curable composition gel, passing through from side to side. The distance from the power supply connection for the EL light source to the sheet steel sample was 20.3 cm. A second steel sheet, as described above, was placed on top of the curable composition so that it contacted the electroluminescent light source and the curable composition. This process was repeated at distances of: 40.5 cm, 58.4 cm, 139.7 cm, 195.6 cm, 214.9 cm, 416.9 cm, 424.2 cm, 434.3 cm and 449.6 cm from the power connection for the electroluminescent light fiber.
[0079] The electroluminescent light fiber was switched on, using a fixed output power supply, available from ELAM, Inc., with power input of 120 VAC, and output of 100 VAC at 3000 Hz. Periodically, sandwich bonds were pulled apart and the uncured curable composition was wiped away. The total width of the remaining cured material was measured with a dial caliper, and the results recorded, along with illumination time, and a net cure depth (NCD) calculated by subtracting the diameter of the fiber, and dividing the result by two. This value represented the depth of cure in one direction from the fiber. The results were tabulated in Table 1. Under the same set of conditions a sandwich bond without exposure to EL light showed no hardening of the photocuring gel.
TABLE 1 Bond Distance from Total Illumination Total Width of Net Cure Power Supply, cm Time, minutes Cure, mm Depth, mm 20.3 13 slight skin formed n/a 40.6 23 3.5 .6 58.4 33 4 .85 139.7 43 4.7 1.2 195.6-449.6 163 6-6.5 1.85-2.1
[0080] The above data show that the depth of cure into the curable composition is time related, and the light output from the EL device is uniform along the cable, since the specimens at different distances from the power connection cured relatively consistently.
EXAMPLE 2
[0081] Six sandwich bonds were prepared as described Example 1, except the electroluminescent light source used was a 2.3 mm outside diameter by approximately Imeter long NEW BLUE EL light fiber, from ELAM, Inc., at a power of 140 VAC at 10 kHz. Results are tabulated in Table 2.
TABLE 2 Total Illumination Time, Net Cure Depth, minutes Total Width of Cure, mm mm 15 5.72 1.71 30 6.25 1.975 60 7.82 2.76 95 8.65 3.175 120 8.69 3.195 150 8.85 3.275
[0082] The above data show increased cure depth in the curable resin over time as compared to Example 1.
EXAMPLE 3
[0083] A base solution was made by mixing together using a spatula in an opaque plastic container 9 grams CR3 and 1 gram CR4. To this mixture was added 0.05 grams SN1, 0.015 grams ED1, 0.01 grams DYE2, and 0.20 grams PI2 to form a slightly orange colored fluid mixture.
[0084] Approximately 1 milliliter of this mixture was placed in a small glass vial of about 1.2 cm. inside diameter. The free end of an approximately 1.2 m long by 1.2 mm outside diameter electroluminescent light fiber, commercially available as HI-BRITE BLUE, from ELAM, Inc., was positioned vertically in the fluid and held in place at a temperature of 72° F. (20° C.) with a clamping fixture. The EL fiber was powered with 212 volts AC at approximately 21 kHz, and produced 13.3 Lux of light per centimeter of length. A layer of curing epoxy formed around the wire immersed in the mixture. The diameter of this curing layer was measured at various times of illumination, The results are listed in Table 3.
TABLE 3 Total Illumination Time, Total Diameter of Cure, minutes mm NCD mm 10 3.94 1.28 20 4.39 1.51 60 7.42 3.02
After a day with no additional light, at room temperature, the material in the vial had thickened substantially beyond the initial gelled region. After several days more, the entire mass had hardened to a glassy solid.
[0085] The invention is not limited to the specific embodiments illustrated above which are illustrative and not restrictive. It may be embodied in other specific forms without departing from the scope of the invention which is indicated in the claims. | 4y
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This is a divisional of application Ser. No. 08/368,917, filed Jan. 5, 1995, now U.S. Pat. No. 5,551,142.
BACKGROUND OF THE INVENTION
The present invention relates to devices for making repetitive stamping operations on a workpiece and, more particularly, to devices for stamping notches in stator laminations.
Typically, large electric motors include a stator core which is composed of a stack of relatively thin, circular laminations made of metal such as copper. Grooves are formed in the core of the stator by notching teeth-like slots on each of the laminations which are aligned when the laminations are arranged in a stack. Coils or rods formed from several insulated wires (windings) are secured in such slots. The slots are typically formed by placing pre-notched stator laminations, which have a central opening already formed therein, over a spindle or hub on a turntable which indexes the laminations between a die set which forms the notches. An example of such a stator lamination is disclosed in 1995 U.S. Pat. No. 5,551,142, the disclosure of which is incorporated herein by reference.
A disadvantage of such a prior art system is that it lacked means for positively securing the pre-notched laminations to the turntable, and for automatically removing the finished laminations from the spindle of the turntable. Further, while such progressive stamping devices are less expensive than devices for notching the entire lamination at once, they are less accurate since the lamination must be indexed as the notching procedure is performed.
Accordingly, there is a need for a stator lamination jig system which facilitates the mounting of the pre-notched lamination on the turntable, and the removal of the finished, notched lamination from the turntable. Further, there is a need for a stator lamination jig system which securely holds the lamination during the notching process without manual assistance.
SUMMARY OF THE INVENTION
The present invention is a stator lamination jig system for securely clamping a pre-notched stator lamination during a notching process, and for ejecting the finished, notched lamination from the jig upon completion of the notching process. In a preferred embodiment of the invention, the jig system includes an air actuated lower support table which is actuated to hold the lamination during notching, and subsequently is actuated to release the finished, notched lamination at the conclusion of the notching process.
The invention also includes an air actuated hold-down plate which clamps the lamination against the support table during the notching process, thereby eliminating the need for manual holding of the lamination during notching. The lower support table includes a circular ejection plate having a plurality of ejection plugs seated thereon and a drive plate, which supports the lamination during notching.
During the notching operation, the support table is lowered to allow the ejection plugs to retract into the drive plate, while the hold-down plate is clamped against the lamination to fix the lamination against the drive plate. When the notching procedure is completed, the lower support table is actuated to drive the circular ejection plate and ejection plugs upwardly to release the lamination from its seated position on the drive plate.
Accordingly, it is an object of the present invention to provide a stator lamination jig system in which the clamping of the lamination against a support surface and ejection of the notched lamination is fully automated; a system in which the lamination is clamped securely during the notching process, so that the speed of the notching operation can be increased without the loss of accuracy; a system which is relatively inexpensive to construct and which is reliable and easy to maintain.
Other objects and advantages of the present invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view, partially in section, of the table assembly of the stator lamination jig system of the present invention;
FIG. 2 is a top plan view of the system shown in FIG. 1; and
FIG. 3 is a front elevational view of the upper assembly of the system of FIG. 1.
DETAILED DESCRIPTION
As shown in FIG. 1, the stator lamination jig system of the present invention, generally designated 10, supports a typical stator lamination 12. The jig system 10 includes an air actuated lower support table, generally designated 14, which includes an ejection cylinder assembly 106, an upper assembly 108, and a drive motor assembly 110. The table 14 includes a rotatable, substantially circular drive plate 16 for supporting the stator lamination 12 (see also FIG. 2).
As shown in FIG. 2, the drive plate 16 includes a plurality of through holes 18 on an outer periphery thereof and a plurality of drill holes 20 extending through and spaced about a radially inner, raised hub portion 21 thereof. Drill holes 20 in the drive plate reduce the weight of the equipment. Spaced along the outer periphery of the drive plate 16 are three adjustable location bosses 22,23,24, of which bosses 22 and 23 are rectangular. Bosses 22 and 23 are shaped to fit notches formed in the lamination 12 (see FIG. 1) and can be replaced with differently shaped bosses to accommodate different sized laminations 12.
The table 14 includes an ejection plate 26, typically made of 1018 steel, and a plurality of nylon ejection plugs 28 slidably supported thereon. The ejection plugs 28 each include small rim portions 30 at lower ends thereof, and the ejection plugs 28 are shaped and positioned to slidably extend through the holes 18 of drive plate 16. The rim portions 30 prevent the ejection plugs 28 from sliding upwardly and out of their corresponding holes 18. The number of nylon ejection plugs 28 employed preferably corresponds to the number of through holes 18 in the drive plate 16.
The ejection plate 26 is rotationally fixed and has a substantially flat upper surface which allows the rims 30 of the ejector plugs 28 to slide over the surface of the ejection plate when the drive plate is rotated by the motor assembly 110, as will be described in greater detail below.
The lamination support system is driven by the motor assembly 110, which includes indexing motor 32 shown in FIG. 1. The motor 32 includes an output shaft 34 which extends through the ejection cylinder assembly 106 and engages the drive plate 16. The output shaft 34 extends through the ejection plate 26 and drive plate 16 to act as the spindle for the table 14 during the notching process.
The drive plate 16 includes a cylindrical drive bushing 56 which extends downwardly therefrom and is shaped to receive the reduced diameter upper end 112 of the output shaft 34. Upper end 112 is non-rotatably secured to bushing 56 by a key 64 which engages keyway 62. Set screws 58, 60 are threaded through bushing 56 and retain upper end 112 within bushing 56. Bushing 56 is attached to a recess formed in the hub 21 of drive table 16 by screws 66 and the drive table is radially located relative to output shaft 34 by locating pin 68, which extends through the hub bushing. Consequently, the output shaft 34 of motor 32 rotates the bushing 56 which, in turn, rotates drive plate 16, without rotating ejection cylinder assembly 106.
The support table 14 includes an ejection cylinder assembly, generally designated 106, which includes the ejection plate 26. The ejection assembly 106 includes an ejection cylinder 36 having a centrally located opening 38 through which the output shaft 34 of the indexing motor 32 extends. The ejection cylinder 36 includes an outer cylindrical housing 40 and an inner cylindrical wall 42 which defines an inner chamber 44. The inner cylindrical wall 42 is connected at a lower end to the outer housing 40 by annular cylinder wall 114, which extends between the inner wall and outer housing, but is unconnected to the outer housing at its upper end.
The ejection cylinder 36 also includes a piston 48 shaped to reciprocate within the chamber 44. The piston 48 is annularly shaped and includes three O-rings 50,52,54. The inner O-ring 50 provides a seal between the piston 48 and the inner cylindrical wall 46, the outer O-ring 52 provides a seal between the piston 48 and the outer cylindrical housing 40 and the upper O-ring 54 provides a seal between the upper piston shaft 116 and the outer housing 40.
The ejection cylinder 36 includes two side ports 70, formed in housing 40, which are connected by hoses 72 to a pneumatic valve 74. The valve 74 is connected to, and regulates the flow of compressed air from, a source 75 of compressed air, which may be shop air or a compressed air cylinder. The valve 74 has 3 positions: a first position in which no air enters or escapes the ejection cylinder 36, thereby holding the piston 48 (and ejection plate 26) in position; a second position in which compressed air from source 75 enters the cylinder 36 above piston 48, thereby pressurizing that portion of the chamber and driving the piston downwardly, which lowers ejection plate 26 and actuates the portion of the chamber below the piston, and conversely, a third position wherein the portion of the chamber below the piston is pressurized, thereby driving the piston and ejection plate upwardly and evacuating the portion of the chamber above the piston.
The valve 74 is connected to a programmable logic controller ("PLC") 76 for control of the cylinder assembly 114 in the aforementioned manner. The PLC 76 also actuates the indexing motor 32 through control line 77. The PLC 76 therefore controls when the indexing motor 32 begins operation, in coordination with the associated notching equipment 102 (see FIG. 3), which PLC controls through line 118.
As shown in FIG. 3, the jig system 10 includes a generally circular hold-down plate 78 which is positioned above the drive plate 16 (FIG. 1) and clamps the lamination 12 against the drive table from above. The hold-down plate 78 is typically made of 6150 steel and includes concentric, downwardly extending inner and outer annular ridges 80. These ridges 80 provide the contact with the stator lamination 12 and clearance to accommodate the hub 21. The hold-down plate 78 also has a plurality of through holes (not shown) to reduce weight.
The jig system 10 also includes bracket 82, which includes a bushing 120 that rotatably receives a shaft 122 which is attached to the plate 78. The shaft 122 is journaled into the bushing 120 and includes an enlarged head 124 which prevents the shaft from sliding downwardly through the bushing.
As shown in FIG. 3, a double-acting pneumatic cylinder 98 is mounted on H-beam 96 which, in turn, is attached to support bracket 100. Support bracket 100 is mounted to a conventional notching press, schematically shown at 102, by means of bracket 104. H-beam 96 supports double acting pneumatic cylinder 98 which, in turn, is connected rod plate 90. Rod plate 90 supports sensor mounting plate 92 which in turn supports proximity switch 94. PLC 76 controls valve 130 which controls compressed air flow to cylinder 98 from source 75, so that PLC can coordinate the action of cylinder 98 with cylinder 36 (FIG. 1). Further, PLC controls notching machine 102, so that the operation of the machine is coordinated with the operation of the jig system 10.
The cylinder rod 88 of the cylinder 98 is attached to bracket 82 (see also FIG. 1). Upper plate 128 of bracket 82 supports indicator rod 88, which is slidably received by plate 90, and oriented such that displacement of bracket 82 displaces rod 88 past switch 94. This switch 94 is used to determine whether the hold-down plate 78 is in an up (ejection) position or down (lamination securing) position. The guide rod 88 cooperates with the up switch 94 in order to control rotation.
The operation of the jig system 10 is as follows. The pre-notched stator lamination 12 is first placed on the drive table 16, as shown in FIG. 1 and shown in phantom in FIG. 2. At this time, the table 14 is lowered so that the ejection plugs 28 are permitted to retract by gravity below the upper surface of the drive plate. The cylinder 84 is actuated to displace the hold down plate 78 downwardly to clamp the lamination 12 against the plate 16, as shown in FIG. 1.
The indexing motor 32 is actuated by the PLC 76 to drive the lower support table 14, while the notching device 102 performs a notching operation on the lamination 12. The engagement of the hold-down plate 78 against the top of the stator lamination 12 causes the hold-down plate to rotate as well. The PLC coordinates the indexing of the plate 16 with the operation of the notching machine 102.
When the notching procedure is completed, the PLC 76 actuates the cylinder 98 to raise hold-down plate 78 and actuates the cylinder 36 to drive the circular ejection plate 26 and nylon ejection plugs 28 upwardly to automatically displace the finished, notched lamination 12 from its seated position on the lower support table 14. The stator lamination jig 10 is then ready for the next pre-notched lamination.
Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. | 4y
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